Instructions for the operation, maintenance and repair of ventilation systems. Job description of an electrician for repair and maintenance Operation manual for repair and maintenance

This safety instruction has been developed for the safe repair and maintenance of vehicles and tractors.

1. GENERAL REQUIREMENTS FOR LABOR PROTECTION

1.1. This instruction provides for the basic requirements for labor protection and safe work on the repair and maintenance of vehicles and tractors.
1.2. TO independent work for the repair and maintenance of cars and tractors, persons over 18 years of age who have the appropriate qualifications, have passed a medical examination, theoretical and practical training, and have tested their knowledge of labor safety requirements in the prescribed manner are allowed.
1.3. In production repair work it is necessary to comply with the Internal Labor Regulations approved by the enterprise.
1.4. The most dangerous and harmful production factors operating during the maintenance and repair of vehicles are:
- components and parts of vehicles (during the repair process, a suspended vehicle may fall or components and parts removed from it);
– garage repair and technological equipment, tools, fixtures. It is forbidden to use tools, fixtures, equipment without training and instruction;
— electricity;
- insufficient illumination of the workplace and the serviced (repaired) unit, unit.
1.5. Need to follow the rules fire safety know how to use fire extinguishers. Smoking is allowed only in designated areas.
1.6. You must report any violations of safety requirements at your workplace, as well as malfunctions of devices, tools and personal protective equipment to your immediate supervisor and do not start work until the violations and malfunctions are eliminated.

2. HEALTH REQUIREMENTS BEFORE STARTING WORK

2.1. Before starting work, it is necessary to put on overalls, safety shoes; inspect and prepare your workplace, remove all unnecessary items without cluttering up the aisles.
2.2. Check the availability and serviceability of tools, devices, while:
- wrenches should not have cracks and nicks, the jaws of the keys should be parallel and not rolled up;
— sliding keys must not be loose in moving parts;
- metalwork hammers and sledgehammers should have a slightly convex, not oblique and not knocked down, without cracks and work hardening, the surface of the striker, should be securely fastened to the handles by wedging with pointed wedges;
- the handles of hammers and sledgehammers must have a smooth surface;
- percussion instruments (chisels, crosscuts, barbs, cores, etc.) should not have cracks, burrs and work hardening. Chisels must be at least 150 mm long;
- files, chisels and other tools should not have a pointed edge work surface, be securely fixed on a wooden handle with a metal ring on it;
- the power tool must have good insulation of live parts and reliable grounding.
2.3. The floor in the workplace must be dry and clean.
2.4. A portable lamp must have a protective grid, a serviceable cord and an insulating rubber tube. Portable lamps must be connected to the mains with a voltage not exceeding 42 V.

