EMU FORMATION CHECKING AND ATTENDING MINOR FAULTSAC EMU/MEMU rakes are running for suburban as well as short distance mainline services in different areas of Indian Railways to cater to growing demand of passenger traffic. As these trains run on high-density routes, even a small failure can cause a big disturbance in the smooth flow of traffic. Quick and correct troubleshooting is of great relevance in case of any failure online.
PREPARATION OF EMU
Ensure the following keys are available along with EMU logbook and refer logbook for any remarks.
- Reverser key
- Brake isolating valve key – 2 Nos.
- BL key.
- Guard’s key
- Ensure EMU is standing on an OHE wired track.
- Check all the wheels on the rails.
- Check the position of the drain cocks and close them if open.
- Check all the isolating cocks are kept in ‘Open position’.
- Ensure all the jumpers, inter coach coupler and hose connections are intact.
- Ensure intermediate driving cabs, HT room, and LT room doors are in locked condition.
- Check buffers, cattle guards and other underframe equipment for any abnormality.
- Ensure BIVS is in turned ‘OFF’ position and BCH is in the released position in the rear motor coach.
- Ensure availability of head-code boards.
- Check for availability of fire extinguishers, emergency telephone and two numbers of iron/ wooden wedges.
- Check hand brakes are released.
EP Brake Testing:
- Switch ‘ON’ EP supply switch in BL box and ensure the EP supply green lamp is glowing.
- Place the BCH between 1 and 2 position in step by step and check the BC pressure raises gradually up to 1.6 kg/cm2.
- Keep the BCH in ‘release’ position and ensure BC pressure comes to ‘0’.
Auto Brake Testing:
- Switch ‘OFF’ EP supply switch and quickly move the BCH to position ‘4’ (Auto) and check the dropping of BP pressure and raising of BC pressure to 1.6 kg/cm2.
- Bring back the BCH to position ‘3’ (LAP) and check the BC pressure remains steady.
- Bring back the BCH to position ‘1’ and ensure the brakes are released (BC gauge reads ‘0’ and BP gauge reads 5kg/cm2).
- During auto brake application if BCH moved towards EP/ release position auto brakes are released fully.
Emergency Brake Testing:
- Quickly move the BCH from position ‘1’ to position ‘5’ and watch the BP pressure drops to ‘0’ and BC gauge reads 1.6 kg/cm2.
- Return the BCH from position ‘5’ to ‘1’. Check BP raises to 5 kg/cm2 and BC drops to ‘0’.
Guard’s Emergency Valve Testing:
- Ensure MR pressure is 6 to 7 kg/cm2, BP pressure is 5 kg/cm2 and BC pressure is 0 kg/cm2.2.
- Turn the Guard’s emergency valve to ‘ON’ position and check BP is dropping and BC pressure reads 1.6 kg/cm2.
- Release Guard’s brake valve and check the charging of BP and releasing of BC pressure to ‘0’.
Normal Lights & Fans Testing:
- Unlock Guard’s control switch and ensure Guard’s supply ‘ON’ indication lamp glows.
- Switch ‘ON’ normal lights and fans and check their working.
- Switch ‘OFF’ lights and fans whenever not necessary.
Testing of head light, tail light, head code light, flasher light, bell, and wiper:
- Ensure head light MCBs on driver’s desk are ‘ON’.
- Ensure head light ‘dim/ bright’ toggle switch is in the bright position.
- Switch ‘ON’ head light; by operating the head light switch to ‘HL ON’ position. Ensure headlight is glowing brightly.
- Put HL dim/bright toggle switch to ‘dim’ position; ensure head light is glowing in dim condition.
- Switch ‘ON’ tail light by operating tail light switch. Ensure taillight is glowing.
- Operate the head code rotary switch to ‘ON’ and check the head code light is glowing.
- Ensure flasher light MCB is ‘ON’ in desk panel. Operate flasher toggle switch to ‘ON’, check flasher light is flickering.
- By keeping the Guard’s rotary switch ‘ON’, check the code bell is in working condition on both sides of the cab. Also, ensure the alarm bell is in working condition.
- Ensure the pneumatic wiper is in working condition.
- Ensure foot operated horns are sounding properly.
- Ensure all destination boards pertaining to the entire link of working are available and change the ‘destination board’ according to the direction of working.
PROCEDURE FOR STABLING EMU/ MEMU :
- Stop the train at the stabling line.
- Trip ABB/VCB & lower all Pantos.
- Apply emergency brake; ensure BP drops to ‘0’ and BC raise to 1.6 kg/cm2.
- Turn ‘OFF’ BIVS.
- Place BCH on release position.
- Ensure that BP is not charging further.
- Remove BL key.
- Switch ‘OFF’ battery in all MCs.
- Ensure wheels wedges are provided on the wheels towards down gradient.10. Apply parking brake, if the parking brake is provided.
PROCEDURE FOR REAR MOTOR COACH DRIVING:
- Call the Guard to the leading motor coach.
- Apply auto brakes and turn ‘OFF’ BIVS.
