客車輔A修作業(yè)Operationprocedurefor

項(xiàng)目四客車運(yùn)用維修主講人：余建勇Lecturer:YuJianyong客車輔(A1)修作業(yè)Operationprocedureforauxiliary(A1)repairofpassengercar鄭州鐵路職業(yè)技術(shù)學(xué)院車輛運(yùn)用與管理ApplicationandManagementofRailwayVehicle客車輔（A1）修作業(yè)BusAuxiliary(A1)RepairOperations鄭州鐵路職業(yè)技術(shù)學(xué)院安全注意事項(xiàng)：確認(rèn)防溜Makesurethe

anti-slipfacilitiesareinplace作業(yè)前到安全員處簽字確認(rèn)后上脫軌器；作業(yè)前到值班室簽字、插設(shè)防護(hù)號(hào)志Sign

with

thesafetyofficerbeforeoperationandgetonthederailmentdeviceafterconfirmation;Signin

thedutyroom

beforeoperation,inserttheprotection

signal按規(guī)定穿戴勞保用品Wearing

laborprotectionarticlesasrequired通過(guò)道口注意“一站二看三確認(rèn)四通過(guò)”Payattentionto"onestop,twolooks,threeconfirmationsandfourpasses"whenpassingthroughthecrossing雨雪天氣時(shí)當(dāng)心滑倒，登高作業(yè)時(shí)防止墜落，地溝作業(yè)時(shí)當(dāng)心碰頭，現(xiàn)場(chǎng)作業(yè)時(shí)，不侵鄰限。Watchoutforslippinginrainyandsnowyweather,preventfallingwhenclimbing,watchoutformeetingwhenworkingintrench,don'tencroachonneighboringlimitswhenworkingonsite.二、客車輔（A1）修作業(yè)

BusAuxiliary(A1)RepairOperations鄭州鐵路職業(yè)技術(shù)學(xué)院（一）（二）（四）（三）（五）（六）（七）落成及質(zhì)量檢查單車試驗(yàn)設(shè)置防護(hù)信號(hào)作業(yè)準(zhǔn)備檢修作業(yè)電子防滑器試驗(yàn)撤除防護(hù)信號(hào)及歸隊(duì)二、客車輔（A1）修作業(yè)Theoperationprocessisdividedintoeightsteps:operationpreparation→settingprotectionsignal→overhauloperation→singlevehicletest→electronicanti-skiddevicetest→completionandqualityinspection→protectionsignalremove→operationcompletion.(一)作業(yè)準(zhǔn)備Operationpreparation鄭州鐵路職業(yè)技術(shù)學(xué)院12做好風(fēng)源排水除塵工作。Doagoodjobofdrainingandremovingdustfromthewindsource.3456微控單車試驗(yàn)器每日開(kāi)工前必須進(jìn)行自檢，確保試驗(yàn)器狀態(tài)良好。Themicro-controlledbicycletestermustbeself-checkedbeforestartingworkeachdaytoensurethatthetesterisingoodcondition.檢查工具、材料。Checktoolsandmaterials.調(diào)閱輔修前1個(gè)月TPDS數(shù)據(jù)，非空簧客車報(bào)警當(dāng)量≥18且17及以上報(bào)警超過(guò)3次，空氣彈簧客車≥17時(shí)換輪或鏇輪。ChecktheTPDSdataonemonthbeforeauxiliaryrepair,thealarmequivalentofnon-airspringpassengercarsisnotlessthaneighteenandseventeen≥18and17orabovealarmsformorethanthreetimes.Iftheairspringpassengercarsarenotlessthanseventeen≥17,changewheelsorrotatewheels.作業(yè)之前必須正確佩戴勞保用品，嚴(yán)防人身傷害。Wear

