Drawings for VL10 electric locomotive

2.1 main components of the unit, their purpose and operation

The TK8 brake switch has a frame consisting of two sides and three angles. Cam elements, cam shaft, drive and locking device are installed on it. Cam element is assembled on two textolite strips connected at the bottom and at the top by struts. Brackets with fixed contacts and are attached to the plates, and in the middle part - bracket of movable contacts. Rocker with upper and lower movable contacts is pivotally mounted on it.

Not every electric locomotive device connected to the electric circuit must break the current. Some of the devices are designed for switching in circuits without breaking the current, i.e. at the time when the current does not pass through this circuit. Such switches in power circuits of electric locomotives are made by reversers and brake switches.

A reverser is a device that switches excitation windings or anchors of traction motors to change the direction of movement of an electric locomotive.

Brake switches are installed on electric locomotives with electric braking to change electric circuits when switching from traction mode to braking mode and vice versa.

On electric locomotives VL10 there are cam switches with group drive. As a reverser use two PK022T switches; as brake switches - two TC8B switches, respectively.

Reversers from brake switches differ in the number of cam elements and locking fingers. Otherwise, all of these switches have the same device with minor non-principle differences.

Brake switches have ten cam elements, and reversers - four or six. Each pair of reverser elements switches windings of two series-connected traction motors. On most electric locomotives, excitation windings are switched by the reverser due to the fact that a relatively small voltage is obtained between adjacent contacts of the reverser, determined by a drop in voltage in the winding.

Condition of the unit operation on the locomotive, characteristic damages and causes of their occurrence

Electrical devices of EPS operate in difficult conditions. They are affected by voltage and electric current varying in value. Devices are subject to dynamic influences during the movement (blows, pushes, vibration), to temperature fluctuations of the environment in quite wide limits (±40 °C and more). Mud, dust, moisture, as well as their location (in the body, on the roof, under the body) indicate a significant impact on the decrease in the operability of the devices. During the operation of the EPS, individual devices are often turned on and off. Therefore occur heating, podgar, and melting of contact parts, the mobile system is developed.

Most damage to electrical devices is caused by breakdown of insulation of current-carrying parts, which leads to melting, destruction of parts. In case of incorrect selection of material of friction surfaces and poor lubrication of hinges, accelerated wear of their and contact surfaces occurs. This in turn disrupts the clarity of the apparatus, leads to an increase in the transient resistance in contact, damage to the insulation.

Devices with the pneumatic drive, besides the listed above damages, have the following: wear of valves of gates, pistons, cylinders, cracks, leak of air in connections.

Serviceability and clear operation of electrical devices largely determine the reliability and reliability of the EPS operation. Therefore, they must ensure good contact, clear operation of the arc extinguishing and drive system, especially when the contacts are opened under current. The devices must have reliable fasteners, protection against penetration of dust, water, snow, dirt, sufficient insulation resistance.

Method of cleaning, inspection and control

Before disassembly, group switch is blown with compressed air. The frame is cleaned of dirt and old paint with scrapers or metal brushes. Parts of pneumatic drive are washed with kerosene, cam shaft is rubbed with napkins wetted in gasoline or alcohol and wiped with dry lint-free napkins.

Contact elements are washed with gasoline and rubbed with dry napkins. Arc-extinguishing chambers are cleaned from soot and metal deposit.

To ensure normal operation of contactors and other devices, the main parameters of the contact device are checked: failure, solution, pressing, contact profile, etc., since they change during operation during wear. Integrity and density of fitting of insulators and cam washers, camshaft and locking drum are also checked; order of actuation (disconnection) of contactor elements and their technical condition. Failure is required to compensate for contact wear. As the wear of the contacts increases, the failure decreases, which can lead to a decrease in the contact pressure and, consequently, to their heating. Failure is measured with a probe or special templates. The solution (rupture) of the contacts in operation depends on the thickness of the contacts.