3. REQUIREMENTS OF LABOR PROTECTION DURING WORK

3.1. All types of maintenance and repair of the vehicle on the territory of oil depots should be carried out only at places specially designed for this purpose.
3.2. Start maintenance and repair of the vehicle only after it has been cleaned of dirt, snow and washed.
3.3. After placing the vehicle at the maintenance or repair station, it is imperative to check whether it is braked by the parking brake, whether the ignition is turned off, whether the gear lever is set to the neutral position, and whether special wheel chocks are placed at least two under the wheels. Hang a sign on the steering wheel "Do not start the engine - people are working!".
3.4. After lifting the vehicle with a hydraulic lift, it is necessary to fix the lift with a stop against spontaneous lowering.
3.5. Repair of the vehicle from below outside the inspection ditch, overpass or lift should be carried out only on a sunbed.
3.6. For safe passage through the inspection ditch, as well as for work in front and behind the vehicle, use walkways, and for descending into the inspection ditch, use ladders specially installed for this purpose.
3.7. Remove or install the wheel together with the brake drum using a special trolley. If the removal of the hubs is difficult, use special pullers to remove them.
3.8. All work on the maintenance and repair of the vehicle should be carried out with the engine off, with the exception of work, the technology of which requires the engine to be started. Such work is carried out at special posts, where exhaust gas is provided.
3.9. Before starting the engine, make sure the shift lever is in neutral and that no one is under the vehicle or near the rotating parts. Inspection of the vehicle from below is carried out only when the engine is not running.
3.10. Before turning the propeller shaft, check that the ignition is switched off. Set the gearshift lever to neutral position and release the parking brake. After carrying out the necessary work, apply the parking brake again. Turn the cardan shaft only with the help of a special tool.
3.11. Remove the engine from the vehicle and install it on it only when the vehicle is on wheels or on special stands.
3.12. Before removing the wheels, place tragus of the appropriate carrying capacity under the suspended part of the vehicle or trailer and lower the suspended part onto them, and install special wheel chocks in the amount of at least two under the non-lifting wheels.
3.13. When disassembling and assembling and other fastening operations that require great physical effort, use pullers, wrenches, etc. If necessary, pre-lubricate nuts that are difficult to loosen with kerosene or special liquids.
3.14. Before removing units and assemblies associated with power, cooling and lubrication systems, when liquid leakage is possible, first drain fuel, oil or coolant from them into a special container.
3.15. Before removing the spring, be sure to unload it from the weight by raising the front or rear and then installing the frame on the trestle.
3.16. To carry out work under the raised body of a dump trailer and when replacing or repairing the lifting mechanism, first free the body from the load and be sure to install an additional inventory device (stop, clamp, bar).
3.17. Before repairing the tank for the transportation of oil products, completely clean it of oil product residues.
3.18. Repair of fuel tanks should be carried out after complete removal of fuel residues and neutralization.
3.19. Spilled oil or fuel should be removed with sand or sawdust, which after use must be poured into special metal boxes with lids.
3.20. Choose the right size wrench, mainly use ring and socket wrenches, and in hard-to-reach places– ratchet wrenches or swivel head.
3.21. Correctly apply the wrench to the nut, do not tighten the nut with a jerk.
3.22. When working with a chisel or other chopping tool, it is necessary to use goggles to protect the eyes from damage by metal particles, and also to put a protective washer on the chisel to protect hands.
3.23. It is necessary to press out tightly seated fingers and bushings using special tools.
3.24. Units and assemblies removed from the vehicle must be placed on special stable stands, and long parts should only be placed horizontally.
3.25. When working on drilling machines, small parts should be installed in a vise or special devices.
3.26. When working on a grinding machine, you should stand on the side, and not against the rotating abrasive wheel, while using goggles or screens. The gap between the handpiece and the abrasive wheel should not exceed 3 mm.
3.27. When working with a power tool with a voltage of more than 42 V, use protective equipment (dielectric rubber gloves, galoshes, rugs) issued together with the power tool.
3.28. Connect the power tool to the mains only if there is a working plug connector.
3.29. In the event of a power outage or a break in work, the power tool must be disconnected from the mains.
3.30. It is necessary to remove dust and chips from the workbench, equipment or part with a sweeping brush or a metal hook.
3.31. It is forbidden:
- perform work under a vehicle or a unit hung only on a lifting mechanism without a support for tragus or other safety devices;
- lift the units with an oblique tension of the cable or chain of the lifting mechanism, as well as moor the units with a sling, wire, etc.;
- work under a raised body of a dump trailer without a special inventory fixing device;
- use random coasters and linings instead of a special additional emphasis;
- work with damaged or incorrectly installed stops;
- perform any work on cylinders under pressure;
- carry the power tool holding it by the cable, as well as touch the rotating parts with your hand until they stop;
- blow off dust and chips with compressed air, direct a stream of air at people standing nearby or yourself;
- store oiled cleaning materials at the workplace and store clean cleaning materials together with used ones;
- wash units, components and parts, and the like with flammable liquids;
- block up the passages between the racks and exits from the premises with materials, equipment, containers, removed units, etc.;
- store used oil, empty containers from fuel and lubricants;
- use ladders;
- twist, flatten and bend hoses and tubes, use oily hoses;
- use nuts and bolts with crumpled edges;
- hold small parts when drilling them;
- install gaskets between the link of the key and the faces of nuts, bolts, as well as increase the keys with pipes or other objects.

4. REQUIREMENTS FOR LABOR PROTECTION IN EMERGENCY SITUATIONS

4.1. In case of emergencies (fire, fire) it is necessary:
- stop work;
- Notify the supervisor.
4.2. When extinguishing a fire, remember:
- sand is used to extinguish small fires of solid and liquid substances;
- asbestos cloth, tarpaulin, felt mat is used to extinguish small burning surfaces and clothes on a person.
4.3. If it is impossible to eliminate the source of fire on your own, use the fire warning system and call the fire brigade by calling 101.
4.4. In case of injury or sudden illness of employees, immediately organize first aid, if necessary, call an ambulance by calling 103.

