The scope of work performed is 3 diesel locomotives. Types of maintenance and repair of locomotives
3. Current repairs of diesel locomotive TGM6A
Current repair of TR-3 diesel locomotive TGM6A
Carry out all the work within the scope of the current repair of TR-2 and, in addition, perform the operations listed below.
1) Inspect the main bearings, bolts, washers and nuts for fastening the hangers.
2) Check the thickness, free diameter and interference (in special device) of the main bearing.
3) Check the placement of the crankshaft.
4) Inspect and measure the cylinder liners without the cylinder cover.
5) Separate the piston head from the trunk, clean the cooling cavity and replace o-rings, check the fastening of the pins in the head and the condition of the drain pipes, eliminate the existing faults.
6) Measure the pistons along the guide piece, piston pin bores and pin diameter.
7) Remove and inspect the camshaft drive splined sleeve.
8) Remove the camshaft and check the condition of the bearings and separable bushings, tighten the nuts securing the washers (tightening torque 1.2 kN-m).
9) Remove the regulator from the diesel engine, disassemble, wash and make the necessary repairs.
10) Remove from the diesel engine, disassemble and inspect the oil pump. Flush, inspect, and adjust the oil bypass and pressure relief valves.
11) Check the lateral clearance in the meshing of the rotary shaft worm with the teeth of the drive disc.
Hydraulic transmission.
1) Make a revision of the feed pump by turning Special attention on the condition of the bearings, wear of the sprocket and the sealing collar of the working ^ pump.
2) Fill the hydraulic transmission with turbine oil, make it work on it for at least 1 hour, then drain the oil and fill with fresh oil.
3) Measure the pressure in the nozzles of the lubrication system, which should be at least 0.01 MPa (0.1 kgf / cm2) by Idling diesel engine and 0.02 MPa (0.2 kgf / cm2) at the rated speed of the crankshaft.
4) Remove the automation units (speed switching unit, speed sensor) from the locomotive, subject them to a complete revision and jointly check their operation and set up on a special adjustment stand.
The carriage part.
1) Check the gearing of the axial gearboxes, for which, disconnect the cardan shafts from the hydraulic transmission and axial gearboxes, inspect all the shafts, raise the locomotive frame and roll out the bogies, open the hatch covers of the axial gearboxes, check the condition gear wheels, the location of the contact patch and the side clearance of the conical pair (its clearance should be no more than
1.6 mm, and the gap of the cylindrical pair is no more than 2.6 mm); check the axial play of the driving and driven shafts (should be no more than 0.5 mm).
2) Check the condition of the rubber shock absorbers of the reaction rods of the axial gearboxes, friction pairs and rubber shock absorbers in the bogie supports. When installing shock absorbers after inspection, each of them must be installed on the support on which it was located before removal. In the event of failure of one shock absorber, replace all four of the same bogie, and the shock absorbers must be selected as follows
so that the difference in deflection does not exceed 1.5 mm (check by pressing 70 kN).
3) Replace the grease in the cavity of the bearings and the axle stop of the roller bearing.
4) Carry out flaw detection of parts of propeller shafts and jet rods.
5) Inspect and inspect wheelsets in accordance with Instruction TsT / 2306, roller axle boxes - TsT / 2361.
Ancillary equipment.
1) Remove, flush and pressurize the water sections.
2) Remove the compressor from the locomotive and carry out work in accordance with the Instructions for its operation.
3) At least once every 4 years, carry out hydraulic test air tanks with a pressure exceeding the operating pressure by 0.5 MPa (5 kgf / cm2).
Electrical equipment.
Remove all electrical machines from the locomotive and disassemble, replace the unusable bearings with new ones, inspect and, if necessary, repair the generator armature windings. Grind and grind the manifold if necessary. The depth of the grooves during freezing of the collector should be kept within 0.8-1.0 mm. Replace worn brushes with new ones of the same brand.
The program for the repair of traction rolling stock in the repair locomotive depot Dalnevostochnoye provides for the following types Maintenance and current repairs: maintenance TO_2, TO_3; current repairs TP_1, TP_2, TP_3; average repair of SR.
In the repair system, much attention is paid to the maintenance of locomotives. Maintenance is a complex of operations to maintain the operability and serviceability of a locomotive.
Maintenance differs from repairs in the volume and content of work. Most of the maintenance work is performed at the TPP without removing the equipment and using machining. The main restoration work during maintenance: adjustments, locksmithing on site, replacement of unusable or quickly wearing parts when they reach their maximum tolerances with new ones, tightening, fastening, adding or changing lubricants in friction units.
Maintenance should ensure a high coefficient of technical readiness of locomotives, their uninterrupted and trouble-free operation in accordance with the train schedule, long-term operability. The running gears, braking equipment, locomotive signaling devices, speed meters, vigilance control devices and radio communication devices are subject to special control, that is, all components and assemblies, the good condition of which ensures the safety of train traffic.