With new or reconstituted contacts, the solution must meet technical requirements, since reducing the solution can lead to overlapping of the contacts. An increased solution formed by the wear of the contacts can lead to their overheating when closed. It is recommended to prevent wear of contacts greater than 1/3 of their thickness. The solution shall be changed by templates or conventional measuring tools.

Technology of repair (replacement, restoration, way of restoration) and increase in reliability

Remove swivel nuts that attach tubes.

Disconnect the tubes connecting the pneumatic valve.

To turn off two bolts of M10x25 and two M10x80.

Remove junction box with valves.

Disconnect two valves.

Remove two paronite gaskets.

Remove four tubes with a diameter of 8 mm.

Transfer the valves to the valve repair area.

Remove 60 M10x35 bolts from busbars and lead wires attachment.

Disconnect the busbars.

To turn off 20 nuts of M10.

Remove 20 M10x70 bolts.

Remove 20 plates.

Remove cam elements from selector switch (10).

Bend and knock out the cotter pin 3x20.

Remove push-pull rods of interlocking hinges.

To turn off M10x20 bolts fixing blocking.

Unlock.

Loosen nut M24, which attaches the gear.

To turn off four bolts of M12x30 fixing the pneumatic drive.

Disconnect pneumatic cylinder from the frame.

Remove M24 nut.

Press the gear off the shaft.

To turn off six bolts of M10x30.

Press the bearing housings out of the frame.

Remove the cam shaft from the frame.

Bend the cotter pin 3x20 and knock out.

Remove pivot joint axis.

Disconnect the lever from the hinge strut.

Bend and knock out the cotter pin 3x20.

Remove the lapping springs.

Take out the rod.

Remove the movable contacts.

To turn off M8x25 bolts.

Release the fixed contacts from the posts.

To turn off 6 bolts of M8x60.

Remove contact posts successively from the plates.

Remove the hinge strut from the lever.

Remove the bracket.

Remove M30 nut.

Remove cam washers in sequence.

Drill the 8x82 cylindrical pin.

Kick out the 8x82 cylindrical pin.

Remove the ring from the shaft.

Bend the cotter pin 3x20 and knock out.

Remove the push-pull rod.

Remove M6 nuts.

Remove contact fingers assembled.

Remove Mbx18 screws.

Remove locking contacts.

Bend and knock out the cotter pin.

Remove the roller from the frame.

To unscrew M5x12 screws.

Remove fingers from finger holders.

Remove M10x30 bolts.

Remove covers and gaskets.

Remove M16 nuts.

Remove washers and pistons.

Remove M10x25 bolts.

Remove rails with stop.

Remove the stop from the rack.

Then the main parts are repaired.

Framework

Clean the frame of old paint with a shaver and a metal brush. Brew the detected cracks by electric welding and grind. After welding, the surface must lie in the same plane.

Not more than 2 mm is allowed to be parallel. Run the thread in the holes with the throttle M10. Measure the dimensions between the mounting holes. They must not exceed 1 mm from the drawings. If the size of the hole deviates, brew by electric welding and drill new ones. After survey (repair) of a framework paint gray GF92HS enamel.

Cam element

During inspection of Getinax slats, their surfaces must be painted with electrically insulating enamel, and have no cracks, dents, bulged. If there are cracks and breakdowns, drill the split parts of the struts, disassemble the straps and replace the unsuitable parts. Clips of 15x15 edges to a depth of 5 mm are allowed. To smooth out the damaged sites of a covering an emery paper and to enamel GF92HS red.

Weld cracks on contact and hinge struts and treat them with a filler.

Run thread in holes with thrower M8. The diameters of the hole in the hinge post are checked. The diameter of the hole shall not exceed 12.5 mm. Drill the developed holes with a drill by 12.5 mm and with further installation of the new roller by 0 12.5. Galvanize the contact posts.

Movable contacts having a thickness of less than 10 mm are replaced by new ones. Measure the length of the fixed contacts and check the soldering quality at the bus connection with the contact. If the connection loosens, rivet it, if it is impossible, drill it with drill 0 8, install a new one and perform soldering with solder of POSS 302.