laborprotectionarticles

correctlybeforeoperationtopreventpersonalinjury查詢本車一個(gè)輔（A1）修期內(nèi)臨修換閥情況，對(duì)2次及以上臨修換閥的車輛（非104閥故障引起的TCDS制動(dòng)報(bào)警臨修換閥除外）在吹塵作業(yè)時(shí)進(jìn)行重點(diǎn)吹塵。Checkaboutthesituationoftemporaryvalvereplacementduringtheoneauxiliary(A1)repairperiodofthisvehicle,focusondustblowingforvehiclesthathavebeentemporarilyrepairedandreplacedfortwoormoretimes.(二)設(shè)置防護(hù)信號(hào)Settingofprotectionsignals鄭州鐵路職業(yè)技術(shù)學(xué)院到達(dá)作業(yè)列車股道時(shí)，指定專人負(fù)責(zé)確認(rèn)脫軌器狀態(tài)，并插設(shè)防護(hù)號(hào)志。Whenarrivingatthetrackoftheoperationtrain,designateaspecialpersontoconfirmthestateofthederailmentdeviceandinsertaprotectivesignal.(二)設(shè)置防護(hù)信號(hào)Settingupprotectivesignals（三）檢修作業(yè)Overhauloperation鄭州鐵路職業(yè)技術(shù)學(xué)院1.空氣管系檢修Airpipingsystemoverhaul總風(fēng)軟管、制動(dòng)軟管檢查Masterairhose,brakehoseinspection制動(dòng)軟管更換Brakehosereplacement（1）檢查制動(dòng)軟管、總風(fēng)軟管Checkthebrakehoseandmainairhose.（三）檢修作業(yè)

Overhauloperations鄭州鐵路職業(yè)技術(shù)學(xué)院（2）檢查折角塞門和截?cái)嗳TInspectionoffoldingandtruncatedgates截?cái)嗳T、折角塞門作用靈活，安裝無(wú)松動(dòng)，角度正確。作用不良者更換為檢修合格品。Cutofftheplugdoor,foldingangleoftheroleoftheplugdoorflexible,installationisnotloose,theangleiscorrect.Replacethepoorlyfunctioningoneswithqualifiedproductsforoverhaul.（三）檢修作業(yè)Overhauloperations鄭州鐵路職業(yè)技術(shù)學(xué)院（3）管系及閥體等

Pipingsystemsandvalvebodies,etc.管系各管卡、吊架無(wú)松動(dòng)、丟失，管子腐蝕超過(guò)管子壁厚1/2，超過(guò)時(shí)須更換。高度調(diào)整閥、空重車閥、差壓閥安裝牢固，配件無(wú)缺損。Pipesystemofeachpipeclamps,hangersarenotloose,lost,pipecorrosionmorethanpipewallthicknessof1/2,morethanthetimetobereplaced.Heightadjustmentvalve,air-heavyvehiclevalve,differentialpressurevalveisfirmlyinstalled,andthefittingsarenotdefective.緊急制動(dòng)閥閥體、手把不得有裂損、彎曲。緩解指示器安裝牢固、作用良好，面罩清潔顯示清晰、正確。Emergencybrakevalvebodyandhandleshallnotbecrackedorbent.Reliefindicatorsaresecurelymountedandfunctioningwell,andmaskcleaningdisplaysareclearandcorrect.緊急制動(dòng)閥手柄Emergencybrakevalvehandle緩解指示器mitigationindicator鄭州鐵路職業(yè)技術(shù)學(xué)院2.除銹吹塵

