客车辅A修作业Operationprocedurefor

项目四客车运用维修主讲人：余建勇Lecturer:YuJianyong客车辅(A1)修作业Operationprocedureforauxiliary(A1)repairofpassengercar郑州铁路职业技术学院车辆运用与管理ApplicationandManagementofRailwayVehicle客车辅（A1）修作业BusAuxiliary(A1)RepairOperations郑州铁路职业技术学院安全注意事项：确认防溜Makesurethe

anti-slipfacilitiesareinplace作业前到安全员处签字确认后上脱轨器；作业前到值班室签字、插设防护号志Sign

with

thesafetyofficerbeforeoperationandgetonthederailmentdeviceafterconfirmation;Signin

thedutyroom

beforeoperation,inserttheprotection

signal按规定穿戴劳保用品Wearing

laborprotectionarticlesasrequired通过道口注意“一站二看三确认四通过”Payattentionto"onestop,twolooks,threeconfirmationsandfourpasses"whenpassingthroughthecrossing雨雪天气时当心滑倒，登高作业时防止坠落，地沟作业时当心碰头，现场作业时，不侵邻限。Watchoutforslippinginrainyandsnowyweather,preventfallingwhenclimbing,watchoutformeetingwhenworkingintrench,don'tencroachonneighboringlimitswhenworkingonsite.二、客车辅（A1）修作业

BusAuxiliary(A1)RepairOperations郑州铁路职业技术学院（一）（二）（四）（三）（五）（六）（七）落成及质量检查单车试验设置防护信号作业准备检修作业电子防滑器试验撤除防护信号及归队二、客车辅（A1）修作业Theoperationprocessisdividedintoeightsteps:operationpreparation→settingprotectionsignal→overhauloperation→singlevehicletest→electronicanti-skiddevicetest→completionandqualityinspection→protectionsignalremove→operationcompletion.(一)作业准备Operationpreparation郑州铁路职业技术学院12做好风源排水除尘工作。Doagoodjobofdrainingandremovingdustfromthewindsource.3456微控单车试验器每日开工前必须进行自检，确保试验器状态良好。Themicro-controlledbicycletestermustbeself-checkedbeforestartingworkeachdaytoensurethatthetesterisingoodcondition.检查工具、材料。Checktoolsandmaterials.调阅辅修前1个月TPDS数据，非空簧客车报警当量≥18且17及以上报警超过3次，空气弹簧客车≥17时换轮或镟轮。ChecktheTPDSdataonemonthbeforeauxiliaryrepair,thealarmequivalentofnon-airspringpassengercarsisnotlessthaneighteenandseventeen≥18and17orabovealarmsformorethanthreetimes.Iftheairspringpassengercarsarenotlessthanseventeen≥17,changewheelsorrotatewheels.作业之前必须正确佩戴劳保用品，严防人身伤害。Wear

laborprotectionarticles

correctlybeforeoperationtopreventpersonalinjury查询本车一个辅（A1）修期内临修换阀情况，对2次及以上临修换阀的车辆（非104阀故障引起的TCDS制动报警临修换阀除外）在吹尘作业时进行重点吹尘。Checkaboutthesituationoftemporaryvalvereplacementduringtheoneauxiliary(A1)repairperiodofthisvehicle,focusondustblowingforvehiclesthathavebeentemporarilyrepairedandreplacedfortwoormoretimes.(二)设置防护信号Settingofprotectionsignals郑州铁路职业技术学院到达作业列车股道时，指定专人负责确认脱轨器状态，并插设防护号志。Whenarrivingatthetrackoftheoperationtrain,designateaspecialpersontoconfirmthestateofthederailmentdeviceandinsertaprotectivesignal.(二)设置防护信号Settingupprotectivesignals（三）检修作业Overhauloperation郑州铁路职业技术学院1.空气管系检修Airpipingsystemoverhaul总风软管、制动软管检查Masterairhose,brakehoseinspection制动软管更换Brakehosereplacement（1）检查制动软管、总风软管Checkthebrakehoseandmainairhose.（三）检修作业

Overhauloperations郑州铁路职业技术学院（2）检查折角塞门和截断塞门Inspectionoffoldingandtruncatedgates截断塞门、折角塞门作用灵活，安装无松动，角度正确。作用不良者更换为检修合格品。Cutofftheplugdoor,foldingangleoftheroleoftheplugdoorflexible,installationisnotloose,theangleiscorrect.Replacethepoorlyfunctioningoneswithqualifiedproductsforoverhaul.（三）检修作业Overhauloperations郑州铁路职业技术学院（3）管系及阀体等