Fixed contacts with thickness less than 43 mm are replaced by new ones, developed and melted places are treated with a file. After replacement or repair, they are tin 9MK. Shunts with a wire break of more than 5% 180 + 230 pieces are replaced .

During inspection of the lever, detected traces of corrosion, cracks and dents with a depth of more than Z mm, an area of ​ ​ more than 1 mm and a number of more than 4 pieces on the cheeks are disassembled. The lever cheeks are bent by setting the ruler cheek on the plane. The gap between the ruler and the cheek plane is measured using a set of probes No. 4, it must be no more than 2 mm. If the clearance is more than 2 mm, if possible, the cheeks are flashed without disassembly, the same cheeks with dents up to Z mm deep and an area up to 1 cm2 are flashed without disassembling the lever. If impossible, the lever is disassembled, the cheeks are flashed with a depth of more than Z mm and an area of ​ ​ more than 1 cm2 using a hammer.

Measure the height of the collar and the diameter of the spliced part of the rivet. The shoulder height must be not less than 0.7 mm, diameter not less than 10 mm. In case of cracks on bushings, weakening of rivet joint, mismatch of collar dimensions and diameter of riveted part with technical requirements, rivets are drilled by drill and knocked out. The ends of the new rivets are flared and again measure the height of the collar and the diameter of the rivet, then the ends are painted with gray enamel GF92XS. When flattening the rivets on the press it is necessary to follow the specified safety measures according to the press certificate and safety instructions when working on the press.

We inspect and measure the spike, at a height of less than 4 mm it is drilled and replaced. The new one is installed in a heated state, after splitting in hot form, lower it into water.

Check the characteristics of the springs according to the drawings in cases of non-compliance with the drawing data, replace. Galvanize suitable springs. It is permitted to restore the steel springs with subsequent heat treatment.

Cam shaft

When repairing the cam shaft, first of all, its thread is inspected. The detected torn thread must be welded and cut again. Diameter of shaft necks for bearings is checked. In case of deviation from dimensions, wear and balls, necks are built up and processed on lathe.

At least 7.2 mm in case of cracks, brew and treat the ring. If dimensions do not correspond, replace it, refer to JI ( process.

Wash the bearings in kerosene, blow them with compressed air and wipe them with napkin. Check them for ease of rotation, paying attention to jamming and braking. In case of abnormal rotation of the bearing, rinse again and check again. Bearings with mechanical damages of parts (chips, cracks, fractures, radial run-out, and burrs on separators), corrosion on raceways, overheating traces shall be replaced. Strict control is also carried out on cam washers. Camshafts with cracks and wear of working surface more than 2 mm are replaced by new ones.

The failure of the keyway when its dimensions deviate from the drawing sizes of more than 8 + 0,013 mm is welded by electric welding and processed on a milling machine.

Blocking

Inspect the locking frame. Measure the thickness of the straps of the framework, which must be at least 9.2 mm, if the thickness does not match, replace the straps according to the technical process. Cut the detected cracks and process. The thickness of the bar at the thrust is also measured, if the size of the bar is less than 7.2 mm, it must be replaced, the cracks are brewed and processed.

Inspect and measure the roller diameter at the place of installation on the frame, diameter is not less than 19 mm. The thickness of the plate installed on this roller is not less than 7.2 mm, in case of non-conformity, replace. Roller necks having wear, as well as crumpled ends are restored by welding and subsequent treatment. Examine the contact pins and plates and replace the plates with thickness less than 2.5 mm if the thickness of the fingers in the working part is less than 1 mm and with cracks.

Finger holders and contact holders having balls and nicks must be cleaned and polished.

Drum

Clean all drum parts from dirt and inspect. If there are burns and cracks, replace the bakelite cylinder. Grind small surface heats of the cylinder with a depth of up to 1 mm with emery paper on a fabric basis.