- Keep BCH in the release position.
- Take out the reverser key, BIVS key, and BL key.
- Go to the rear motor coach, unlock BL.
- Turn ‘ON’ BIVS and charge BP pressure.
- Work the train up to the next block station duly observing GR & SR rules.
- Contact TLC and seek advice.
PROCEDURE FOR REMOVING JUMPER:
- Stop and secure the train as per procedure laid down in GR & SR rules.
- Call the Guard to leading MC before leaving the cab.
- Open ABB/VCB and lower pantographs in all MCs.
- Remove the jumper and secure in dummy socket.
PROCEDURE FOR DETACHING THE COACH :
- Stop & secure the train as per procedure laid down in GR & SR rules.
- Call the Guard to leading MC before leaving the cab.
- Close BP and MR end cocks both sides of the coach.
- Remove the jumpers and secure in dummy socket.
- Open MR & BP pipe and secure in dummy socket.
- First, slack the check nut, then slack the wing nut and move the front portion.
PROCEDURE FOR JOINT BRAKE CONTINUITY TEST:
Joint brake continuity test shall be conducted by the Guard and Motorman before the commencement of the first trip from shed/ stabling line or on the platform as given below:
The motorman shall start the main compressors and build up 7 kg/cm2 pressure in MR and turn ‘ON’ the BIVS and ensure the following:
- Brake pipe pressure is 5 kg/cm2
- Brake cylinder pressure is ‘0’.
- EP supply lamp is glowing.
- Motorman shall give 5 bells to indicate the Guard to be ready for the brake test.
Guard shall ensure the following:
- Brake pipe pressure is 5 kg/cm2.
- Brake cylinder pressure is ‘0’4.
- Guard shall acknowledge by giving 5 bells and watch brake cylinder pressure gauge.
- Motorman shall move BCH between ‘1’ and ‘2’ position and hold the brake cylinder pressure to 0.7 kg/cm2. Guard will note the brake cylinder pressure, which will be about 0.7 kg/cm2 and will confirm by giving one bell.
- Motorman shall move BCH to position ‘2’ and observe that brake cylinders gauge reads 1.6 kg/cm2. Guard will note 1.6 kg/cm2 pressure accordingly in the brake cylinder gauge and confirm by giving one bell.
- Motorman shall return BCH to release position ‘1’ and observe that the brake cylinder pressure returns to ‘0’. Guard will note that brake cylinder pressure returning to ‘0’ and confirm by giving one bell.
- Guard shall open the emergency valve by means of the Guard’s emergency brake handle to destroy BP pressure to ‘0’ kg/cm2. Motorman shall observe BP pressure rapidly dropping towards ‘0’ and will move BCH to emergency position ‘5’.
- The Guard after observing the brake cylinder gauge indicating 1.6 kg/cm2 and BP gauge showing ‘0’ kg/cm2 shall close the emergency valve. Motorman shall return the brake handle to position. ‘1’ and check BC pressure drops to ‘0’.The Guard will confirm by giving one bell.
- The motorman shall wait till BP pressure is built up to 5 kg/cm2 and then move the brake handle between position ‘3’ and ‘4’ to reduce BP pressure to 3.5 kg/cm2 and ensure BC pressure raises to 1.6 kg/cm2.
- Place the handle in LAP position ‘3’ and observe BP pressure remain steady. Guard will observe BP pressure dropping to 3.5 kg/cm2 and BC pressure raises to 1.6 kg/cm2 and will confirm by giving one bell.
- The motorman shall put the brake handle to release position. BP pressure shall raise to 5 kg/cm2 and BC pressure comes to ‘0’. The motorman will indicate the completion of joint brake test by giving 5 bells.
- After ensuring BP pressure restored to 5 kg/ cm2 and BC pressure comes to ‘0’, Guard shall also acknowledge the completion of the joint brake test by giving 5 bells.
SIMPLE PROBLEMS OCCUR NORMALLY:
NORMAL LIGHTS NOT GLOWING
- Check 5A, MCB at Driver’s desk.
- Check Guard’s supply MCB is ‘ON’.
- Switch ‘ON’ push button switch.
- Operate light contractor and try.
- Check MCB and fuse of the unit at relay panel and record in the logbook.
SIGNAL BELL NOT WORKING:
- Check 5A Guard’s supply MCB in Driver’s desk is ‘ON’. If it stripped, reset the same.
- Check Guard’s supply indication lamp is glowing.
- Switch ‘ON’ Guard’s control reset MCB for bell push.
- If still not working, use alarm bell for bell code. Record the same in the logbook.
- Work as per GR & SR rules:
ALARM BELL NOT WORKING:
- Check 5A MCB for alarm bell on Driver’s desk. If it is tripped, reset the same.
- If still not working, inform the same to TLC.
EP BRAKE NOT WORKING:
- EP supply lamp will not glow
- Stop train by applying emergency brake.
- Check (5A) MCB for EP brake in Driver’s desk.
- Check EP supply switch is in ‘ON’ position (in BL box).
