The plan of the main production building of the depot for the repair of passenger cars is shown in Fig. H.P. The basic principles of the placement of sections and sections of the depot for the repair of passenger cars are the same as for the freight carriage depot. In accordance with the design features of passenger cars, the depot has a number of additional production areas and departments and somewhat different equipment. Before being repaired, the wagons are washed and disinfected inside and outside.

For the mechanization of work related to the repair of bogies of passenger cars, technological equipment is used (Fig. X.12). The equipment is designed for the repair of 2,000 bogies per year, occupies an area of ​​360 m 2, and the conveyor line has a length of 36 m. The bogies, pumped out from under the car at the wagon assembly area, are captured by a car for their repair and transported to the bogie compartment. Here, with the help of wrenches installed on the repair machine, the nuts of the spinons are unscrewed and the wheel sets are lowered, which are sent to the department for their repair. The carts are transported by the machine to the production line and lowered onto the technological carts in the first position of the conveyor. The trolley is then transported by a conveyor into a washing machine, which is located in the second position. Washing is carried out with hot water at a pressure of 1.98 MPa by moving the movable nozzles around the trolley. After washing, the cart is moved by the conveyor to the third position. The mechanically coupled conveyor carts have a 6 m stroke equal to the distance between positions. The conveyor positions are equipped with hoists. To return the conveyor to its original position, the carriages are lifted in all positions, and the released technological conveyor bogies are returned to their original position. After that, the wagon bogies are again lowered onto the technological conveyor bogies, and the repair continues. The time taken to move and return the conveyor to its original position is 3 minutes. In the third position, the trolleys are disassembled using a press, a tilter and a crane, and the linkage is removed. Using a press, the central suspension is squeezed and disassembled. Then the trolley frame is turned by the tilter. In this position, control the distance between the pins and inspect the lower part of the cart. Then the frame of the disassembled cart is moved to the fourth position for assembling the cart. In the fifth position, small parts are installed and final assembly is performed. Sixth

Rice. X.11. The plan of the main production building of the depot for the repair of passenger cars: / - carriage assembly area with a painting room; // - automatic coupler repair department; /// - section for the repair of electrical equipment of cars; IV- repair area refrigeration equipment; V - department for the repair of heating and water supply devices; VI - roofing and tin department; Vii- auto brake repair department; VIII - carpentry department; IX - glass and wallpaper compartment; X- electric welding department; XI- woodworking and mechanical department; XII- service premises; XIII- generator repair; XIV.- pantry; Xv- instrumental department; Xvi- department of repair and manufacture of polymer parts; XVII - department for the repair of locks and filters; Xviii- forging and spring department; XIX-

repair area for roller bearings; Xx- bogie-wheeled section; XXI- park of bogies and wheelsets

position the cart is lifted. The wheel sets are installed on the raised cart with the help of the machine and the nuts of the spin-tones are screwed on. Then the bogie is moved to the wagon assembly site for rolling under the wagon.

The separation program is determined by the number of bogies coming from the wagon assembly area (100%) and bogies rolled out from under the wagons sent for current uncoupling repairs (15-20%).

The section for the repair of electrical equipment of passenger CMV is intended for performing depot and current repairs, technical inspections and revision of electrical equipment of passenger cars. Electrical equipment assemblies are repaired in an impersonal way, that is, faulty assemblies are replaced with new or pre-repaired ones. Finished products sent to the storeroom, from where they are issued for installation on a carriage.

Elements and assemblies of electrical equipment that require adjustment and adjustment at the stand after repair are issued to the carriage only in a sealed form. The absence or violation of the seals is regarded as a malfunction.

The site has the following departments: for the repair of electrical machines, repair of electrical equipment, radio equipment and instrumentation, batteries, repair of non-removable electrical equipment, technical inspections and revisions, repair of gear-cardan drives. The list of compartments may change depending on the design features of the passenger cars assigned to the depot.

The section for the repair of refrigeration units, passenger cars (Fig. X.13) is designed to perform depot and current repairs, technical inspections and revision of refrigeration equipment of passenger cars.

Repair of refrigeration equipment is carried out on the principle of replacing faulty units and parts that were repaired in advance.

Rice. X.13. Plan of the repair area for refrigeration units of passenger cars:

/ - separation of the discharge of refrigeration units from freon and oil and their charging; // - separation of dismantling, cleaning and washing; /// - department of repair and testing of instrumentation, automation and valves; / V - ■ department of disassembly, assembly and testing of refrigeration units and compressors; V- Compressor repair department; VI- department of repair of heat exchangers, accumulation plates and filters of dryers; Vii- painting department

mi or new. Repair and maintenance work, ensuring the good condition of the refrigeration equipment of passenger cars, is carried out in a special section.

The repair and completing section of the passenger depot (except for the sections for the repair of the automatic coupler, mechanical fitter, electric welding, spring-spring and automatic brake, considered when describing the cargo depot) includes the following sections.

The department for the repair of hydraulic vibration dampers of passenger car bogies is located in three separate rooms: cleaning of vibration dampers; repair and revision, painting, storage and regeneration of working fluid.

The department uses the following equipment: dry cleaning table, dynamic test bench, washing machine for vibration damper parts, stands for disassembly and repair, assembly stand, tanks for collecting working fluid during disassembly, regeneration unit, tanks for storing new and regenerated working fluid, dispenser , from which the damper, when assembled at the stand, is filled with a strictly defined volume of liquid, spray booth, racks for faulty dampers and their parts, as well as racks for remanufactured parts and repaired vibration dampers, etc.

Locksmith's department carries out repair of door locks, handles, hinges, sets of windows, doors and furniture. In this ot-

division carry out fitting and assembly work, as well as make parts for locks, handles and hinges. The department has work benches, a table-top drilling machine, shears for cutting sheet steel, and a sharpening machine. Workplaces are equipped with electric and pneumatic hand tools.