If the thickness of the plate power and locking segments is less than 4 mm, the segments are replaced. The thickness of the insulation segments shall be less than the thickness of the contact segments by 1.5K2 mm. When replacing segments of an opening in a drum under screws for fastening of segments to close up wooden traffic jams on GF92HS enamel. When replacing all segments on the cylinder, the initial marking line must be shifted so that the screws do not fall into the previous holes. Holes for screws are drilled by drill 0 2.5 to a depth of 15 mm. To paint a drum GF92HS enamel gray.

Pneumatic drive

Wash all parts of the drive in kerosene. Examine. Replace the cylinder with cracks, including welded ones. The internal diameter of the cylinder is more than 100.4 mm replaced. A rack with cracks and tooth fracture, as well as with a tooth thickness of less than 6 mm at a height of 4 mm, is replaced.

Gears with teeth cracks and teeth thickness less than 6 mm at height 4.12 mm are replaced.

If the length of the stop is less than the drawing dimensions, build up and process.

Galvanize the air distributor tubes and replace the tubes with cracks and dents.

Lubricate the drive cylinder with rubber cuffs with ZhT79L TU 02540020105595404 lubricant with ZhTKZ65 TU 32CT54678 lubricant, in the amount of 120 grams per drive.

Air drive is painted with grey PF115 enamel from outside.

Then build. After replacement and repair of parts assemble the lever by connecting the lever jaws with the insert. Galvanize the lever, then install rivets, bushings and bearings between the cheeks. Spread rivets, controlling the size of the collar and diameter.

Assemble levers with movable contacts. Take turns to put contact posts on the bar. Put on brackets and attach them with bolts. After assembly, the contact line must be at least 80% of the width of the contacts, and the displacement of the contacts relative to each other must not be more than 1.5 mm. Bearings are lubricated by TSIATIM201, only those that do not have protective washers.

Camshaft assembly after repair:

Press the assembled ring on the shaft.

Insert Pin and Splice.

Put cam washers on the shaft in sequence, according to the drawing, install electrical cardboard gaskets between them and attach them with a nut. Gaskets are installed only if necessary to eliminate hanging of the roller from the cam washer.

After the lock is repaired, it must be assembled. To combine openings of the holder and to fix them by the M5X12 screw. To establish blocking fingers, on the place, having combined their openings with openings of paltsederzhatel and to fix them by M5x12 screws.

Insert the roller into the framing hole. Insert cotter pins into the roller holes and bend them.

To combine openings of paltsederzhatel with openings of the roller and to fix them by M6x12 screws. Align the tie rod hole with the roller hole. Insert the rod on the roller. We fix, install the push-pull rod, and bend the cotter pin into its hole.

After inspection and repair of TK8B brake selector switch, first, the assembled shaft is inserted into the frame holes. Then press the assembled bearing bodies on each side into the frame holes and attach them with bolts.

Installation of the gear on the shaft. After the key is installed in the key groove of the shaft, press the gear (pos. 1 and attach it with nut M24 with installation of spring washer.

Assembly and installation of pneumatic drive. Insert stop inside the cylinder and attach it with two M10x25 bolts with installation of spring washers.

After installation of stop lubricate its surface with ZhT79L lubricant TU0254-002-01055954-01. On the rack, install pistons and washers. Put new cuffs on pistons with a period of no more than two years from the day of manufacture. Attach pistons and washers on opposite ends of rack with nuts MB with installation of spring washer. The pistons shall not extend outside the cylinder. Apply gaskets at cylinder ends to eliminate air leaks during operation. Then align the four cover holes with the flange holes at the end of the cylinder and attach with M10x30 bolts. For fastening of the pneumatic drive on a framework we combine four openings of fastening of a cylinder with openings of a framework and we fix by M12x30 bolts with statement of spring washers.

To combine four openings of the junction box with gates, with framework openings, to insert tubes guides, to fix by M10x80 bolts imposing of new paronitovy laying. Screw the nipples into the cylinder and into the junction box, connect the junction box and the cylinder with tubes. When assembling, expand the ends of the new tubes to 0 12 mm at a length of 10 mm. New tubes bend in place when installing the air pipe.