Maintenance TO_2 and TO_3 is periodic and is designed to control technical condition units and systems of the locomotive in order to prevent failures in operation.
Maintenance TO_2 is carried out by an integrated team at the locomotive maintenance point (PTOL), which is a specialized department of the locomotive repair depot. The PTOL is equipped with the appropriate equipment and the necessary stock of parts and materials. Performed by highly qualified repair workers. In the TO-2 process, the following is checked: the sequence of operation of electrical devices, the condition of the batteries, the operation of diesel units and speed controllers, the condition of the axle boxes of the wheel pairs, spring suspension and the lever system of brakes, as well as blowing compressed air into electrical machines.
Maintenance of TO_3 is carried out by the complex team of the TO-3 workshop and employees - specialists from other workshops of the depot. This type of maintenance takes special place among other types of maintenance. In terms of the volume of repair work and the downtime of locomotives, this type of maintenance is more related to repairs. With TO-3, the work provided for by TO-2 is performed, and additionally: they inspect and check the rotational speed of the diesel engine crankshaft and the operation of the limit regulator; check the tightness and blow air into the refrigerator sections; remove and test the nozzles on the stand; the pistons are inspected and the windows of the diesel cylinder liners are cleaned of carbon deposits; filters are washed or replaced with new ones; inspecting and blowing air into electrical machines; measure the resistance of power and auxiliary circuits; check the fastening of motor-axial bearings and engine mounts; check the condition and characteristics of pantographs; inspect fuses and contactors of devices for high-voltage circuits and control circuits; inspect wheelsets, axle boxes, spring suspension; fixing parts of the crew; check the electrolyte level and density of batteries, sandbox nozzles and sand supply, etc.
Repair - a complex of operations to restore the serviceability, operability and resource of a locomotive, routine appearance, corresponding to the requirements of PTE, as well as elimination of failures and malfunctions arising during the operation of the TPN on the line or detected during the maintenance process. The repair system is designed to eliminate malfunctions and restore operability, ensure failure-free operation and operational reliability by disassembling, restoring the size and properties or replacing unusable parts, catch and locomotive assemblies.
Volumes compulsory works carried out for all types of maintenance and repair of TPMs of each type and type (series), are regulated by the Rules of the current and overhaul electric rolling stock, diesel locomotives, diesel trains, Instructions for the maintenance of electric trains in operation.
Locomotive current repair - repairs carried out to ensure or restore the operability of the locomotive and consisting in the replacement and restoration of individual units and systems.
The current repair of TR-1 includes the work provided for by the maintenance of TO-3, and additionally: inspection of the gears of the traction electric drive; checking the clearances of motor-axial bearings; revision of auto-brake equipment; checking the clearance of the diesel crankshaft bearings; revision and cleaning of turbochargers with filming from a diesel locomotive; inspection of piston rings and cylinder liners of a diesel engine; fuel equipment check; setting the voltage regulator; checking the operation of electrical circuits; checking the performance of compressors, the operation of the reverse current relay, sandboxes; thorough inspection of the crew's running gear, especially the wheelsets; revision of pantographs; survey, cleaning and repair of arcing chambers, contactors and high-speed circuit breaker.
During the current repair of TR-2, the work provided for by TR-1 is carried out, and in addition: turning of wheelset tires (if necessary) without rolling out from under the locomotive; revision of the articulation of electric locomotive bogies with a disconnector; revision of center plate supports with body lifting and automatic coupler friction devices; revision of motor-axial bearings of gear drives, auto-brake equipment; disassembly and repair of the piston group of a diesel engine, fuel pumps, crankshaft speed regulator; revision of axle boxes; repair of traction motor cooling fans. After the repair is completed, diesel locomotives are subjected to full rheostat tests.
During the current repair of TR-3, all work is carried out in the amount of TR-2 and additionally: revision of bearings of traction motors and auxiliary machines, impregnation of their windings, groove and groove of collectors; roll-out of bogies with disassembly and repair of engines and assemblies; turning of tires and inspection of wheelsets; removal and repair of batteries; repair with disassembly of electrical equipment. In addition, diesel locomotives are disassembled with a crankshaft cut; disassembly, inspection and repair of diesel engine crankshaft bearing liners, water and oil pumps, air blowers, refrigerator sections, speed controllers, twin-machine units. After repairs, complete rheostatic tests of diesel locomotives are performed to adjust and tune diesel generators for set parameters... The repair is completed by running the locomotive on the line and eliminating defects identified during the running-in.
Current repairs of TR-1, TR-2 and TR-3 are carried out in the shops of the repair locomotive depot. Renovation work are carried out by specialized and complex repair teams. The scope of work for each type of repair is shown in diagrams 2.1.1, 2.1.2 and 2.1.3:
The approved scope of work for each service and repair is called its characteristic. The time interval or mileage between two adjacent TO or TP having the same characteristics is called the overhaul period.
Preventive maintenance is assigned after a certain mileage (or operating time) of the locomotive has been completed.