Pipingsystemsandvalvebodies,etc.管系各管卡、吊架无松动、丢失，管子腐蚀超过管子壁厚1/2，超过时须更换。高度调整阀、空重车阀、差压阀安装牢固，配件无缺损。Pipesystemofeachpipeclamps,hangersarenotloose,lost,pipecorrosionmorethanpipewallthicknessof1/2,morethanthetimetobereplaced.Heightadjustmentvalve,air-heavyvehiclevalve,differentialpressurevalveisfirmlyinstalled,andthefittingsarenotdefective.紧急制动阀阀体、手把不得有裂损、弯曲。缓解指示器安装牢固、作用良好，面罩清洁显示清晰、正确。Emergencybrakevalvebodyandhandleshallnotbecrackedorbent.Reliefindicatorsaresecurelymountedandfunctioningwell,andmaskcleaningdisplaysareclearandcorrect.紧急制动阀手柄Emergencybrakevalvehandle缓解指示器mitigationindicator郑州铁路职业技术学院2.除锈吹尘

Rustremovalanddustblowing（1）清理各风管路、副风缸、工作风缸、制动缸、气路控制箱外部尘垢。Cleanthedustanddirtontheoutsideofeachairline,secondaryaircylinder,workingaircylinder,brakecylinder,andaircontrolbox.（2）连接单车试验器，进行除尘。Connectthebicycletestertoremovedust.除尘方法：关闭截断塞门及另一端折角塞门，用木槌敲打主支管、副风缸、工作风缸及连通管。Closethetruncatedplugdoorandtheotherendofthebendingangleplugdoor,withamallettobeatthemainbranchpipe,deputywindcylinder,workingwindcylinderandconnectingpipe.待风压充至600kPa，微控单车选择“快充位”，连续三次以上开、闭另一端折角塞门。Whenthewindpressureischargedto600kPa,themicro-controllerselects"fastchargingposition",andopensandclosestheotherendofthebendingangleplugdoorformorethanthreeconsecutivetimes.开通截断塞门，将车辆另一端的折角塞门关闭。依次连续三次以上开、闭副风缸、工作风缸等排水塞门，每次吹尘不少于2s、中间间隔不少于2s，关闭各排水塞门。Openthecut-offplugdoor,theotherendofthevehicle'sfoldingangleplugdoorclosed.Openandclosethedrainplugdoorofvicewindcylinderandworkingwindcylinderformorethanthreeconsecutivetimesinturn,blowingdustfornotlessthan2seachtime,withanintervalofnotlessthan2sinbetween,andcloseeachdrainplugdoor.（三）检修作业(iii)Overhauloperations郑州铁路职业技术学院检查压力表状态，检定标记须在有效期内。压力表等级须为1.6级，量程为0～1000kPa。Checktheconditionofthepressuregauge,thecalibrationmarkshallbewithinthevalidityperiod.Thepressuregaugemustbeclass1.6witharangeof0to1000kPa.除尘：用钢丝刷清扫组合式集尘器体和集尘盒表面污垢，检查螺栓孔附近无裂纹；止尘伞及立柱无变形、折断等；之后进行吹尘。Dusting:Cleanthesurfacedirtofthecombineddustcollectorbodyanddustcollectionboxwithawirebrush,andcheckthattherearenocracksneartheboltholes;Duststoppingumbrellaandcolumnwithoutdeformation,fractureandsoon;Afterthat,blowingdust.更换后须与微控单车试验器进行风压校对。Thereplacementshallbewindpressurecalibratedwiththemicro-controlledbicycletester.3.压力风表检修Pressuregaugeoverhaul4.远心集尘器检修Telecentricdustcollectoroverhaul（三）检修作业

