RAILWAYSECTORMaintenanceoflarge-scaleroadmaintenancemachineryRegularmaintenanceoflarge-scaleroadmaintenancemachinery1Inadditiontodailymaintenance,themaintenanceworkperformedafterthemachinehasbeenrunningforacertainperiodoftimeiscalledregularmaintenance.Regularmaintenancereferstothemandatoryinspection,adjustment,andmaintenanceofthemachineonaregularbasisaccordingtotheoperatingconditionsofthemachine.Regularmaintenanceoflarge-scaleroadmaintenancemachineryRegularmaintenanceisamorecomprehensiveinspectionandmaintenanceduringtheuseofthemachine,fromwhichcertainfailuresthathaveoccurredorareabouttoappearcanbefoundandeliminatedtopreventproblemsbeforetheyoccur.Therefore,regularmaintenanceplaysaveryimportantroleinensuringthesafetyandnormaloperationofthemachine.Regularmaintenanceoflarge-scaleroadmaintenancemachineryRegularmaintenanceisdividedintoprimary,secondaryandtertiarymaintenanceaccordingtothemaintenancecycle.Regularmaintenanceoflarge-scaleroadmaintenancemachineryPrimarySecondaryTertiaryThefirstlevelofmaintenanceiscarriedoutevery100hand200hoftheengine,andevery50hofotherworkingdevicesEvery300hand600hwhentheengineworks,Forotherworkingdevices,performasecondarymaintenanceevery200hours.Forevery1200hand2400hoftheengine,Forotherworkingdevices,athree-levelmaintenanceisperformedevery400hoursofwork.1.Engine(1)Maintenanceoftheengineevery100hoursofoperation①Samplingandtestingtheengineoil,andreplacingtheengineoilaccordingtotheoilinspectionandanalysisnotice.Iftheengineoilneedstobechanged,itmustbedoneinawarmstate.Whendrainingtheoil,tightenthedrainplugafteralltheoilhasflowedout.Whenrefillingnewengineoil,itisnecessarytoensurethatthefillingportandthenewengineoilareclean,andeffectivefilteringandcleaningmeasurescanbetakenwhennecessary.Stoprefuelingwhentheoillevelreachestheupperscaleoftheoildipstick,andchecktheoillevelagainaftertheenginehasbeenrunningforashorttime.Regularmaintenanceoflarge-scaleroadmaintenancemachineryBFL513CseriesdieselengineBFL513CdieselenginestructureInjector;2-Pushrod;3-Tappet;4-Fuelinjectionpump;5-Fantransmissionbox;6-Airdistributioncamshaft;7-Coolingfan;Fuelfillercap;11-shockabsorber;12-oilhydraulicpump;13-oilfilter;14-oilreturnpump;15-oilpan;16-crankshaft;17-mainbearingcap;18-connectingrod19-pistonoilcoolingnozzle;20-cylinderblockbolt;21-crankcase;22-cylinderblock;23-piston;24-cylinderhead;25-exhaustpipe;26-intakepipe;27-flameglowplug;28-Valvecover.②Cleanthecoarsefilterofthefuelfilter.Loosenthecompressionnuttopushthesnapringtooneside,takeoutthefilterelement,andcleanthefilterelementandfilterbodyindieseloil.Whenassembling,thefilterbodyshouldbecorrectlyassembledwiththesealingring.Regularmaintenanceoflarge-scaleroadmaintenancemachinery③Cleantheoutersurfaceoftheengine.Iftheengineisequippedwithatorqueconverterradiatorandanintercooler,theyshouldalsobecleanedatthesametime.Inharshworkingconditions,thecleaningoftheheatsinkisparticularlyimportant.Becausethedustaccumulatedonthecylinderblock,cylinderhead,andoilradiatorandthesludgecontainingdieselandengineoiladheretotheheatsink,itwillreducetheheatdissipationefficiency.Inparticular,theverticalcoolingfinpassageofthecylinderheadshouldalwaysbeunobstructedandshouldbecleanedcarefully.Regularmaintenanceoflarge-scaleroadmaintenancemachineryDrycleaningisrecommendedforcleaningtheheatsink,suchasblowingwithawirebrushandcompressedair,andblowingfromtheexhaustside.Ifitiscleanedwithapaintcleaner,itshouldbesoakedforenoughtime,andthenrinsedwithhigh-pressurewater.Finally,runtheenginetoevaporatetheresidualwaterandavoidrustonthesurfaceoftheparts.Cleaningwiththescrubbersteamnozzleisthebestmethod.Whencleaning,thefuelinjectionpump,generator,startermotorandotherelectricalappliancesshouldbecoveredandprotectedtopreventcontactwithwater.Regularmaintenanceoflarge-scaleroadmaintenancemachineryMostoftheexhaustmanifoldoftheengineiscoveredwithinsulatingmaterial.Iftheengineiscleanedwithflammableagent,itmustnotbebroughtintocontactwiththeinsulatingmaterial.Otherwise,aftertheengineisrunning,thereisariskofacombustionaccidentwhenthetemperaturerises.Whilecleaningtheengine,checkthesealingconditionoftherubberpipeontheintakepipeandtheexhaustpipeonthecylinderhead.Checkwhetherthefunctionoftheengineemergencystopdeviceisflexibleandreliable.Regularmaintenanceoflarge-scaleroadmaintenancemachinery(2)Maintenanceoftheengineevery200hReplacethefiltercartridgeorfilterelementoftheoilfilter.Disassembletheoilfiltercartridge:firstloosenthetwoclampscrewswithascrewdriver,andremovetheclampdownwards,loosenthefiltercartridgewithascrewdriver,andthenunscrewitbyhand.Cleanthesealingsurfaceofthefilterbracketwhenitisdirty.Installthefiltercartridge:Applyasmallamountofoilontherubbersealring,turnthefiltercartridgebyhanduntilitrestsonthesealring,andthentightenthefiltercartridgewithbothhands.Itisstrictlyforbiddentotightenthefiltercartridgewithtools.Tightentheclamptopreventthefiltercartridgefromlooseningautomatically.Regularmaintenanceoflarge-scaleroadmaintenancemachinerySchematicdiagramoffuelsupplysystemwork1-switchwithkey;2-heatingstartswitch;3-heatingindicatorlight;4-heatingresistance;5-solenoidvalve;6-fuelpump;7-fuelinjectionpump;8-flameheaterplug;9-fuelinjector;10-primaryfuelfilter;11-two-stagefuelfilter;12-fueltankAfterinstallingtheoilfilter,performatestrun.Itshouldbeobservedwhethertheoilpressureisnormalandthesealofthefiltercartridgeisgood.Regularmaintenanceoflarge-scaleroadmaintenancemachineryDieselfiltercomponents1-oilinlet;2-filtercover;3-handpump;4-bleedscrew;5-flangeforinstallation;6-heater;7-oiloutlet;8-spinningfilter;9-setWatertank;10-drainscrew;11-oiloutletIftheengineisequippedwithanoilfilterwithareplaceablefilterelement,replaceandcleanthefilterelementaccordingtothefollowingtimeandrequirements.Aftertheenginehasbeenworkingfor20-30hours,removetheoilfilterassembly,loosentheboltswithawrench,takeoutthepaperfilterelement,replacethemetalmeshfilterelementorpaperfilterelement,tightenthebolts,andthenreplacetheoilfilterassemblyInstalledonthebody.Regularmaintenanceoflarge-scaleroadmaintenancemachineryAfterreplacingthemetalmeshfilterelement,themetalmeshfilterelementshouldbecleanedregularly,usuallyafterrunningfor200hours.Accordingtothequalityoftheoilused,thecloggingofthemetalmeshfilterelementbythedirtisdifferent,sothecleaningcycleofthefilterelementshouldbedeterminedaccordingtopractice.Tocleanthemetalmeshfilterelement,firstremovetheoilfilterassembly,thenuseawrenchtoloosenthebolts,takeoutthemetalmeshfilterelementandbrushitcleanindieseloil.Assembletheoilfilterassembly.Ifthemetalmeshisfoundtobedamagedduringcleaning,anewfilterelementshouldbereplaced.Regularmaintenanceoflarge-scaleroadmaintenancemachineryCleanthefiltercoveronthecoolingfanfluidcoupling.Afterlooseningthelockingcirclip,removethefanguard,removethefiltercoverandcleantheinside.PayattentiontothecorrectpositionoftheO-ringsealduringinstallation,andreplaceitimmediatelyifitisdamaged.Checkandtightenthefasteningboltsontheengine.Regularmaintenanceoflarge-scaleroadmaintenancemachinery(3)Maintenanceoftheengineafterevery300hoursofoperationFornewenginesorenginesthathaveundergoneoverhaul,thefirstvalveclearanceshouldbecheckedaftertheenginehasbeenrunningfor50hours,andthevalveclearanceshouldbecheckedevery300hoursundernormaloperatingconditions.Undersevereworkingconditions,suchasfrequentlystartingtheengineeveryday,andtheenvironmentwithalotofdust,etc.,theinspectionperiodshouldbeshortened.CheckingthevalveclearanceWhentheengineiscold,useafeelergaugewithathicknessof0.2~0.3mmtocheck.Thevalveclearancethatdoesnotmeettherequirementsshouldbeadjusted.Regularmaintenanceoflarge-scaleroadmaintenancemachinery(4)Maintenanceoftheengineevery600hCheckthecylinderheadtemperaturealarm.Removethetemperaturesensor(forthermometer)ortemperaturealarmswitch(fortemperaturealarmlamp)fromthecylinderhead,andimmersetheminhotoilat170～175℃.Atthistime,thepointerofthethermometershouldpointtotheredareaOrthewarninglightison.Checkthestatusofthegenerator.Checkthetightnessandsealingstateoftheintakeandexhaustmanifolds,andfurthertightentheconnectingboltsifnecessary.Regularmaintenanceoflarge-scaleroadmaintenancemachinery(5)Maintenanceoftheengineafterevery1200hoursofoperation①Replacethefilterelementofthedieselfilter.Afterevery1200hoursofworkoriftheenginepowerisfoundtobereducedinnormaltimes,thefilterelementofthedieselfiltermustbereplaced,andthesealingsurfaceofthefilterbracketshouldbecleanedatthesametime.Regularmaintenanceoflarge-scaleroadmaintenancemachineryDieselfiltercomponents1-oilinlet;2-filtercover;3-handpump;4-bleedscrew;5-flangeforinstallation;6-heater;7-oiloutlet;8-spinningfilter;9-setWatertank;10-drainscrew;11-oiloutletAfterthenewfilterelementisinstalled,theairinthefiltershouldbedrained.Thespecificmethodis:loosenthebleedscrewplugfor2to3turns,turnthehandleofthefuelpumptothelefttoloosenit,pressthehandoilpump,andtightenthebleedplugagainwhenthereisnofoamspilledfromthebleedscrewplug.Screwplug.Regularmaintenanceoflarge-scaleroadmaintenancemachineryDieselfiltercomponents1-oilinlet;2-filtercover;3-handpump;4-bleedscrew;5-flangeforinstallation;6-heater;7-oiloutlet;8-spinningfilter;9-setWatertank;10-drainscrew;11-oiloutlet②Checkthetightnessandsealingofthesuperchargedairpipe,exhaustpipeandtheinletandoutletoilpipesoftheexhaustgasturbocharger.Payspecialattentiontothesealingandtightnessoftheconnectingpipebetweenthesuperchargedairpipeandtheexhaustgasturbocharger.,Andcleantheexhaustgasturbocharger.Regularmaintenanceoflarge-scaleroadmaintenancemachinery③Checkthefunctionoftheflameglowplug.Checkthefunctionoftheflameglowplugbeforeenteringthecoldseason.Whencheckingtheelectricalfunctionoftheflameglowplug,placetheenginestartswitchinthepreheatingposition,andtheheatingindicatorlightmustbeonafterabout1minuteofpreheating.Whencheckingthefuelsupplyoftheflameglowplug,loosentheconnectionthreadoftheflameglowplugafewturns,puttheenginestartswitchonthestartposition,andstartthemotortomaketheengineidling.Atthistime,thedieselfuelmustflowoutoftheconnectionthread.Ifthereisnodieseloutflow,thefaultshouldbeeliminatedintherepairshop.Whenperformingtheaboveinspection,itshouldbenotedthattheenginethrottlemustbeplacedinthestopposition.Regularmaintenanceoflarge-scaleroadmaintenancemachineryBlockedflameglowplugsshouldbereplaced.Whenthefunctionoftheflameglowplugisintact,theintakepipeneartheflameglowplugfeelswarmwhentouchedbyhandduringthestart-upprocess.Regularmaintenanceoflarge-scaleroadmaintenancemachinery④Maintainthegeneratorandpayattentiontothefollowingpoints:aWhentheengineisrunning,theconnectionlinebetweenthebatteryandthegeneratormustnotbedisconnected.b.Theconnectingwireofthebatterymustnotbeconnectedwrongly.cIfthechargingindicatorisdamaged,replaceitimmediately.dWhencleaningtheengine,thegeneratorshouldbecoveredtoavoidenteringthedirt.e.Thegroundcontactmethodcannotbeusedtocheckwhetherthegeneratorwirehasvoltage.⑤Checkthestartingmotor.Regularmaintenanceoflarge-scaleroadmaintenancemachinery(6)Maintenanceoftheengineevery2400h①Replacethecrankcasebreathervalve,removethefourhexagonbolts,removethebreathercover,andreplacethevalvecore.