The department for the repair of heating, water supply and ventilation devices is intended for flushing, inspection and repair of air heaters, expanders, heating and water supply pipes, taps, tanks, working and spare filters, pumps and other units and parts of the heating and ventilation system. The department is equipped with racks for laying pipes and fittings received for repair; a bathroom in which parts are washed, cleaned from rust and dirt; work benches for inspection and determination of the scope of repairs; devices for threading pipes, cutting and bending pipes; work benches for the repair of valves, taps and various fittings, equipped with a vice and devices for lapping cork valves; table and stand for repair and testing of tanks, expanders and air heaters, racks for repaired units and parts. Filters are washed, repaired and impregnated usually in a separate room, which has racks for storing faulty and repaired filters, a two-chamber washer for washing filters, a bath for impregnating them with oil, and a centrifuge for removing excess oil. Here, paronite gaskets are impregnated with glycerin, heated to a temperature of 50-60 ° C. They are soaked in a special bath for 4-5 hours.

The boiler repair department is equipped with racks, workbenches for disassembly, a bathtub for removing dirt and old paint, a stand for descaling, a bathtub for rinsing the inner surface with a soda solution and running water, a stand for tinning the inner surface, a stand for repairing burnt fire box reflectors, faulty hatches of the boiler furnace and ash pan, a workbench for repairing fittings, a stand for testing fittings, a stand for painting boilers, a chamber for their drying, a stand for testing boilers.

Instead of tinning, the surface can be metallized with aluminum. In this case, after washing, the boilers are sent to the metallization department, where they are cleaned in a shot blasting chamber and metallized. After metallization, the boilers are returned to the compartment for general assembly.

Boilers that have faults in the electrical heating system are sent after the repair of the body and fittings to the section for the repair of electrical equipment of the cars.

The locksmith-picking department is intended for the repair and assembly of bogie assemblies: brake traverses, linkage, shoes with suspensions, parts for central suspension, liners for side bearings and leashes, over-axle friction dampers of vibrations of the bogies K.VZ-5 and KVZ-TsNII and spinons.

Parts of the trolleys enter the compartment in a cassette and are fed to the table for inspection, control and determination of the scope of work. The traverses and under-beams are fed to the storage table of the flow-conveyor line. In the first position, the worn-out ears of the traverse holes are welded, and the unusable ears are replaced. In the second position, the traverse trunnions and the necks of the beams are welded. The welded traverses and podlyuchnye beams are fed to the low-frequency collector, from which they are placed in cassettes for transportation to the mechanical compartment for processing. After mechanical processing These parts are checked at the inspection site, and then they are fed in cassettes to the third position, where holes are drilled in the ears of the traverse for rollers or bushings, and, if necessary, holes for cotter pins - in the trunnions on a special device. In the fourth position, the worn out bushings are removed and new bushings are pressed onto the trunnions, and the bushings are also pressed into the holes of the ears. The position is equipped with presses for pressing bushings and testing crossheads.

For the repair of parts of the linkage, the department has a storage table, on which the linkage is inspected, disassembled and the amount of repair is determined; welding cabin, where vertical levers, tightenings, suspensions and other parts that require welding are received (then they are sent to the mechanical compartment for processing); table for repair and assembly of linkage parts; press for replacing worn bushings. Brake rods are also repaired here, and there is a special test bench for testing them.

Repair and assembly of shoes with suspensions, parts for central suspension and axle box assembly are carried out on special tables. Parts requiring hardfacing are sent to the welding department, then to the mechanical department for processing, after which they go to the collection.

The department of polymer products and repair of rubber parts is intended for the repair of rubber and plastic products and the spraying of polymer materials on the surface of metal parts of cars. The department has a machine for injection molding of parts made of nylon, an installation for heat treatment of parts in oil and water and an oven for heating metal parts before and after spraying, a bath for spraying polymer on a part in a fluidized bed, a press for extracting parts from a press. forms.

For the repair of rubber parts, there is a workbench table, a press for pressing with simultaneous vulcanization of seals in a mold and gluing ready-made seals to technical rubber by vulcanization in a special device, a press for gluing rubber soufflés, an autoclave, etc.

The upholstery and carpentry department is intended for the repair of internal doors, sofas, tables, window frames and other wooden products of the internal equipment of carriages and has three separate rooms: for carpentry and assembly work; machine tool; for the production of wallpaper.

The department has the following equipment: circular and band saws, sharpening, planing-jointing, milling, combined and lathe, carpentry workbenches and a sewing machine for the repair and manufacture of draperies, covers, etc.

The metallization department is designed to cover parts of water supply and heating systems with a metal layer by spraying to protect against corrosion. The department has two rooms: shot blasting of parts and spraying of coatings. The department contains racks for parts requiring shot blasting; shot blasting chamber with apparatus; table; tool cabinets; racks for parts to be metallized; Workbench; racks for finished products.

The department of electroplating coatings is intended for applying protective and decorative coatings on car parts and for polishing aluminum parts. The department has rooms: grinding and polishing, coating, generator and ventilation chamber. A grinding and polishing machine, an installation for rolling emery powder onto felt wheels, racks for materials, tools and parts, and a glue machine are located in the grinding and polishing work room. In the coating room, galvanic baths are installed, each of which is equipped with a shield on which a voltmeter, an ammeter, a disconnector for connecting to the network and a rheostat are mounted. In addition to baths, they install assembly and disassembly tables, racks, drying cabinets, as well as a set of pendants and more. auxiliary equipment... In the generator room there are low-voltage generators, and in the ventilation chamber there are medium-pressure fans for suction of harmful gases from galvanic baths.

