項目四客車運用維修主講人：余建勇Lecturer:YuJianyong客車輔(A1)修作業Operationprocedureforauxiliary(A1)repairofpassengercar鄭州鐵路職業技術學院車輛運用與管理ApplicationandManagementofRailwayVehicle客車輔（A1）修作業BusAuxiliary(A1)RepairOperations鄭州鐵路職業技術學院安全注意事項：確認防溜Makesurethe

anti-slipfacilitiesareinplace作業前到安全員處簽字確認后上脫軌器；作業前到值班室簽字、插設防護號志Sign

with

thesafetyofficerbeforeoperationandgetonthederailmentdeviceafterconfirmation;Signin

thedutyroom

beforeoperation,inserttheprotection

signal按規定穿戴勞保用品Wearing

laborprotectionarticlesasrequired通過道口注意“一站二看三確認四通過”Payattentionto"onestop,twolooks,threeconfirmationsandfourpasses"whenpassingthroughthecrossing雨雪天氣時當心滑倒，登高作業時防止墜落，地溝作業時當心碰頭，現場作業時，不侵鄰限。Watchoutforslippinginrainyandsnowyweather,preventfallingwhenclimbing,watchoutformeetingwhenworkingintrench,don'tencroachonneighboringlimitswhenworkingonsite.二、客車輔（A1）修作業

BusAuxiliary(A1)RepairOperations鄭州鐵路職業技術學院（一）（二）（四）（三）（五）（六）（七）落成及質量檢查單車試驗設置防護信號作業準備檢修作業電子防滑器試驗撤除防護信號及歸隊二、客車輔（A1）修作業Theoperationprocessisdividedintoeightsteps:operationpreparation→settingprotectionsignal→overhauloperation→singlevehicletest→electronicanti-skiddevicetest→completionandqualityinspection→protectionsignalremove→operationcompletion.(一)作業準備Operationpreparation鄭州鐵路職業技術學院12做好風源排水除塵工作。Doagoodjobofdrainingandremovingdustfromthewindsource.3456微控單車試驗器每日開工前必須進行自檢，確保試驗器狀態良好。Themicro-controlledbicycletestermustbeself-checkedbeforestartingworkeachdaytoensurethatthetesterisingoodcondition.檢查工具、材料。Checktoolsandmaterials.調閱輔修前1個月TPDS數據，非空簧客車報警當量≥18且17及以上報警超過3次，空氣彈簧客車≥17時換輪或鏇輪。ChecktheTPDSdataonemonthbeforeauxiliaryrepair,thealarmequivalentofnon-airspringpassengercarsisnotlessthaneighteenandseventeen≥18and17orabovealarmsformorethanthreetimes.Iftheairspringpassengercarsarenotlessthanseventeen≥17,changewheelsorrotatewheels.作業之前必須正確佩戴勞保用品，嚴防人身傷害。Wear

laborprotectionarticles

correctlybeforeoperationtopreventpersonalinjury查詢本車一個輔（A1）修期內臨修換閥情況，對2次及以上臨修換閥的車輛（非104閥故障引起的TCDS制動報警臨修換閥除外）在吹塵作業時進行重點吹塵。Checkaboutthesituationoftemporaryvalvereplacementduringtheoneauxiliary(A1)repairperiodofthisvehicle,focusondustblowingforvehiclesthathavebeentemporarilyrepairedandreplacedfortwoormoretimes.(二)設置防護信號Settingofprotectionsignals鄭州鐵路職業技術學院到達作業列車股道時，指定專人負責確認脫軌器狀態，并插設防護號志。Whenarrivingatthetrackoftheoperationtrain,designateaspecialpersontoconfirmthestateofthederailmentdeviceandinsertaprotectivesignal.(二)設置防護信號Settingupprotectivesignals（三）檢修作業Overhauloperation鄭州鐵路職業技術學院1.空氣管系檢修Airpipingsystemoverhaul總風軟管、制動軟管檢查Masterairhose,brakehoseinspection制動軟管更換Brakehosereplacement（1）檢查制動軟管、總風軟管Checkthebrakehoseandmainairhose.（三）檢修作業

Overhauloperations鄭州鐵路職業技術學院（2）檢查折角塞門和截斷塞門Inspectionoffoldingandtruncatedgates截斷塞門、折角塞門作用靈活，安裝無松動，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Overhauloperations鄭州鐵路職業技術學院（3）管系及閥體等

Pipingsystemsandvalvebodies,etc.管系各管卡、吊架無松動、丟失，管子腐蝕超過管子壁厚1/2，超過時須更換。高度調整閥、空重車閥、差壓閥安裝牢固，配件無缺損。Pipesystemofeachpipeclamps,hangersarenotloose,lost,pipecorrosionmorethanpipewallthicknessof1/2,morethanthetimetobereplaced.Heightadjustmentvalve,air-heavyvehiclevalve,differentialpressurevalveisfirmlyinstalled,andthefittingsarenotdefective.緊急制動閥閥體、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.緊急制動閥手柄Emergencybrakevalvehandle緩解指示器mitigationindicator鄭州鐵路職業技術學院2.除銹吹塵