The basis for establishing a system of scheduled preventive maintenance is monitoring changes in the state of locomotives, leading to failures under normal operating conditions.
Rice. 2.1.1
Rice. 2.1.2 - List of operations carried out within the scope of current repair of TR-2
Rice. 2.1.3
Medium repair of a locomotive (SR) is a repair carried out to restore serviceability and partial restoration of a locomotive's resource. In the process of secondary repairs, the following are carried out: removal of traction motors, auxiliary machines, equipment from the locomotive; repair of worn-out parts; partial replacement of them with new ones; impregnation of windings of electrical machines; repair of bogie frames and bodies; full examination of wheelsets with replacement, if necessary, of tires; development and repair of spring suspension; change of batteries; exterior and interior painting.
During this repair, they carry out an audit, inspection and adjustment of those units and parts of the EPC, the malfunctions of which cannot be eliminated and prevented without disassembling them. They carry out an audit of bearing assemblies, restoration of insulation of electrical machines, replacement of worn out wheelset tires.
TR-3 is the most difficult and time-consuming of the repairs carried out at the depot. When repairing, disconnect all connections of the body with bogies and body sections with each other. The body is then lifted, the carts are rolled out along the stall track, after which the body is lowered onto temporary supports and most of the electrical apparatus, auxiliary machines and other equipment are removed.
The carts are disassembled and the mechanical parts are sent to the respective depot workshops. Bogie frames are repaired on site or in the bogie compartment.
All electrical machines are repaired in the electrical machine department, devices - in the electrical equipment department.
After repair, the body is painted in a dedicated room with enhanced ventilation. The description of the technology of repair of e.s.s. are devoted to chapters 2-5.
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It is important:
If you urgently need to go, and it is heavy rain, night or dazzling sun outside, then most likely this will not stop you. But if you have already decided on a trip in such conditions, only one awareness of the difficulties of the upcoming trip is not enough.
Repair of electrical machines is carried out at current repair TR-3 diesel locomotive. The repair cycle of electrical machines must correspond to the repair cycle of a diesel locomotive and provide for the maintenance dielectric strength isolation, inspection, revision of assemblies and parts, bringing them up to the established standards for current repairs.
During the current repair of TR-3, perform the following mandatory work:
- - inspection of the electrical part of the skeleton with checking the inter-reel connections and lead wires; fixing pole cores; correct installation of the main and auxiliary poles and the fit of the coils; drying and impregnation of armature windings of traction electric motors and auxiliary machines, the condition of which requires replacement of bandages, wedges securing the winding, or the run of which (except for ED-118A, ED-118B, ED-108A and traction electric motors with polyamide insulation and impregnated in an epoxy compound) exceeds 360 thousand km on every second (from the construction or overhaul of the KR-2) current repair of the TR-3, followed by their coating with hot-drying insulating enamel. Anchors should be impregnated without removing bandages and wedges, if this was not required due to the condition. Anchor windings that do not have the damage listed above and whose mileage is less than 360 thousand km should be covered with electrical insulating enamel in accordance with the Instructions for impregnation. Pole coils, the insulation resistance of which in the cold state is below 20 megohms or are damaged, should be repaired with removal from the core. Pole coils, the insulation resistance of which is higher than the specified value, should be coated after cleaning with enamel in accordance with the current Instruction for impregnation N 105.25000.00275 / 89 of the branch of PKTB TsTVR for locomotives;
- - examination and repair of the mechanical part of the skeleton (stator) and its parts;
- - inspection and repair of the mechanical part of the armature (rotor);
- - magnetic or ultrasonic flaw detection of bearing inner rings and shaft journals;
- - processing, chamfering with chamfering and grinding of collectors (processing and grinding of collectors should be carried out only if necessary with minimal metal removal);
- - revision and repair of bearing assemblies, motor-axle bearings, brush holders and their brackets, traverses, manhole covers and fasteners;
- - verification and testing;
- - finishing and painting of electric vehicles.
Remove and disassemble electrical machines from the diesel locomotive, it is allowed not to remove the traction generators of shunting diesel locomotives from the diesel locomotive, provided that the insulation resistance in the cold state is not less than 20 megohms; the coils fit tightly on the poles and varnish coating the magnetic system and the armature are in satisfactory condition.
It is allowed to turn and grind the collector (perform only if it is necessary to significantly deplete, burns, etc.) of the generator on a diesel locomotive using a device, provided that the geometry and roughness are provided according to the requirements of the drawing. When turning and grinding, measures must be taken to prevent the ingress of copper chips into the winding of the machine.
When disassembling electric machine remove grease and lining from the motor-axle bearings, make an external inspection and defect, and measure:
- - insulation resistance of circuits with the identification of areas with low insulation;
- - radial clearances and axial runs of the armature in bearings;
- - air gaps between the pole cores and the steel sheet stack of the armature core;
- - the diameters of the motor-axle necks.
It is forbidden to dismantle anchors and skeletons unnecessarily (i.e. if the anchor or skeleton of this machine does not require major repairs).