23. Post-repair warranty
24. List of referenced normative documents

Appendix A:
List of units and parts of increased resource
Appendix B:
Parameters of springs for central and axle-box suspension of bogies of 1435 mm track gauge
Appendix B:
Standards of tolerances and wear of components and parts of cradle bogies of passenger cars
Appendix D:
Standards of tolerances and wear of components and parts of wheelchair bogies of passenger cars
Appendix D:
Buffer types
Appendix E:
Specifications for Acid and Alkaline Batteries
Appendix G:
Block diagram of SKBiSPP equipment
Change registration sheet

1. Introduction

1.1 General

1.1.1 These Guidelines are intended for organizing the depot repairs of passenger cars owned by Russian Railways and subsidiaries, in car depots and at car repair plants.
The manual was developed on the basis of the design and operational documentation of the manufacturers and materials for investigating malfunctions arising during operation, as well as analyzing the wear of components and parts of passenger cars, establishes technical requirements to the scope of work performed during the depot repair, and indicates the permissible rates of wear of units and parts.
The guidelines apply to passenger all-metal locomotive-hauled carriages. railways RF gauge of 1520 mm with a speed of up to 200 km / h, as well as for passenger cars of Russian railways circulating in international traffic (except for cars of the VLAB-200 type).
In connection with the publication of this Manual, the previously valid regulatory documents:
- “Passenger cars, all-metal. Depot Repair Manual "CV 4255,
- “Passenger cars, all-metal. Depot Repair Manual "033 PKB TsL-04 RD,
- Passenger carriages on wheelchair bogies with disc brakes built by JSC TVZ.
- Manual for depot repair (DR) "047 PKB TsL-2007 RD,
- “Passenger carriages of models 61-4170, 61-4188, 61-4189 built by JSC TVZ.
- Manual for depot repairs "031 PKB TsL-03 RD shall be considered invalid.

When developing the manual, the repair requirements set out in the documents were taken into account in full:
- “Passenger cars, all-metal. Supplement to the Manual on the depot (DR) and overhaul (KR-1, KR-2) of bogies KVZ-TsNII-M "545 PKB TsV,
- “Air-conditioned compartment passenger carriage model 61-820 K.
- Depot Repair Manual "009 PKB TsL-98 RD,
- “Air-conditioned passenger compartment carriages of models 61-4179, 61-4174, 61-4186.
- Depot Repair Manual "019 PKB TsL-01 RD,
- “Passenger carriages of models 61-4170, 61-4188, 61-4189 built by JSC TVZ,
- the requirements for the repair of bogies set forth in the document “Manual for depot repair.
- Two-axle trolley type TVZ-TsNII-M "007 PKB TsL-98 RD.

1.1.2 Depot repairs are performed for the types of cars and within the timeframes established by order No. 15 of January 13, 2011 of the Ministry of Transport of the Russian Federation "On Amending the Order of the Ministry of Railways of the Russian Federation of April 4, 1997 No. 9C".

1.1.3 Depot repairs of cars are carried out at enterprises that have the necessary sections and departments equipped with the appropriate equipment.
Production areas and departments related to traffic safety are subject to certification in accordance with the provisions on certification of areas:
- Regulations on the certification of wheel-roller sections of carriage depots "RD 32 TsL 030-2009,
- "Regulations on the certification of the department for the repair of a gear-cardan drive" RD 32 TsL 015-03,
- "Regulations on the certification of control points of automatic coupling of passenger carriage depots (KPA)" RD 32 TsL 016-03,
- "Regulations on the certification of a production site for the repair and maintenance of electrical and refrigeration equipment" RD 32 TsL 017-03,
- "Regulations on the certification of the production site for the repair and maintenance of hydraulic vibration dampers of passenger cars in the depot, PTO" RD 32 TsL 018-03,
- "Regulations on the certification of control points of automatic brakes and automatic sections of passenger carriage depots (ACP)" RD 32 TsL 019-03.

1.1.4 Car repair enterprises must have technological equipment that ensures the repair of cars of the required volume and quality, in accordance with the requirements of this Manual, and contributes to a high technical level of repair with the lowest labor and material costs.
The location and layout of the sections and departments of the depot and workshops of the car repair enterprises should provide for the flow of technological processes and the reduction of transportation routes for parts and assembly units during the repair of cars.
The materials and components used in the repair must comply with the requirements of the design documentation, and those subject to mandatory certification in accordance with the current documents must have the appropriate documents and, where this is provided for by the documentation, marking directly on the product.
It is allowed to replace imported equipment and devices with domestic counterparts as agreed established order.
Make changes to the design of the main assembly units passenger cars (load-bearing elements of the body and frame, bogies, automatic couplers, brakes, wheelsets and axleboxes) are allowed only with the permission of Russian Railways, and the rest component parts of the carriage - with the permission of the Head of the Passenger Transport Department or his deputy.
Work on the modernization of passenger cars must be carried out in accordance with the technical documentation agreed in the established procedure.
For the production of depot repairs, a technological stock of necessary spare parts and materials must be created in the depot.
The dimensions of the technological stock of the main units are set taking into account the work performed and the actual consumption.
Carriages equipped with units and parts of increased service life undergo maintenance and repair in accordance with Order No. 15 of January 13, 2011 of the Ministry of Transport of the Russian Federation "On Amendments to the Order of the Ministry of Railways Russian Federation dated April 4, 1997 No. 9C ".
The list of units and parts of increased resource is given in Appendix A.

1.1.5 Means of measurement and tolerance control of industrial production, as well as not standardized, must be in good condition and timely undergo mandatory periodic state or departmental verification in accordance with the normative documents of the base organization of the metrological service.
Measuring instruments that have passed verification must have a verification mark or a corresponding verification document (certificate, certificate) must be issued.
Specific measuring instruments must be indicated in the technological processes for the repair of individual components and parts of cars developed on the basis of this Manual.

1.1.6. Repair of wagons should be carried out by highly qualified workers and specialists who know the technological process and organization of repair of wagons (units, parts). The personnel who repair the wagons must undergo training annually. In the cases stipulated by regulatory documents, these persons, after completing the training, are subjected to verification tests with the issuance of a document in the established form.