Rustremovalanddustblowing（1）清理各風管路、副風缸、工作風缸、制動缸、氣路控制箱外部塵垢。Cleanthedustanddirtontheoutsideofeachairline,secondaryaircylinder,workingaircylinder,brakecylinder,andaircontrolbox.（2）連接單車試驗器，進行除塵。Connectthebicycletestertoremovedust.除塵方法：關閉截斷塞門及另一端折角塞門，用木槌敲打主支管、副風缸、工作風缸及連通管。Closethetruncatedplugdoorandtheotherendofthebendingangleplugdoor,withamallettobeatthemainbranchpipe,deputywindcylinder,workingwindcylinderandconnectingpipe.待風壓充至600kPa，微控單車選擇“快充位”，連續三次以上開、閉另一端折角塞門。Whenthewindpressureischargedto600kPa,themicro-controllerselects"fastchargingposition",andopensandclosestheotherendofthebendingangleplugdoorformorethanthreeconsecutivetimes.開通截斷塞門，將車輛另一端的折角塞門關閉。依次連續三次以上開、閉副風缸、工作風缸等排水塞門，每次吹塵不少于2s、中間間隔不少于2s，關閉各排水塞門。Openthecut-offplugdoor,theotherendofthevehicle'sfoldingangleplugdoorclosed.Openandclosethedrainplugdoorofvicewindcylinderandworkingwindcylinderformorethanthreeconsecutivetimesinturn,blowingdustfornotlessthan2seachtime,withanintervalofnotlessthan2sinbetween,andcloseeachdrainplugdoor.（三）檢修作業(iii)Overhauloperations鄭州鐵路職業技術學院檢查壓力表狀態，檢定標記須在有效期內。壓力表等級須為1.6級，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，檢查螺栓孔附近無裂紋；止塵傘及立柱無變形、折斷等；之后進行吹塵。Dusting:Cleanthesurfacedirtofthecombineddustcollectorbodyanddustcollectionboxwithawirebrush,andcheckthattherearenocracksneartheboltholes;Duststoppingumbrellaandcolumnwithoutdeformation,fractureandsoon;Afterthat,blowingdust.更換后須與微控單車試驗器進行風壓校對。Thereplacementshallbewindpressurecalibratedwiththemicro-controlledbicycletester.3.壓力風表檢修Pressuregaugeoverhaul4.遠心集塵器檢修Telecentricdustcollectoroverhaul（三）檢修作業

Overhauloperations鄭州鐵路職業技術學院5.分配閥檢修Distributionvalveoverhaul取出的濾塵器(網)，放于干凈處；Removethedustfilter(net)andplaceitinacleanplace;選擇“快充位”用600kpa壓力空氣進行吹塵，連續開閉截斷塞門2-3次，每次吹塵不少于2s，中間間隔不少于2s；一個輔（A1）修期內發生2次及以上臨修換閥（非104閥故障引起的TCDS報警除外）的要開閉截斷塞門5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裝防塵罩；卸下閥的安裝面上應裝防塵罩Themountingsurfaceoftheunloadingvalveshouldbefittedwithadustcover；濾塵器(網)或杯須無銹蝕、堵塞、破損。Thefilter(mesh)orcupshallbefreeofrust,clogging,orbreakage.（三）檢修作業Overhauloperations鄭州鐵路職業技術學院6.基礎制動裝置Basicbrakes(1)單元制動缸及夾鉗Unitbrakecylindersandclamps清除單元制動缸雜物，對制動夾鉗裝置進行除垢；Removedebrisfromtheunitbrakecylinderanddescalethebrakecaliperunit;單元制動缸銷軸壓板螺栓緊固，銷軸不竄出，防脫檔齊全；Unitbrakecylinderpinpressureplateboltsaretight,thepindoesnotrunout,anti-disengagementgearcomplete;各制動銷套配合間隙不超過3mm，襯套無松動竄出，螺栓緊固，開口銷狀態良好；Eachbrakepinbushingclearancedoesnotexceed3mm,noloosebushingout,boltsaretight,cotterpinsingoodcondition;基礎制動裝置各部須配件齊全，狀態良好，各杠桿、吊桿、夾鉗良好、無裂紋；Thebasicbrakingdevicemustbecompleteaccessories,goodcondition,eachlever,boom,clampgood,nocracks;檢查閘片與制動盤兩側間隙之和不超過3～5mm。Checkthegapbetweenthebrakepadandthebrakediskonbothsidesofthesumdoesnotexceed3~5mm.閘片最薄處厚度不小于5mm，閘片須成對更換；作用不良的基礎制動裝置配件需更換Thethicknessofthethinnestpartofthebrakepadsisnotlessthan5mm,andthebrakepadsshouldbereplacedinpairs;thepoorfunctionofthebasicbrakefittingsneedtobereplaced.（三）檢修作業Overhauloperations鄭州鐵路職業技術學院(2)制動盤Brakediscs制動盤盤轂無松動、裂紋；Brakedischubwithoutloosenessandcracks;制動盤整體厚度不小于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;制動盤與盤轂連接螺栓緊固，螺栓、開口銷無折損、丟失；Brakediscanddiskhubconnectingboltsaretight,boltsandcotterpinsarenotbrokenorlost;盤面熱裂紋長度距內、外邊緣≥10mm時，裂紋長度須小于95mm，否則應小于65mm。Thelengthofthermalcracksonthedisksurfaceshallbelessthan95mmwhenthelengthofthecrackis≥10mmfromtheinnerandouteredges,otherwiseitshallbelessthan65mm.（三）檢修作業Overhauloperations鄭州鐵路職業技術學院“”制動拉桿不磨輪座和車軸，拉桿不抗轉向架；Braketierodsdonotwearwheelseatsandaxles,andtierodsdonotresistbogies;制動梁不彎曲、變形、磨耗，緩解簧（或安全托）無裂損、丟失，螺栓不松動；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、制動拉桿、移動杠桿及支座良好，各開口銷角度符合規定：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;圓開口銷磨耗小于原直徑1/4；Roundcotterpinwearislessthan1/4oftheoriginaldiameter;扁開口銷磨耗剩余厚度不小于1.5mm。Theremainingthicknessoftheflatcotterpinisnotlessthan1.5mm.(3)踏面制動基礎制動裝置