Rustremovalanddustblowing（1）清理各風(fēng)管路、副風(fēng)缸、工作風(fēng)缸、制動(dòng)缸、氣路控制箱外部塵垢。Cleanthedustanddirtontheoutsideofeachairline,secondaryaircylinder,workingaircylinder,brakecylinder,andaircontrolbox.（2）連接單車試驗(yàn)器，進(jìn)行除塵。Connectthebicycletestertoremovedust.除塵方法：關(guān)閉截?cái)嗳T及另一端折角塞門，用木槌敲打主支管、副風(fēng)缸、工作風(fēng)缸及連通管。Closethetruncatedplugdoorandtheotherendofthebendingangleplugdoor,withamallettobeatthemainbranchpipe,deputywindcylinder,workingwindcylinderandconnectingpipe.待風(fēng)壓充至600kPa，微控單車選擇“快充位”，連續(xù)三次以上開(kāi)、閉另一端折角塞門。Whenthewindpressureischargedto600kPa,themicro-controllerselects"fastchargingposition",andopensandclosestheotherendofthebendingangleplugdoorformorethanthreeconsecutivetimes.開(kāi)通截?cái)嗳T，將車輛另一端的折角塞門關(guān)閉。依次連續(xù)三次以上開(kāi)、閉副風(fēng)缸、工作風(fēng)缸等排水塞門，每次吹塵不少于2s、中間間隔不少于2s，關(guān)閉各排水塞門。Openthecut-offplugdoor,theotherendofthevehicle'sfoldingangleplugdoorclosed.Openandclosethedrainplugdoorofvicewindcylinderandworkingwindcylinderformorethanthreeconsecutivetimesinturn,blowingdustfornotlessthan2seachtime,withanintervalofnotlessthan2sinbetween,andcloseeachdrainplugdoor.（三）檢修作業(yè)(iii)Overhauloperations鄭州鐵路職業(yè)技術(shù)學(xué)院檢查壓力表狀態(tài)，檢定標(biāo)記須在有效期內(nèi)。壓力表等級(jí)須為1.6級(jí)，量程為0～1000kPa。Checktheconditionofthepressuregauge,thecalibrationmarkshallbewithinthevalidityperiod.Thepressuregaugemustbeclass1.6witharangeof0to1000kPa.除塵：用鋼絲刷清掃組合式集塵器體和集塵盒表面污垢，檢查螺栓孔附近無(wú)裂紋；止塵傘及立柱無(wú)變形、折斷等；之后進(jìn)行吹塵。Dusting:Cleanthesurfacedirtofthecombineddustcollectorbodyanddustcollectionboxwithawirebrush,andcheckthattherearenocracksneartheboltholes;Duststoppingumbrellaandcolumnwithoutdeformation,fractureandsoon;Afterthat,blowingdust.更換后須與微控單車試驗(yàn)器進(jìn)行風(fēng)壓校對(duì)。Thereplacementshallbewindpressurecalibratedwiththemicro-controlledbicycletester.3.壓力風(fēng)表檢修Pressuregaugeoverhaul4.遠(yuǎn)心集塵器檢修Telecentricdustcollectoroverhaul（三）檢修作業(yè)