1.1.7 In production departments (sections) there should be reject isolators (closed rooms or containers) in which rejected units and parts are stored. Access to the defect isolator should be made only with the permission of the employees of the quality service of the enterprise.

1.1.8 The following documentation should be available at the repair sites:
- technological documentation;
- safety instructions;
- job descriptions;
- guidance documents;
- test logs, accounting renovation works(in cases stipulated by regulatory documents);
- design documentation (when manufacturing new parts or restoring parts after surfacing).

1.1.9 Specifications received on test equipment and measuring instruments, which include microprocessor technology for automated registration of the test, must be recorded on paper and signed by the responsible officials. Printing from magnetic media to paper is allowed on other printing equipment. Test results should also be recorded in journals.
Documents recording testimony during tests, as well as logs, should be recorded and retained.
Based on the documents on the repair (form VU-36), information is entered into the passport of the car of the form VU-5 and into the electronic passport of the car.

1.1.10 When cars are released from repair, they must have: information frames or boards for listing inventory items, internal regulations for passengers and train schedules, schematic diagrams of electrical equipment, heating, water supply, etc. (placed on the walls in the appropriate places of the car); a complete set of light bulbs, a set of V-belts to drive a car generator.
Restaurant cars with a liquid fuel kitchen stove must be equipped with a working burner ignition wick stored in a cover, a wick extinguishing tank, a wick holder, three keys for valves (taps) of fuel fittings, a set of grate bars and an ash pan door.

1.2 Preparing cars for repair

1.2.1 It is forbidden to disassemble the components and assembly units of the passenger carriage sent for repair.

1.2.2 Together with the cars, the car repair enterprise must be given technical passports, forms, accompanying sheets of the VU-26 form, certificates of the sanitary and epidemiological station about the washing and disinfection of cars, technical inventories of non-removable equipment and inventory of cars, and for damaged cars, in addition, acts of damage carriages of the VU-25 form.
In the absence of documentation on the car sent for repair, the car depots (sections) of the car registration must start new ones.

1.2.3 Damaged passenger cars with an unexpired depot repair period are sent for repair, depending on their technical condition after drawing up an act of the VU-25 form or an inventory confirming the need for this repair.
The transfer of such a car is carried out in accordance with the concluded agreement.

1.2.4 In wagon depots, before being put on a repair position, each car is inspected by the deputy head of the depot for repair, a senior foreman or a foreman together with a car receiver, check the correctness of uncoupling the car for repair using a stencil, and determine the scope of work followed by drawing up a defective list of repair work.
At the factories, each car is inspected by the head of the inventory bureau, an employee of the production department and a representative of the road (the sealed cars are examined by a representative of the inspection), after which an acceptance certificate for a passenger car of the ZRU-25 form is drawn up, which reflects the technical condition and completeness of the car.

1.3 Arrangement of cars for repair, fault detection

1.3.1 Before setting up cars for repair or sending cars for repair to other depots and car repair plants, carriage depots (sections) of the home road must clean them of garbage, coal, slag, rinse them inside and out and disinfect (if necessary, do disinfestation) , in accordance with the requirements of the "Technological instructions for external and internal washing of passenger car bodies" TI-TsLPV-1.
Particular attention should be paid to the cleaning of sanitary facilities and refrigeration containers. Before setting up wagons for repair, the collection tanks of environmentally friendly toilet complexes must be emptied, disinfected and cleaned from mechanical contamination in accordance with the requirements of the "Standard of sanitary and hygienic and anti-epidemic safety during routine maintenance, dismantling and repair of environmentally friendly toilet complexes. of closed type passenger cars for various purposes and cars of electric trains "ST 1.15.11.04-07. At restaurant cars with a liquid fuel stove and passenger cars with liquid fuel heating boilers, the fuel is drained in the prescribed manner.
At restaurant cars with a gas stove, gas cylinders are disconnected, safety devices and cylinders are removed from the car and sent for inspection and refueling.
The repair of passenger cars is recommended to be carried out by the flow method, in which, after completing a certain amount of work at a given position, the cars are sequentially moved from one repair position to another. The positions are arranged in the sequence stipulated by the “Typical Technological Process of Depot Repair of All-Metal Cars” (DR) TK-10 in the depot and at car repair plants.

1.3.2 Bogies are rolled out from under the wagons and delivered to the bogie area for repair.

1.3.3 The components and parts of the car are inspected, the defective ones are removed and sent to the appropriate departments for repair.

1.3.4 The procedure and scope of disassembly of assembly units of wagons is indicated in the relevant sections of this Manual.

1.3.5 Determination of wear and serviceability of parts in the process of flaw detection is carried out by external examination and special measuring instruments, templates and devices, means of magnetic and ultrasonic flaw detection.

1.3.6 All parts after disassembly of components and assemblies must be cleaned before flaw detection and repair.

1.3.7 During defect detection, the parts are divided into suitable for installation on a carriage without repair; requiring repair and restoration; unsuitable for further work and not subject to repair and restoration.

1.4 Repair of passenger cars

1.4.1 Depot repairs on uncoupled and sanitized wagons are carried out by specialized integrated crews after issuing a notification of the VU-23 form.

1.4.2 During depot repairs, flaw detection and repair are performed: bogies, car body and frame, buffer devices, transition platforms, hydraulic vibration dampers, brake equipment, shock-traction devices and automatic couplers, electrical equipment, electronic information system, control and diagnostic systems (C&D), heating and air conditioning systems, water supply systems, internal equipment, vestibule doors, toilet complexes.

1.4.3 Cars are repaired by replacing faulty components and parts with a new one of the appropriate type or repaired that meet the requirements of the design documentation, specifications and characteristics of this series of cars.

1.4.4 When repairing car equipment, in addition to this Manual, it is necessary to use the current technical documentation, the list of which is given in section 24.

1.4.5 The electrical equipment of the cars during the depot repair is repaired in accordance with this Manual, “Electrical equipment of passenger cars. Repair manual "030 PKB TsL-03 RK and other normative and technical documentation.