Overhauloperations郑州铁路职业技术学院5.分配阀检修Distributionvalveoverhaul取出的滤尘器(网)，放于干净处；Removethedustfilter(net)andplaceitinacleanplace;选择“快充位”用600kpa压力空气进行吹尘，连续开闭截断塞门2-3次，每次吹尘不少于2s，中间间隔不少于2s；一个辅（A1）修期内发生2次及以上临修换阀（非104阀故障引起的TCDS报警除外）的要开闭截断塞门5次以上，每次吹尘不少于2s，中间间隔不少于2s；Select"fastchargingposition"with600kpapressureairtoblowdust,continuouslyopenandclosethecut-offplugdoor2-3times,eachblowingdustnotlessthan2s,withanintervalofnotlessthan2s;anauxiliary(A1)repairperiodoccursfor2timesandmorethanthetemporarymaintenanceofthereplacementvalve(exceptforTCDSalarmcausedbythefailureofnon-104valves)toopenandclosethecut-offplugdoormorethan5times,eachblowingdustnotlessthan2s,withanintervalofnotlessthan2s;阀体拆卸：Valvebodydisassembly:卸下阀的安装面上应装防尘罩；卸下阀的安装面上应装防尘罩Themountingsurfaceoftheunloadingvalveshouldbefittedwithadustcover；滤尘器(网)或杯须无锈蚀、堵塞、破损。Thefilter(mesh)orcupshallbefreeofrust,clogging,orbreakage.（三）检修作业Overhauloperations郑州铁路职业技术学院6.基础制动装置Basicbrakes(1)单元制动缸及夹钳Unitbrakecylindersandclamps清除单元制动缸杂物，对制动夹钳装置进行除垢；Removedebrisfromtheunitbrakecylinderanddescalethebrakecaliperunit;单元制动缸销轴压板螺栓紧固，销轴不窜出，防脱档齐全；Unitbrakecylinderpinpressureplateboltsaretight,thepindoesnotrunout,anti-disengagementgearcomplete;各制动销套配合间隙不超过3mm，衬套无松动窜出，螺栓紧固，开口销状态良好；Eachbrakepinbushingclearancedoesnotexceed3mm,noloosebushingout,boltsaretight,cotterpinsingoodcondition;基础制动装置各部须配件齐全，状态良好，各杠杆、吊杆、夹钳良好、无裂纹；Thebasicbrakingdevicemustbecompleteaccessories,goodcondition,eachlever,boom,clampgood,nocracks;检查闸片与制动盘两侧间隙之和不超过3～5mm。Checkthegapbetweenthebrakepadandthebrakediskonbothsidesofthesumdoesnotexceed3~5mm.闸片最薄处厚度不小于5mm，闸片须成对更换；作用不良的基础制动装置配件需更换Thethicknessofthethinnestpartofthebrakepadsisnotlessthan5mm,andthebrakepadsshouldbereplacedinpairs;thepoorfunctionofthebasicbrakefittingsneedtobereplaced.（三）检修作业Overhauloperations郑州铁路职业技术学院(2)制动盘Brakediscs制动盘盘毂无松动、裂纹；Brakedischubwithoutloosenessandcracks;制动盘整体厚度不小于96mm；Theoverallthicknessofthebrakediskisnotlessthan96mm;半盘连接部位和盘毂不得有裂纹，散热片不得有贯穿裂纹；Nocracksinthehalf-discconnectingpartsanddischub,andnopenetratingcracksintheheatsink;制动盘与盘毂连接螺栓紧固，螺栓、开口销无折损、丢失；Brakediscanddiskhubconnectingboltsaretight,boltsandcotterpinsarenotbrokenorlost;盘面热裂纹长度距内、外边缘≥10mm时，裂纹长度须小于95mm，否则应小于65mm。Thelengthofthermalcracksonthedisksurfaceshallbelessthan95mmwhenthelengthofthecrackis≥10mmfromtheinnerandouteredges,otherwiseitshallbelessthan65mm.（三）检修作业Overhauloperations郑州铁路职业技术学院“”制动拉杆不磨轮座和车轴，拉杆不抗转向架；Braketierodsdonotwearwheelseatsandaxles,andtierodsdonotresistbogies;制动梁不弯曲、变形、磨耗，缓解簧（或安全托）无裂损、丢失，螺栓不松动；Brakebeamsarenotbent,deformed,orwornout,reliefsprings(orsafetyrests)arenotcrackedorlost,andboltsarenotloose;缓解簧磨耗板不得丢失或窜出；Reliefspringwearplateshallnotbelostorrunout;各拉杆吊座，拉杆吊、固定杠杆、制动拉杆、移动杠杆及支座良好，各开口销角度符合规定：60°～70°；Eachtierodsuspensionseat,tierodsuspension,fixedlever,brakelever,mobileleverandsupportgood,eachcotterpinangleinaccordancewiththeprovisions:60°~70°;各圆销、衬套磨耗及销套间隙不大于3mm；Eachroundpin,bushingwearandpinbushingclearanceisnotmorethan3mm;圆开口销磨耗小于原直径1/4；Roundcotterpinwearislessthan1/4oftheoriginaldiameter;扁开口销磨耗剩余厚度不小于1.5mm。Theremainingthicknessoftheflatcotterpinisnotlessthan1.5mm.(3)踏面制动基础制动装置