Overhauloperations鄭州鐵路職業(yè)技術(shù)學(xué)院5.分配閥檢修D(zhuǎn)istributionvalveoverhaul取出的濾塵器(網(wǎng))，放于干凈處；Removethedustfilter(net)andplaceitinacleanplace;選擇“快充位”用600kpa壓力空氣進(jìn)行吹塵，連續(xù)開(kāi)閉截?cái)嗳T2-3次，每次吹塵不少于2s，中間間隔不少于2s；一個(gè)輔（A1）修期內(nèi)發(fā)生2次及以上臨修換閥（非104閥故障引起的TCDS報(bào)警除外）的要開(kāi)閉截?cái)嗳T5次以上，每次吹塵不少于2s，中間間隔不少于2s；Select"fastchargingposition"with600kpapressureairtoblowdust,continuouslyopenandclosethecut-offplugdoor2-3times,eachblowingdustnotlessthan2s,withanintervalofnotlessthan2s;anauxiliary(A1)repairperiodoccursfor2timesandmorethanthetemporarymaintenanceofthereplacementvalve(exceptforTCDSalarmcausedbythefailureofnon-104valves)toopenandclosethecut-offplugdoormorethan5times,eachblowingdustnotlessthan2s,withanintervalofnotlessthan2s;閥體拆卸：Valvebodydisassembly:卸下閥的安裝面上應(yīng)裝防塵罩；卸下閥的安裝面上應(yīng)裝防塵罩Themountingsurfaceoftheunloadingvalveshouldbefittedwithadustcover；濾塵器(網(wǎng))或杯須無(wú)銹蝕、堵塞、破損。Thefilter(mesh)orcupshallbefreeofrust,clogging,orbreakage.（三）檢修作業(yè)Overhauloperations鄭州鐵路職業(yè)技術(shù)學(xué)院6.基礎(chǔ)制動(dòng)裝置Basicbrakes(1)單元制動(dòng)缸及夾鉗Unitbrakecylindersandclamps清除單元制動(dòng)缸雜物，對(duì)制動(dòng)夾鉗裝置進(jìn)行除垢；Removedebrisfromtheunitbrakecylinderanddescalethebrakecaliperunit;單元制動(dòng)缸銷軸壓板螺栓緊固，銷軸不竄出，防脫檔齊全；Unitbrakecylinderpinpressureplateboltsaretight,thepindoesnotrunout,anti-disengagementgearcomplete;各制動(dòng)銷套配合間隙不超過(guò)3mm，襯套無(wú)松動(dòng)竄出，螺栓緊固，開(kāi)口銷狀態(tài)良好；Eachbrakepinbushingclearancedoesnotexceed3mm,noloosebushingout,boltsaretight,cotterpinsingoodcondition;基礎(chǔ)制動(dòng)裝置各部須配件齊全，狀態(tài)良好，各杠桿、吊桿、夾鉗良好、無(wú)裂紋；Thebasicbrakingdevicemustbecompleteaccessories,goodcondition,eachlever,boom,clampgood,nocracks;檢查閘片與制動(dòng)盤兩側(cè)間隙之和不超過(guò)3～5mm。Checkthegapbetweenthebrakepadandthebrakediskonbothsidesofthesumdoesnotexceed3~5mm.閘片最薄處厚度不小于5mm，閘片須成對(duì)更換；作用不良的基礎(chǔ)制動(dòng)裝置配件需更換Thethicknessofthethinnestpartofthebrakepadsisnotlessthan5mm,andthebrakepadsshouldbereplacedinpairs;thepoorfunctionofthebasicbrakefittingsneedtobereplaced.（三）檢修作業(yè)Overhauloperations鄭州鐵路職業(yè)技術(shù)學(xué)院(2)制動(dòng)盤Brakediscs制動(dòng)盤盤轂無(wú)松動(dòng)、裂紋；Brakedischubwithoutloosenessandcracks;制動(dòng)盤整體厚度不小于96mm；Theoverallthicknessofthebrakediskisnotlessthan96mm;半盤連接部位和盤轂不得有裂紋，散熱片不得有貫穿裂紋；Nocracksinthehalf-discconnectingpartsanddischub,andnopenetratingcracksintheheatsink;制動(dòng)盤與盤轂連接螺栓緊固，螺栓、開(kāi)口銷無(wú)折損、丟失；Brakediscanddiskhubconnectingboltsaretight,boltsandcotterpinsarenotbrokenorlost;盤面熱裂紋長(zhǎng)度距內(nèi)、外邊緣≥10mm時(shí)，裂紋長(zhǎng)度須小于95mm，否則應(yīng)小于65mm。Thelengthofthermalcracksonthedisksurfaceshallbelessthan95mmwhenthelengthofthecrackis≥10mmfromtheinnerandouteredges,otherwiseitshallbelessthan65mm.（三）檢修作業(yè)Overhauloperations鄭州鐵路職業(yè)技術(shù)學(xué)院“”制動(dòng)拉桿不磨輪座和車軸，拉桿不抗轉(zhuǎn)向架；Braketierodsdonotwearwheelseatsandaxles,andtierodsdonotresistbogies;制動(dòng)梁不彎曲、變形、磨耗，緩解簧（或安全托）無(wú)裂損、丟失，螺栓不松動(dòng)；Brakebeamsarenotbent,deformed,orwornout,reliefsprings(orsafetyrests)arenotcrackedorlost,andboltsarenotloose;緩解簧磨耗板不得丟失或竄出；Reliefspringwearplateshallnotbelostorrunout;各拉桿吊座，拉桿吊、固定杠桿、制動(dòng)拉桿、移動(dòng)杠桿及支座良好，各開(kāi)口銷角度符合規(guī)定：60°～70°；Eachtierodsuspensionseat,tierodsuspension,fixedlever,brakelever,mobileleverandsupportgood,eachcotterpinangleinaccordancewiththeprovisions:60°~70°;各圓銷、襯套磨耗及銷套間隙不大于3mm；Eachroundpin,bushingwearandpinbushingclearanceisnotmorethan3mm;圓開(kāi)口銷磨耗小于原直徑1/4；Roundcotterpinwearislessthan1/4oftheoriginaldiameter;扁開(kāi)口銷磨耗剩余厚度不小于1.5mm。Theremainingthicknessoftheflatcotterpinisnotlessthan1.5mm.(3)踏面制動(dòng)基礎(chǔ)制動(dòng)裝置