1.4.6 Gearbox-cardan drives of carriage generators are repaired in accordance with the documentation “Gearbox-cardan drives of carriage generators of passenger CMV. Repair manual "038 PKB TsL-04 RD.

1.4.7 Parts of cars according to the established list are tested in accordance with the requirements of the documents:
- “Details of freight and passenger cars. Tensile test method "656-2000 PKB TsV;
- "Fluxgate method non-destructive testing car parts "RD 32.149-00;
- "Eddy current method of non-destructive testing of car parts" RD 32.150-2000;
- "Magnetic particle method of non-destructive testing of car parts" RD 32.159-2000;
- "Guidelines for complex ultrasonic testing of wheelsets of cars" RD 07.09-97;
- “Non-destructive testing of car parts. General Provisions"RD 32.174-2001;
- "Non-destructive testing system at JSC FPC." Elements of wheelsets of 1520 mm gauge passenger cars. Requirements for ultrasonic testing "STO FPK 1.11.001-2011;
- "Non-destructive testing system at JSC FPC." Fluxgate method for non-destructive testing of passenger car parts "STO FPK 1.11.002-2011;
- "Non-destructive testing system at JSC FPC." Eddy current method of non-destructive testing of parts of passenger cars ”STO FPK 1.11.003-2011 and other valid documents.
When released from repair, such parts must have marks indicating the place, date of repair (manufacture) and testing.

1.4.8 Components and parts of cars are repaired by welding and surfacing in accordance with the "Instruction for welding and surfacing of units and parts during the repair of passenger cars".
Parts of cars, which are subjected to mechanical processing after welding and surfacing, are brought to drawing dimensions.

1.4.9 Carriage parts made of polymers are repaired in accordance with the “Instructions for the use of polymers in the repair of passenger cars” No. 260 PKB TsV.

1.4.10 Newly supplied wooden parts must comply with the design documentation and meet the requirements of GOST 3191-93 in terms of wood quality and moisture content.
Repair, as well as fireproofing of new wooden parts of cars is carried out in accordance with "Instructions for the repair of wooden parts of freight and passenger cars" No. 031 PKB TsV.

1.4.11 In the absence of requirements in the drawings for fireproofing or antiseptic treatment, the mating surfaces of wooden and metal parts must be primed.

1.4.12 Wagon parts subject to chrome plating in accordance with the requirements of the design documentation may be covered with other anti-corrosion and decorative coatings that do not impair the quality of the wagon condition (except for wagons for international traffic, as well as wagons with two or three-seater compartments).

1.4.13 Fasteners of cars must comply with the design documentation and the following requirements:
- screws and screws with heads affected by corrosion are replaced with serviceable ones;
- the damaged anticorrosive coating of screws and screws is restored by chrome plating, nickel plating, zinc plating or in another way according to the approved technology;
- bolts and screws must be lubricated with industrial oil GOST 20799-88 before being placed on the car;
- bolts fastening parts to the frame of cars and bogies must have cotter pins in accordance with the drawings of the car. The ends of the bolts that do not have cotter pins must protrude from the nut by at least two threads, and not more than the diameter of the bolt, except for bolts, the thread length of which is necessary for adjusting the dimensions according to the design documentation;
- bolted and riveted connections are performed in accordance with the requirements of the design documentation;
- split pins (undersized) GOST 397-79 in the absence special requirements must be no more than 3 mm from the nut or washer. The ends of the cotter pins are bred symmetrically at an angle of 60-90 °. The cotter pin at the castellated nut must fit into the slots in height at least 3/4 of the cotter pin diameter. Cotter pins are not allowed to be reused;
- bolts and rollers, located horizontally, are placed with nuts, washers and cotter pins outward, located vertically - with nuts, washers and cotter pins downward, except for those in which the setting of nuts, washers and cotter pins inward and upward is provided for by the design. Washers must be installed under the nuts, cotter pins and checks, according to the design documentation of the car manufacturer;
- weakened, non-standard rivets with the dimensions of the closing heads that do not meet the requirements of GOST 14802-85, as well as the design documentation on the cars are replaced;
- threaded connections must comply with the document “Threads for parts of wagons of 1520 mm track gauge railways. Types and sizes "RD 32CV 005-89.

1.4.14 It is prohibited:
- replace the riveted joints provided for by the design with welded ones, as well as put simple nuts instead of the castellated nuts provided for by the drawings ( technical conditions), except for design documentation, additionally agreed in the established order;
- mince, scald and tighten rivets;
- burn holes for bolts and rivets in metal parts; leave or install bolts and nuts that have worn out, stripped threads or knocked down edges, as well as install bolts that do not correspond to the design documentation;
- hammer in screws;
- leave unprimed places of contact of parts and assembly units removed for repair or replacement on the body, frame and bogie of the car;
- use materials that do not correspond to those specified in the design documentation, as well as use other materials that are not approved by the established procedure.
During depot repair of wagons, depersonalization of bogies is prohibited.

1.4.15 Rubber parts installed on cars must comply with the design documentation and be made of rubber in accordance with TU 2500-295-00152106-93, RTM 32 TsV 206-87 (with changes 32 TsV 13-90) and RTM 32 TsV 207-80 ...

1.4.16 Storage of components and parts of passenger cars, removed for repair or newly manufactured, must comply with the requirements of applicable standards or other technical documentation.

1.4.17 The assembly of cars after repair is carried out in accordance with this Manual, drawings of the manufacturer, regulatory and technical documentation.

2. Labor protection

2.1 Depot repairs of passenger cars are carried out in accordance with the requirements
- "Industry rules on labor protection in the passenger economy of the Federal Railway Transport" POT RO-13153-TsL-923-02,
- "Collection normative documents on management of labor protection in railway transport "ЦЭУ / 4826,
- as well as "Sanitary rules for the organization passenger transportation on railway transport "SP 2.5.1198-03.