Blocking assembled to establish and fix by M10x20 bolts to a framework and to connect to a shaft.

To establish and attach M10x70 bolts to a framework cam elements and to connect tires according to the scheme.

After installation of all elements, TK8B brake selector switch, on the frame, lubricate TSIATIM 201 grease with gear and rack of pneumatic drive.

Maximum permissible dimensions of parts in operation and of various types of both

To maintain electric locomotives in working condition and ensure their reliable and safe operation, there is a system for maintenance and repair of electric rolling stock. It was introduced by order of the Ministry of Railways of Russia dated December 30, 1999 N TsT725 and regulation No. 3r of 17.01.2005

The following types of maintenance and maintenance of DC electric locomotives of the VL series are provided:

maintenance of TO1, TO-2, TO-3 to prevent malfunctions, maintain electric locomotives in working and proper sanitary and hygienic condition, ensure uninterrupted, accident-free operation and fire safety. Maintenance of TO-3 can be abolished by the head of the railway in agreement with the Department of Locomotive Management of the Ministry of Railways of Russia;

maintenance of TO-4 for turning of wheelset bands, without their rolling out from under the electric locomotive when the optimal values of rolled stock and thickness of the ridges of the bands are reached for this operation area;

maintenance of TO5 performed by:

in the process of preparing an electric locomotive for placement in the reserve of the Ministry of Railways of Russia and long-term maintenance in the reserve of the railway - TO5a;

in the process of preparing an electric locomotive for shipment, in an inactive state, for overhaul to factories or other depots, for ongoing repair to other depots, transfer to the balance of another depot or redeployment - TO5b;

in the process of preparing an electric locomotive for operation after construction, repair at factories or other depots, after redeployment - TO5v;

in the process of preparing the electric locomotive for operation before issuing from the reserve of the Ministry of Railways of Russia or TCL - TO5g.

maintenance of TR1, TR-2 and TR3 for maintenance of operability of electric locomotives, restoration of the main operational characteristics and ensuring their stability during the between-repairs period by audit, repair, adjustment, tests and replacement of details, knots, units;

overhauls (KR-1 and KR-2) are the main means of "improving" electric locomotives and provide for the restoration of load-bearing body structures, complex repair of the frames of trolleys, wheelsets and reduction gears, traction motors and auxiliary machines, electric devices, cables and wires, restoration of drawing sizes of parts, etc. Major repairs of electric locomotives are carried out at repair plants.

The repair cycle includes sequentially repeated types of maintenance and repair. The order of their alternation is determined by the structure of the repair cycle.

The frequency of repair of main electric locomotives, i.e. runs between technical services and repairs, as well as the standards of downtime of electric locomotives at the same time are established by road managers taking into account specific operating conditions.

The standards for the duration of technical services TO4, TO-5, current repairs TP1, TR-2 and TP3 are established by the head of the railway, based on the technical equipment of the depot, rational use of the repair base, uniform loading of repair sections, ensuring high quality repair, testing and acceptance of electric locomotives after repair, as well as taking into account the fulfillment of the established norm depot percentage of faulty electric locomotives.

Equipment used for repair

Auxiliary tool

Wrench wrench: 32x36; 22x24; 46x50; 14x17; 27x30; 12x14. GOST 283971.

Pliers combined with GOST 554775.

Pulley collector B/C.

Hammer 78500051 GOST 231070.

Beard 78510171 GOST 721472.

Socket wrench 78120378 GOST 1173774.

Screwdriver 78100330 GOST 1719971.

Schaber.

Metal brush SM08800.

Panel GOST 136169.

Drilling machine HS12.

Welding generator PSO300.

Milling machine 6N81G.

Workshop repair table.

Paint brush KFP10 SM-048.

Verstak locksmith K2130.

Container for X2138 enamel .

Acetylene generator ANB1.25.

Tsiatin-201 GOST 62611 A.

Bath B/C.

Shop stencil.

AMI60 unit.

Ballot box B/C.