TreadleBrakeBaseBrakeUnit（三）檢修作業(yè)Overhauloperations（三）檢修作業(yè)Overhauloperations鄭州鐵路職業(yè)技術(shù)學(xué)院7.手制動(dòng)機(jī)

Handbrakes清除手制動(dòng)拉桿、支點(diǎn)、托架、螺桿、齒輪箱、鏈及輪等零部件上的塵垢。Removethedustanddirtonthehandbrakelever,pivotpoint,bracket,screw,gearbox,chainandwheelandotherparts.手制動(dòng)拉桿支點(diǎn)轉(zhuǎn)動(dòng)須靈活，緊固件齊全良好無(wú)松動(dòng)。Thepivotpointofthehandbrakelevermustbeflexible,andthefastenersarecompleteandgoodwithoutloosening.分解蝸輪盒檢查；手制動(dòng)拉鏈條無(wú)裂損、鋼絲繩無(wú)破損折斷影響使用；手制動(dòng)機(jī)標(biāo)記須清楚正確。Disassemblethewormgearboxforinspection;nocracksinthehandbrakechainandnobrokenwireropesaffectingtheuse;thehandbrakemarkingsmustbeclearandcorrect.車輛在緩解狀態(tài)下，向制動(dòng)方向擰緊手制動(dòng)機(jī)搖把制動(dòng)，確認(rèn)各基礎(chǔ)制動(dòng)裝置狀態(tài)；Vehicleinthestateofrelief,tothedirectionofthebraketightenthehandbrakemachinecrankbrake,confirmthestateofeachbasicbrakedevice;緩解手制動(dòng)機(jī)，閘片須離開(kāi)制動(dòng)盤(或閘片無(wú)壓力)，閘瓦制動(dòng)客車閘瓦須離開(kāi)輪踏面（閘瓦無(wú)壓力)；Reliefhandbrakemachine,brakepadsshallleavethebrakedisk(orbrakepadswithoutpressure),braketilebrakebusbraketileshallleavethewheeltread(braketilewithoutpressure);反向擰緊手制動(dòng)機(jī)搖把，確認(rèn)是否發(fā)生反向擰緊制動(dòng)的情況；鋼絲繩有90～120mm的松弛量。Reversetighteningofthehandbrakemachinecrank,toconfirmwhetherthereversetighteningofthebrakeoccurs;wireropehas90to120mmofslack.鄭州鐵路職業(yè)技術(shù)學(xué)院1軸箱Axlebox外部除塵檢查Externaldustremovalcheck軸端接地裝置Shaftendgroundingdevice2輪對(duì)Pairofwheels軸身檢查Axlebodyinspection輪對(duì)測(cè)量：踏面圓周磨耗、剝離，輪輞厚度等。Wheelpairmeasurements:treadcircumferentialwear,stripping,rimthickness,etc.（三）檢修作業(yè)

Overhauloperations（四）單車試驗(yàn)

Bicycletest鄭州鐵路職業(yè)技術(shù)學(xué)院制動(dòng)機(jī)試驗(yàn)時(shí)，校對(duì)制動(dòng)壓力表、總風(fēng)壓力表與單車試驗(yàn)器壓力表壓力差小于±10kPa。Brakemachinetest,proofreadingbrakepressuregauge,totalairpressuregaugeandsinglevehicletesterpressuregaugepressuredifferenceislessthan±10kPa.單元制動(dòng)缸制動(dòng)、緩解作用良好，無(wú)漏泄。Unitbrakecylinderbraking,relievingtheroleofgood,noleakage.活塞桿復(fù)位無(wú)卡滯現(xiàn)象。Pistonrodresetwithoutstagnation.制動(dòng)時(shí)閘片壓緊制動(dòng)盤（閘瓦壓緊輪踏面）；緩解時(shí)，閘片對(duì)制動(dòng)盤無(wú)壓力（閘瓦對(duì)輪踏面無(wú)壓力）。Whenbraking,thebrakepadpressesthebrakedisk(thebraketilepressesthewheeltread);whenrelieving,thebrakepadhasnopressureonthebrakedisk(thebraketilehasnopressureonthewheeltread).對(duì)組裝后的空氣管路系統(tǒng)進(jìn)行漏泄檢查，各部無(wú)漏泄；檢查各塞門、單向閥、制動(dòng)緩解指示器、金屬軟管等作用不良者更換。Leakagecheckontheassembledairpipingsystem,noleakageinalldepartments;checkeachplugdoor,checkvalve,brakereliefindicator,metalhose,etc.Replacementofpoorlyfunctioning.（五）電子防滑器試驗(yàn)

Electronicanti-slipdevicetest鄭州鐵路職業(yè)技術(shù)學(xué)院使用毛刷對(duì)主機(jī)、壓力開(kāi)關(guān)接線進(jìn)行清掃，檢查接線及接線排無(wú)燒損、破損，接線壓插接良好。Useabrushtocleanthemainframeandpressureswitchwiring,checkthatthewiringandwiringrowsarenotburnedorbroken,andthatthewiringiscrimpedandpluggedinwell.主機(jī)、壓力開(kāi)關(guān)及接線檢修（五）電子防滑器試驗(yàn)

Electronicanti-slip