- Check BIVS turned fully ON.
- If still not working, control the train with auto brake for further working duly informing TLC and record in the logbook.
Partial Brake Binding:
- Poor hauling, poor acceleration, quick deceleration.
- BC gauge indicates in MC and TC.
- Smoke and smell at binding wheels.
- Stop the train at a convenient place (clear of platforms and bridges), keep the brake controller handle in the release position. Secure the train by providing skid/wedges.
- Call the Guard to lead MC.
- Find out the defective coach by observing smoke, smell over heat from the brake blocks.
- If vent type BIC cocks are provided, close BIC I & II, observe air exhaust through vent and brake blocks are released. If brakes are not released, open BIC I & II follow the below procedure:
- Close both EPIC and AIC cut out cocks.6. Release the brake cylinder pressure by pulling release handle till the complete air is released from auxiliary reservoir and brake cylinders are released.
- Ensure the brake blocks are shacking freely.
- isolate both BICs and work the train duly informing TLC and record in the logbook.
Full Train Brake Binding:
- Brake binding in all coaches on the train.
- Observe BP pressure in Duplex guage. If BP pressure is normal, keep EP supply switch and EP supply MCB in ‘OFF’. Observe brakes are released.
- If brakes are released, work the train with auto brake up to destination
- If brake binding still not released, contact TLC.Note: Ensure auto brake working before starting the train.
Parking Brake Binding:
- Poor hauling, poor acceleration, quick deacceleration.
- Parking brake gauge reads ‘0’.
- Smoke and smell at wheels 1, 4, 5 and 8.
- Press parking release switch, ensure PB gauge reads5 kg/cm2 and parking brakes are released.
- If not successful pull the parking brake release handles provided on wheels 1, 4, 5 and 8.
Note: Parking brake release should be ensured for all MCs.
Mechanical Brake Binding:
In motor coach:
- Release the palm pull rod at one end according to the direction of working (keep the opposite end of the palm pull rod in hanging condition with respect to the working direction).
- Ensure wheels are free from brake binding.
- Keep the palm pull rod safely hanging through security chain on the hook.
- Inform the same of TLC and work onwards. Make record in the log book.
In Trailer coach:
- Remove the brake pull rod assembly.
- Ensure two wheels (one pair) are free from brake binding.
- Inform the same to the TLC and record in the logbook.
RAISE IN BP PRESSURE (MORE THAN 5 KG/CM2):
- Observe BP pressure in Duplex Gauge. If it shows more than 5 kg/cm2, operate BCH to emergency and back to release position and try.
- If it returned 5 kg/cm2, release the brake in all coaches and work the train further.
- If it does not become normal, work with the rear motor coach after releasing brake binding in all coaches manually.
- After releasing, ensure EPIC, AIC, BIC1, and BIC2 are in service.
- After clearing section contact TLC.
AIR SPRING BURST IN MC/TC:
- MR pressure drops in the MR gauge.
- Air leakage sound near burst spring.
- Observe the lowering of leveling valve lever.
- Identify the defective air spring.
- Close the isolating COC of that particular truck.
- Work onwards up to destination with restricted speed 60 kmph.
- Inform TLC at the next station.5. Make entry in logbook.
PARTING OF TRAIN:
- Failure of coupler or articulation bearing bolt.
- BP pressure drops to zero.
- MR pressure will drop gradually.
- There may be heavy jerks.
- Lights and fans may fail in the motor coach and in the passenger area.
- Switch ‘ON’ flasher light and protect the train. Secure the train if required.
- Inform TLC and Station Master of the nearest station for assistance.
- Do not touch exposed jumpers as there may be live wires.
- Close MR and BP end cocks on the opposite ends of the parted portion taking care of exposed live jumpers/ wires.
- Isolate brake binding (normal as well as parking brakes) of the affected coaches.f) Try to raise pantographs if dropped.
- Work as per the guidance of TLC.
- Smoke from axle box and discoloring of axle box.
- Inadequate lubrication and breakage of inner or outer race.
- Pull the rake cautiously up to first available platform at speed not exceeding 8 kmph.
- If it is the motor coach, isolate it.
- Inform TLC and call carriage staff. Cancel the train at first available platform and work it to nearest yard/ car shed as per instructions of carriage staff.
- Heavy running of units.
- Repeated tripping of the concerned motor coach.
- Gear or pinion teeth were broken
- Bearing seized.
- Ensure wheel lock with the help of Guard.
- Isolate concerned motor coach.
- Inform TLC and call for assistance.
- Work the train at speed not exceeding 8 kmph.
- Cancel the train at first available platform and work it to nearest yard/ car shed as per instructions of carriage staff.
- Hammering sound at regular intervals.
- Brake block jammed on the wheel.
- Brake cylinder piston stuck up.
- Triple valve defective.
- Parking brake binding.
- Release brake binding if any.
- Inform TLC and call for assistance.
- Cancel the train if the flat wheel is of 50 mm or more.
- Work the train at speed not exceeding 25 kmph.