2.2 The personnel performing the maintenance and repair of cars must be trained and tested in their knowledge of safety in accordance with the basic provisions "Organization of training and testing of knowledge on labor protection of workers in railway transport" TsSR-325 dated 04.05.95.

2.3 During the depot repair of wagons, the requirements must be met
- "Rules fire safety by rail "TSUO-112,
- "Instructions for ensuring fire safety in passenger train carriages" TsL / TsUO-448,
- “Departmental standards of fire safety Passenger cars.
- Fire safety requirements "VNPB-03,
- Standards for equipping objects and rolling stock of railway transport with primary fire extinguishing means No. G-822u,
- "Fire safety rules during welding and other hot work at national economy facilities" GUPO Ministry of Internal Affairs of the USSR,
- "Fire safety rules in the Russian Federation" PPB-01-93,
- "Interindustry rules on labor protection (safety rules) during the operation of electrical installations" (POTRM-016-2001 RD 153-34.0-03.150-00) and
- "Rules for the technical operation of electrical installations of consumers."

2.4 All workers carrying out the depot repairs must be provided with overalls and protective equipment in accordance with the "Model Norms for the Free Issuance of Certified Personal Protective Equipment", approved by Order No. 1248r of June 16, 2009. Collective and individual means workers' protection must meet the requirements of GOST 12.4.011-89.

2.5 Before lifting the car with electric jacks, make sure that the lift limiter (switch) is in good working order. Raising and lowering the car with four electric jacks simultaneously is carried out under the guidance of the foreman (foreman) of the section. At the same time, the presence of people on the carriage, under the carriage and in the carriage is not allowed.

2.6 Before starting repairs, wagons must be cleaned, washed and, if necessary, disinfected. Drainage tanks of eco-friendly toilets should be emptied of faeces, cleaned, rinsed and disinfected before being sent to a repair station.

2.7 Blowing out ventilation ducts and other units of the car at the repair position is allowed only when the dust-cleaning unit is switched on.

2.8 All production processes of painting are carried out in compliance with the requirements of the "Rules of safety and industrial sanitation for painting shops and sections of railway transport enterprises" TsTVR-4665, taking into account the requirements of the "Unified system of protection against corrosion and aging (ESZKS)" and "Fire safety rules for railway transport of the Russian Federation "TSUO / 112.
Painting inside the carriage in the room is carried out when the supply and exhaust ventilation unit is switched on.

2.9 Work on the roof of the carriage must be performed by an employee who has a medical examination and permission to work at height. Work is carried out using a safety belt.

2.10 Spare parts and materials must be supplied to workplaces in production containers that meet the requirements of GOST 12.3.010-82.

2.11 The movement of goods must meet the requirements of GOST 12.3.020-80.

2.12 When performing welding work, the welder must use a serviceable shield GOST R 12.4.238-2007, goggles GOST R 12.4.238-2007, gloves GOST 12.4.010-75. The places where welding works are performed on the site must be fenced off with portable screens with a height of at least 1.8 m. Welding wires must be protected from mechanical damage, wires with damaged insulation must not be used.

2.13 When performing locksmith, assembly and disassembly work, gloves GOST 12.4.010-75 are used, when cleaning welded seams and grinding work, in addition, protective goggles GOST R 12.4.230.1-2009. The use of an abrasive tool must comply with the requirements of GOST R 53001-2008.

2.14 Repair and testing of refrigeration units is carried out in accordance with the "Safety Rules for Working on Freon Refrigeration Units".

2.15 Repair and testing of electrical equipment of cars should be carried out in accordance with the requirements:
- GOST R 12.1.019-2009 SSBT. Electrical safety. General requirements and the range of types of protection;
- GOST 12.2.007.0-75 SSBT. Electrical products. General safety requirements;
- GOST 12.2.007.3-75 SSBT. Electrical devices for voltages over 1000 V. Safety requirements.

2.16 Operation, construction and inspection of lifting equipment must meet the requirements:
- GOST 1575-87 Hoisting cranes. Rows of basic parameters;
- GOST 12.2.071-90 SSBT. Hoisting cranes. Container cranes. Safety requirements;
- GOST 12.3.009-76 SSBT. Loading and unloading works. General safety requirements;
- GOST 12.3.020-80 SSBT. Processes of movement of goods in enterprises. General safety requirements.

2.17 Work with a defective tool is prohibited.

2.18 When changing the technology of work and the introduction of new technological means, the requirements of the relevant guidance documents on labor protection must be observed.

2.19 Safety and fire safety measures during the repair of the liquid fuel system of passenger cars and restaurant cars:
- disassembly, repair, assembly and testing of the liquid heating system of stoves, kitchens, restaurant cars must be carried out by employees who have been instructed and have the appropriate permission (certificate);
- in order to prevent the emission of a flame, it is forbidden to remove the covers and burners above the firebox while the burner of the carriage kitchen stove is working;
- it is allowed to fill fuel tanks (no more than 95% of their volume) at least two employees. In this case, the use of open fire is prohibited;
- when fuel is ignited in a liquid heating system, all fire extinguishing means, except for water (fire extinguishers, sand, etc.), may be used to extinguish the flame;
- during firing up, it is not allowed to overfill the burners with fuel more than 10 mm above the catalyst grid;
- when repairing the electrical equipment of the liquid heating system of the kitchen of the dining car, the job descriptions for the locksmith - electrician and other professions must be observed.

055PKBTSL-2010RD - Passenger cars. Depot repair manual
Branch Design Bureau of Passenger Facilities (PKB TsL JSC "Russian Railways")

The note contains ___ pages, __ figures, __ tables, __ sources used.

Passenger carriage depot; bogie area; passenger trolley; production area, spring, spring testing machine, cost price.

The project of the bogie section of the passenger carriage depot was developed for the repair of passenger bogies KZV-TsNII, KVZ-5. There are sections for washing, repairing bogies, magnetic testing and tensile testing of parts, a section for assembling springs and testing accumulation springs, a section for repairing and assembling levers, a section for repairing and assembling brake shoe suspensions with shoes and pads. The calculation of the pneumatic wrench has been made.