TreadleBrakeBaseBrakeUnit（三）檢修作業Overhauloperations（三）檢修作業Overhauloperations鄭州鐵路職業技術學院7.手制動機

Handbrakes清除手制動拉桿、支點、托架、螺桿、齒輪箱、鏈及輪等零部件上的塵垢。Removethedustanddirtonthehandbrakelever,pivotpoint,bracket,screw,gearbox,chainandwheelandotherparts.手制動拉桿支點轉動須靈活，緊固件齊全良好無松動。Thepivotpointofthehandbrakelevermustbeflexible,andthefastenersarecompleteandgoodwithoutloosening.分解蝸輪盒檢查；手制動拉鏈條無裂損、鋼絲繩無破損折斷影響使用；手制動機標記須清楚正確。Disassemblethewormgearboxforinspection;nocracksinthehandbrakechainandnobrokenwireropesaffectingtheuse;thehandbrakemarkingsmustbeclearandcorrect.車輛在緩解狀態下，向制動方向擰緊手制動機搖把制動，確認各基礎制動裝置狀態；Vehicleinthestateofrelief,tothedirectionofthebraketightenthehandbrakemachinecrankbrake,confirmthestateofeachbasicbrakedevice;緩解手制動機，閘片須離開制動盤(或閘片無壓力)，閘瓦制動客車閘瓦須離開輪踏面（閘瓦無壓力)；Reliefhandbrakemachine,brakepadsshallleavethebrakedisk(orbrakepadswithoutpressure),braketilebrakebusbraketileshallleavethewheeltread(braketilewithoutpressure);反向擰緊手制動機搖把，確認是否發生反向擰緊制動的情況；鋼絲繩有90～120mm的松弛量。Reversetighteningofthehandbrakemachinecrank,toconfirmwhetherthereversetighteningofthebrakeoccurs;wireropehas90to120mmofslack.鄭州鐵路職業技術學院1軸箱Axlebox外部除塵檢查Externaldustremovalcheck軸端接地裝置Shaftendgroundingdevice2輪對Pairofwheels軸身檢查Axlebodyinspection輪對測量：踏面圓周磨耗、剝離，輪輞厚度等。Wheelpairmeasurements:treadcircumferentialwear,stripping,rimthickness,etc.（三）檢修作業

Overhauloperations（四）單車試驗

Bicycletest鄭州鐵路職業技術學院制動機試驗時，校對制動壓力表、總風壓力表與單車試驗器壓力表壓力差小于±10kPa。Brakemachinetest,proofreadingbrakepressuregauge,totalairpressuregaugeandsinglevehicletesterpressuregaugepressuredifferenceislessthan±10kPa.單元制動缸制動、緩解作用良好，無漏泄。Unitbrakecylinderbraking,relievingtheroleofgood,noleakage.活塞桿復位無卡滯現象。Pistonrodresetwithoutstagnation.制動時閘片壓緊制動盤（閘瓦壓緊輪踏面）；緩解時，閘片對制動盤無壓力（閘瓦對輪踏面無壓力）。Whenbraking,thebrakepadpressesthebrakedisk(thebraketilepressesthewheeltread);whenrelieving,thebrakepadhasnopressureonthebrakedisk(thebraketilehasnopressureonthewheeltread).對組裝后的空氣管路系統進行漏泄檢查，各部無漏泄；檢查各塞門、單向閥、制動緩解指示器、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

Electronicanti-slipdevicetest鄭州鐵路職業技術學院使用毛刷對主機、壓力開關接線進行清掃，檢查接線及接線排無燒損、破損，接線壓插接良好。Useabrushtocleanthemainframeandpressureswitchwiring,checkthatthewiringandwiringrowsarenotburnedorbroken,andthatthewiringiscrimpedandpluggedinwell.主機、壓力開關及接線檢修（五）電子防滑器試驗

Electronicanti-slip