②Removethefuelinjectionpump,checkitonthefuelinjectionpumptester,adjustittothecorrectworkingpressureaccordingtotheengine'srequirements,andreplaceitifnecessary.Theinjectionpressureofthefuelinjectionpump:theopeningpressureoftheBFL413Fseriesenginefuelinjectionpumpis17.5～18.3MPa,andtheinjectionpressureis43.5MPa;theopeningpressureoftheBFL513seriesenginefuelinjectionpumpis27MPa,andtheinjectionpressureis65MPa.Inadditiontoregularmaintenanceofthefuelinjectionpump,itisonlynecessarytocheckthefuelinjectionpumppressurewhentheengineisabnormal.Regularmaintenanceoflarge-scaleroadmaintenancemachinery③Removetheexhaustgasturbocharger,andcleantheturbochargershellandimpellerindieseloilornon-corrosivewashingliquid.Afterreinstallation,carefullycheckthetighteningoftherelevantparts.Regularmaintenanceoflarge-scaleroadmaintenancemachinery2.Powertransmissionandrunningbrakingsystem(1)Inspectionandmaintenanceevery50hoursofwork①Checktheoillevelofthetransfercase,reductionbox,axlegearbox,bridgedriveshaftbox,andpowershiftgearbox,andreplenishitifitisinsufficient.Regularmaintenanceoflarge-scaleroadmaintenancemachineryTransfercaseand2driveshafts②Addlubricatinggreasetothecrossheadoftheenginepoweroutputdriveshaft.③Checkthedriveshaftforcracksanddeformation,andifthereisabnormalnoiseduringtransmission,replaceifthereisany,andtightenthedriveshaftboltsandnuts.④Checkthewearofthebrakeshoe.Ifthebrakeshoethicknessislessthan12mmorthereisacrack,itshouldbereplacedimmediately.Thebrakeshoegapshouldbeadjustedwithintherangeof3～10mm,andshouldbeadjustedwhenthebrakeshoeispartiallyworn.Regularmaintenanceoflarge-scaleroadmaintenancemachinery⑤Checkwhethertheaircompressorisworkingnormally.Whentheenginespeedis2300r/min,thetotalaircylinderpressurewilltakeabout8minutestorisefromzeroto700kPa.⑥Inspecttheconnectingrods,pins,brakebeams,brakecylindersandotherpartsofthebasicbrake,andthereshouldbenoseriouswear,welding,cracking,swinging,etc.⑦Checktheaxle,wheel,axleboxforabnormalnoise,andtightentheaxleboxendcoverboltswhentheyareloose.⑧Carryoutvisualinspectionandtreatmentofthebogie,thereshouldbenocracksorseriousdeformationtoensurethatitisinanormalstate.Regularmaintenanceoflarge-scaleroadmaintenancemachineryBasicbrakingdeviceforfrontbogie1-Frontbrakeaircylinder;2-Brakecylinderlever;3-Brakebeam;4-Brakeshoe;5-Tierod;6-LeverBasicbrakingdeviceforrearbogie1-Rearbrakeaircylinder;2-Handbrake;3-Brakebeam;4-Brakeshoe;5-Uppertierod;6-Lever;7-Lowerrod;8-Hydraulicbrakecylinder08-32typetampingvehiclefoundationbrakedevice⑨Whenstoppingduringoperation,usehandtouchtocheckthesurfacetemperatureoftheaxlebox,andthemaximumtemperatureshouldnotexceed70℃.Regularmaintenanceoflarge-scaleroadmaintenancemachineryaxleboxAxle;2—Boxbody;3—Isolationring;4—rollerbearing;5—screw;6—frontgland;7—screw;8—lockingpiece;9—axleboxcover;10—retainingring;Oilseal;12—retainingringIfthetemperatureistoohighorthelocaltemperatureistoohigh,youshouldopentheaxleboxendcover,checkthelubricatingoilquality,oilquantity,thestateoftherollingbearing,andthebearingbracket,anddealwithitintimeafteridentifyingthecauseaccordingtodifferentsituations.Avoidmixingwater,sandandotherdirtintotheaxleboxtoensureitslife.Regularmaintenanceoflarge-scaleroadmaintenancemachineryaxleboxAxle;2—Boxbody;3—Isolationring;4—rollerbearing;5—screw;6—frontgland;7—screw;8—lockingpiece;9—axleboxcover;10—retainingring;Oilseal;12—retainingring(2)Inspectionandmaintenanceevery200hofwork①Replacethehydraulicoilfilterelementofthepowershifttransmission.②Addlubricatinggreasetothecrossheadofeachdriveshaft.③Addgreasetothesuspensionpinoftheaxlegearbox.④Checkwhethertheboltsofeachpartofthegearboxareingoodcondition.⑤Checkwhethertherearecracksintheprotectivedeviceofthetransmissionshaft,andrepairthemintimeifcracksarefound.⑥Checkwhetherthemainandauxiliarydriveclutchesaredisconnectedandhookedflexibly,andwhethertheinductionswitchandtravelswitchareworkingproperly.Regularmaintenanceoflarge-scaleroadmaintenancemachinery⑦Addlubricatingoiltothehingejointsofthebasicbrakelevermechanism.⑧Addlubricatingoiltothetransmissionmechanismofthehandbrake.⑨Checkwhetherthecouplerandbufferdevice