The calculation of the sling for lifting the container has been performed. The calculation of the economic efficiency from the introduction of new equipment has been made.

Introduction

The introduction of modern cars requires the creation of a modern technical base for their repair and maintenance. Currently, the wagon economy already has a wide network of enterprises for the repair, maintenance and equipment of passenger cars.

The development of systems of periodic repairs is carried out on the basis of the widespread introduction of in-line repair methods, both at assembly sites and at sites that provide repair and assembly of the main car assemblies.

1 Wagon depot for the repair of passenger cars

Requirements for the placement of production sites and depot branches

The main conditions for the placement of production sites in the building of the main building of the depot are technological requirements, as well as optimization of the transport scheme, taking into account both the organization of the inter-section transfer of car parts and assembled units to the car repair position, and the rational movement of people within the building. When planning production sites and departments, the following requirements must be observed:

a) all production units providing repair of parts and assemblies of cars should be located as close as possible to the repair positions;

b) compartments in which heat treatment of parts or their repair with preheating in furnaces is carried out must be placed in one group and isolated from other compartments with a fire-resistant partition;

c) the instrumental-distributing department is located in the middle of the building;

d) the electrical equipment repair area with all its departments should be located in one place, and the battery and impregnation department must be isolated;

e) the carpentry department should be located on the front side of the building;

f) the painting department is located on the continuation of the wagon-assembly section with the obligatory fencing of them with airlock vestibules with a width of at least 6 m.

g) preparation of cars for repair and disassembly should be located outside the main building.

1.2 The main production areas of the passenger

wagon depot

A production site is called a group of workplaces united for one reason or another, separated into an independent administrative unit and headed by a foreman.

Mechanical department designed for processing remanufactured or newly manufactured car parts, assembling and assembling individual units. The department has drilling, grinding, screw-cutting and milling machines, a hydraulic press for pressing in bushings and testing parts of the brake linkage, a stand for magnetic flaw detection of parts.

Locksmith-picking the department is intended for repair and assembling of bogie assemblies: brake traverses, linkage, shoes with suspensions, central suspension parts, slider and driver liners, over-axle frictional vibration dampers and bogie spinners.

Blacksmith department It is intended for repairing car parts by plastic deformation, restoring springs and springs, as well as making blanks. The department is equipped with pneumatic hammers.

Welding department serves to perform welding and surfacing works when restoring car parts. The department is equipped with special cabins. Where are the automatic and semi-automatic welding machines installed?

Automatic coupler checkpoint designed for the repair of car couplers. Repair of automatic couplers is organized on the production line, mechanized stands are provided for the repair of draft gears, repair of traction clamps is carried out on the production line, stands for welding and surfacing works, devices for processing parts of the shank clutch mechanism are used.

Boiler repair department equipped with shelving, workbenches for disassembly, a bathtub for removing dirt and old paint. A descaling stand, a bathtub for rinsing the inside, etc.

Department of polymer products and repair of rubber parts is intended for the repair of rubber and plastic products and the spraying of polymer materials on the surface of the metal parts of the car. The department has a machine for injection molding of nylon parts, an installation for heat treatment of parts. A bath for spraying polymers, a press for extracting parts.

Department of repair of heating devices, water supply, ventilation devices It is intended for the repair of heating, water supply and ventilation devices for cars, that is, water and storage tanks, heating and water supply pipes, pumps, boilers, water heating boilers.

Wheel section designed for the repair of wheelsets. After washing the wheelsets, their dimensions are checked and the journals of the pre-accessible and middle axle parts are controlled with a magnetic flaw detector, as well as with an ultrasonic flaw detector the approaching parts of the wheelset axles. Then the wheel sets are guided to turn the rolling surface of the wheels. After the repair, the wheelsets are measured, the quality of the repair is checked and painted, then they are sent to the bogie compartment. The site has departments for dismantling and mounting bearings, a department for repairing gearboxes.

Painting department serves for painting wagons and their subsequent drying.

Locksmith and lock department repairs door locks, handles, hinges, fittings, windows, doors and furniture. Fitting and fitting and assembly work is carried out. The department has work benches, a drilling machine, a sharpening machine.

Department of repair of trolleys the wagon assembly section is used for disassembly, repair and assembly of bogies. An overhead crane is used to move the bogies from the wagon-assembly section for repairs. Carts are repaired according to the general technological scheme. The pumped out bogies from under the car are fed to the bogie compartment, where they are washed in a washing machine and disassembled. The wheel pairs are directed to the wheel section, other units and parts of the bogies are inspected and the amount of repair is determined, and then sent to the appropriate departments, the central and axle-box spring suspension is replaced. Carts are assembled according to the principle of interchangeability using pre-repaired units and parts. The repaired bogies are transferred to the carriage assembly area for rolling under the car bodies.

Wagon assembly section designed for the production of disassembly, repair and assembly and painting works on the car. Such connections and fastening of parts and assemblies of the car are carried out, which provide it with the necessary operational qualities. The restoration of damaged surfaces of some units of the car is carried out, the mutual position and reliability of fit of the elements of the assembled unit are monitored.

Electrical equipment repair area  electrical shop , is intended for carrying out depot repairs, a single six-month audit and current repairs of the electrical equipment of the cars. The site consists of a department for repairing refrigeration equipment, repairing batteries, repairing radio equipment, repairing electrical units.

Radio equipment repair department equipped with equipment for checking the operation and repair of speakers and volume controls, checking and repairing tape recorders, checking and repairing amplifying equipment.