TreadleBrakeBaseBrakeUnit（三）检修作业Overhauloperations（三）检修作业Overhauloperations郑州铁路职业技术学院7.手制动机

Handbrakes清除手制动拉杆、支点、托架、螺杆、齿轮箱、链及轮等零部件上的尘垢。Removethedustanddirtonthehandbrakelever,pivotpoint,bracket,screw,gearbox,chainandwheelandotherparts.手制动拉杆支点转动须灵活，紧固件齐全良好无松动。Thepivotpointofthehandbrakelevermustbeflexible,andthefastenersarecompleteandgoodwithoutloosening.分解蜗轮盒检查；手制动拉链条无裂损、钢丝绳无破损折断影响使用；手制动机标记须清楚正确。Disassemblethewormgearboxforinspection;nocracksinthehandbrakechainandnobrokenwireropesaffectingtheuse;thehandbrakemarkingsmustbeclearandcorrect.车辆在缓解状态下，向制动方向拧紧手制动机摇把制动，确认各基础制动装置状态；Vehicleinthestateofrelief,tothedirectionofthebraketightenthehandbrakemachinecrankbrake,confirmthestateofeachbasicbrakedevice;缓解手制动机，闸片须离开制动盘(或闸片无压力)，闸瓦制动客车闸瓦须离开轮踏面（闸瓦无压力)；Reliefhandbrakemachine,brakepadsshallleavethebrakedisk(orbrakepadswithoutpressure),braketilebrakebusbraketileshallleavethewheeltread(braketilewithoutpressure);反向拧紧手制动机摇把，确认是否发生反向拧紧制动的情况；钢丝绳有90～120mm的松弛量。Reversetighteningofthehandbrakemachinecrank,toconfirmwhetherthereversetighteningofthebrakeoccurs;wireropehas90to120mmofslack.郑州铁路职业技术学院1轴箱Axlebox外部除尘检查Externaldustremovalcheck轴端接地装置Shaftendgroundingdevice2轮对Pairofwheels轴身检查Axlebodyinspection轮对测量：踏面圆周磨耗、剥离，轮辋厚度等。Wheelpairmeasurements:treadcircumferentialwear,stripping,rimthickness,etc.（三）检修作业

Overhauloperations（四）单车试验

Bicycletest郑州铁路职业技术学院制动机试验时，校对制动压力表、总风压力表与单车试验器压力表压力差小于±10kPa。Brakemachinetest,proofreadingbrakepressuregauge,totalairpressuregaugeandsinglevehicletesterpressuregaugepressuredifferenceislessthan±10kPa.单元制动缸制动、缓解作用良好，无漏泄。Unitbrakecylinderbraking,relievingtheroleofgood,noleakage.活塞杆复位无卡滞现象。Pistonrodresetwithoutstagnation.制动时闸片压紧制动盘（闸瓦压紧轮踏面）；缓解时，闸片对制动盘无压力（闸瓦对轮踏面无压力）。Whenbraking,thebrakepadpressesthebrakedisk(thebraketilepressesthewheeltread);whenrelieving,thebrakepadhasnopressureonthebrakedisk(thebraketilehasnopressureonthewheeltread).对组装后的空气管路系统进行漏泄检查，各部无漏泄；检查各塞门、单向阀、制动缓解指示器、金属软管等作用不良者更换。Leakagecheckontheassembledairpipingsystem,noleakageinalldepartments;checkeachplugdoor,checkvalve,brakereliefindicator,metalhose,etc.Replacementofpoorlyfunctioning.（五）电子防滑器试验

Electronicanti-slipdevicetest郑州铁路职业技术学院使用毛刷对主机、压力开关接线进行清扫，检查接线及接线排无烧损、破损，接线压插接良好。Useabrushtocleanthemainframeandpressureswitchwiring,checkthatthewiringandwiringrowsarenotburnedorbroken,andthatthewiringiscrimpedandpluggedinwell.主机、压力开关及接线检修（五）电子防滑器试验

Electronicanti-slip