Container for metal failures P 229 000.

Containers for garbage K2.243.000.

Cutting tool

Throwers M10 26201433 GOST 326677. M8 28201219 GOST 322071.

Drill 012.5 GOST 88664. 0 8 GOST 88664. 0 2.5 GOST 1090264.

File 28200026 GOST 146569.

Key cutter 22340007 GOST 914068.

Emery paper on fabric basis E3760 50W GOST 500975.

Measuring tool

Measuring ruler 1500 GOST 42775.

Caliper of SC 02500.05 GOST 16673.

Plug on 012 A3 81331013A3 GOST 1481169.

Shoop N-4 GOST 88464.

3ubomer cord NTs1 GOST 536873.

Sheet plug M198.

Mernik TZ01701.

Template M083.

Dynamometer DPU0.02 GOST 1383768.

Probe No. 1 GOST 88264.

Unit test after repair

Check the connection of cam elements and the order of their actuation according to the diagram. On the output tires of the cam elements, according to the scheme, write the symbols of the leads using the black varnish BT99, stencil with font No. 7 and art brush.

Connect the air from the main line to the junction box with air pressure of 6 kg/cm2.

Check the pneumatic actuator in the RH position of the actuator rack. The mark "0" on the gear must be on the same line as the mark "0" on the rack. Clearance between rack and cylinder stop, at extreme positions of piston and fixed position of cam element in washer cavity, is eliminated by welding of plates on stop.

Adjust camshaft turns. When the cam shaft turns by 76 °, the locking pin must turn by 60 ° and the locking pins must open before the power contacts open, and close after the power contacts close.

When adjusting the parameters of TK8B brake selector switch, such as rupture, dip, pressure of power contacts, measuring tools are used. Rupture of power contacts shall be at least 17 mm measured using M082. The failure of the power contacts must be 1014 mm, which are controlled by a size of 710 mm between the contact and the lever insert, and measured by the MFR template. Adjustment of rupture and failure of power contacts and elimination of jamming.

Repair of cam elements is permitted by installation of gaskets with thickness of 1 mm, between the plates and the frame. During adjustment it is allowed to bend the lever insert. Pressure of power contacts is measured by dynamometer DPU0.02.

Workplace Organization

The equipment in operation shall be in full serviceability. The enclosure or protective devices shall be installed in place and secured accordingly. It is forbidden to operate on faulty equipment and in case of absence or faulty fencing.

Newly installed or out of major maintenance equipment can be put into operation only after its commission acceptance with the participation of the shop manager and labor safety engineer.

Verses, tables and racks shall be strong, stable and safe for operation and securely fixed on the floor. Yard boxes must have stoppers.

The surface of the milestones must be ridged with smooth material, tables and racks must not have potholes, burrs, cracks and other defects.

Rack shelves shall be inclined inwards to avoid falling of stored items.

Protruding edges and sharp corners must not be allowed during upholstery of the layout. The width of the workpiece shall be not more than 0.75 m. The distance between the inlays on the workpieces shall correspond to the size of the workpiece and shall be not less than 1 m between the axes of the inlays.

To protect workers from flying fragments, meshes with a height of not less than 1 m with cells not more than 3 mm must be installed on the meshwork.

Parts and materials received for processing shall be placed in special and clearly marked places.

Gears (belt, cable, chain, hinge, etc.) must have strong safety guards. Rotating components of equipment and mechanisms below 2.5 m from the floor shall be protected.

For each worker, a convenient workplace must be provided that does not constrain his actions during the work being performed. The workplace shall be provided with sufficient space for the placement of auxiliary equipment, as well as the necessary equipment for the storage of tools, tooling of blanks and processed products (racks, tables, boxes, bedside tables, etc.).

At the workplace under the worker's feet there must be a serviceable wooden grating, in which the distance between the bars must correspond to 2530 mm.

The workplace shall be sufficiently lit and kept clean.

Cleaning of the workplace shall be carried out during the working day and after each shift as finished products and wastes accumulate at workplaces.