Department of repair of refrigeration equipment for passenger cars designed for depot and current repairs, technical inspections and revisions of refrigeration equipment. Repair is carried out on the principle of replacing faulty units and parts with pre-repaired or new ones.

graduate work

1.2 Proposals to improve the organization of repair of passenger cars in the carriage depot Rostov North Caucasus Railways

Having analyzed all the shortcomings of the carriage depot of the North Caucasus Railways, a number of measures are proposed related to the reconstruction of the depot and the section for repairing the automatic coupler, as well as improving the technical equipment of production areas and departments.

In particular, it is proposed:

Transfer the repair of cars to the flow method;

To make an extension of the painting department for two carriages;

Make an extension for transferring a number of sections and organizing the repair of trolleys using modern method repair of carts;

Make an extension to the automatic coupler repair site and organize a checkpoint, with all its inherent departments;

Introduce painting of cars using self-propelled platforms, on which spray heads are mounted for applying paint in an electrostatic field;

Introduce drying installations at MO;

Apply modern technological equipment in production departments in accordance with the latest Guidelines for depot repair of CM wagons / 1 /.

Railway carriage facilities

Organization road traffic in the city and the development of proposals for its improvement

pedestrian transport traffic The main disadvantage on the surveyed section of the street is the delay of the vehicle and the exit into the oncoming lane, since the stopped MTS occupy most of the lane ...

The carriage depot for the repair of freight cars is intended for depot, current finishing repairs, manufacture and repair of carriage parts for the needs of the depot and maintenance points, as well as equipment repair ...

Organization of work of the wheel section with the introduction of cleaning wheel pairs

In the depot, stationary and in-line methods are used when repairing cars. With the stationary method, the cars from the beginning to the end of the repair are at the same workplaces. Each of them carries out a full range of car repair works ...

Organization of work of the automatic coupler repair department

The degree and intensity of wear during the operation of rolling stock equipment depends mainly on the quality of maintenance and repair, operating modes, quality of parts and materials ...

The end-to-end wagon depot has ten fractional tracks, of which three are repair tracks, two are for wagon sludge, one is a bypass track, two tracks are for loading and unloading materials and wheelsets, two are exhibition tracks for pasture sludge ...

Project of a passenger carriage depot with the development of an automatic coupler control point

Determine the number of positions in the APU (number of stalls) according to the formula (5), see, (5) where T is the time the car is in repair, T = 40 hours; m is the number of shifts, m = 1. We determine the maximum allowable number of positions on the production line according to the formula (6), wag ....

Project of a passenger carriage depot with the development of an automatic coupler control point

The repair of automatic coupler equipment at the relevant enterprise is carried out in several areas: - at the automatic coupler repair area located in a detached production building ...

Repair and maintenance of passenger cars

Renovation of a section of Ilyich Street in the zone of the "2nd school" stopping point

The main disadvantage in the surveyed section of the street is the number of lanes for traffic. The road has 1 lane in each direction. This complicates travel, especially in the area of ​​the stopping point, and also leads to an increase in the likelihood of an accident ...

Improvement of traffic in the area of ​​the stopping point of the route passenger transport "Ul. Kalinina" (towards the street. Surganova)

Proposals for improving the organization of traffic are aimed at eliminating the identified deficiencies. In principle, some shortcomings can be eliminated almost completely ...

Improving the system of transport services for the population

Starting point for development strategic plan improving urban public transport there must be a strong-willed decision of the city authorities. It won't be easy to decide on the transformation ...

Improvement technological processes ground support of air transportation at airports, taking into account modern requirements

Existing organization chart freight transport is imbalanced in economic development capital and regions, as well as does not allow Russia to attract transit traffic ...

The structure and main functions of SOPP (Passenger Transportation Services)

1. Improved computer support; 2. To appoint only specialists with higher education on the organization and maintenance of air transportation or transport services; 3 ...

Maintenance wagons

The passenger carriage depot is a structural subdivision of Russian Railways. It is part of the regional passenger directorate long distance, which is subordinate to the Federal Passenger Company (FPK), which is a subsidiary of joint stock company Russian Railways JSC.

By the type of cars being repaired, the projected carriage depot is a passenger one, and by the nature of the work performed, it is a repair one. The projected depot is intended for the depot (overhaul) repair of cars, repair and assembly of car units and parts. The cars being repaired at the depot enter it in accordance with the terms of contracts concluded with Russian Railways and operating companies (for freight depots).

The production structure of a carriage depot is determined by the composition of production units, their mutual location and forms of technological interconnection. The type of wagons on which the depot is specialized determines the composition of production sites and departments required for the repair of its assemblies and parts. In the projected depot, all sections and repair departments, which are connected by a common technology and are united in the main building of the depot.

The main structural unit of a carriage depot is a production site, which may include several departments.

By the nature of production, all sections and departments of the depot are divided into main, auxiliary and service ones.

Operations are performed in the main areas production process for the repair of wagons and their units. Given the specialization of the projected depot, the main sections in it will include:

• - wagon assembly with departments for external washing and cleaning, preparation of wagons for repair, repair and assembly and painting (or without it);
• - trolley with a park of trolleys;
• - wheeled with a park of wheelsets;
• - roller with dismantling, repair, picking and assembly departments;
• - repair and completing.
• - repair of electrical equipment with departments for electrical machines, electrical equipment, batteries, radio equipment and instrumentation;
• - repair of refrigeration equipment and air conditioning units (VHF).

The repair and completing section includes the following departments: fitting and assembling, repair of hydraulic vibration dampers, locksmith, carpentry and wallpaper, repair of heating systems, water supply and ventilation, repair of boilers, toilets, mirror, polymer products and rubber parts, metallization, electroplating, repair of gear-cardan drives.

Subsidiary areas and departments manufacture products used for production in the main areas. These include: mechanical repair, electric power equipment repair depot, instrumental, storage depot and woodworking (when repairing covered wagons, platforms and passenger cars).

The servicing section includes a repair and utility section, which ensures the operation of a compressor station, a boiler room (if the depot has its own), a transformer substation, water supply and sewerage networks, transport and storage facilities, keeping workwear clean and repairing, current repairs of buildings and structures of the depot.