5. REQUIREMENTS FOR HEALTH AND SAFETY AFTER THE END OF WORK

5.1. Disconnect electrical equipment from the mains, turn off local ventilation.
5.2. Tidy up your workspace. Remove fixtures and tools in the place provided for them.
5.3. If the vehicle remains on special stands, check the reliability of its installation. It is forbidden to leave the vehicle, the unit hung out only lifting mechanism.
5.4. Remove personal protective equipment and put them in the place intended for them.
5.5. Wash your face and hands with soap or take a shower.
5.6. Report any deficiencies found during work to the immediate supervisor.

Labor protection instruction
during the repair and maintenance of vehicles

1. General requirements for labor protection

1.1 Persons who have the appropriate qualifications, who have passed a medical examination, introductory briefing, initial briefing, training and internship at the workplace, testing knowledge of labor protection requirements, requirements for managing load-lifting mechanisms are allowed to independently work on the repair and maintenance of vehicles.
1.2 When working on the repair and maintenance of vehicles, the employee must:
1.2.1 Perform only the work specified in the work instruction;
1.2.2 Comply with the internal labor regulations;
1.2.3 Properly apply personal and collective protective equipment;
1.2.4 Comply with labor protection requirements;
1.2.5 Immediately inform your immediate or superior manager about any situation that threatens the life and health of people, about each accident that occurred at work, or about the deterioration of your health, including the manifestation of signs of an acute occupational disease (poisoning);
1.2.6 To be trained in safe methods and techniques for performing work and providing first aid to victims at work, instructing in labor protection, testing knowledge of labor protection requirements;
1.2.7 To undergo mandatory periodic (during employment) medical examinations (examinations), as well as to undergo extraordinary medical examinations (examinations) at the direction of the employer in cases provided for by the Labor Code and other federal laws.
1.2.8 Be able to provide first aid to victims of electric current and other accidents;
1.2.9 Be able to use primary fire extinguishing means;
1.3 During the repair and maintenance of vehicles of the following hazardous and harmful production factors:
- moving machines and mechanisms;
- falling of the suspended car or components and parts removed from it;
- increased voltage in the electrical circuit, the closure of which can occur through the human body;
- increased or low temperature air of the working area;
- sharp edges, burrs and roughness on the surfaces of workpieces, tools and equipment;
- insufficient or excessive illumination of workplaces;
leaded gasoline;
- the appearance in the work area of ​​explosive, flammable environments;
- harmful substances (leaded gasoline, which causes poisoning by inhalation of its vapors, contamination of the body, clothing, ingestion with food or drinking water).
1.4 When working on the repair and maintenance of vehicles, the employee must be provided with overalls, safety shoes and other personal protective equipment in accordance with the Model Industry Standards for the free issue of special clothing, special footwear and other personal protective equipment and the Collective Agreement.
1.10 In cases of injury or indisposition, it is necessary to stop work, notify the work manager and contact a medical institution.
1.11 For non-compliance with this instruction, the perpetrators are held liable in accordance with the law Russian Federation.

2. Labor protection requirements before starting work

2.1 Put work clothes in order: fasten cuffs; fill the clothes so that there are no hanging ends; keep your hair under a tight-fitting headdress.
When repairing vehicles running on leaded gasoline, wear rubber boots, oversleeves, and rubber gloves.
It is forbidden to work in light footwear (slippers, sandals, etc.).
2.2 Check availability and serviceability hand tool, devices and personal protective equipment, namely:
- wrenches must match the size of the nuts and not have cracks and nicks, the jaws of the keys must be strictly parallel and not rolled up;
- sliding keys must not be loosened in moving parts;
- laying pads between the jaws of the keys and the head of the bolt, as well as lengthening the handles of the keys with the help of pipes and bolts or other objects is prohibited;
- metalwork hammers and sledgehammers must have a slightly convex, not oblique and not knocked down, without cracks, the surface of the striker, must be securely fixed on the handles by wedging with completed wedges;
- the handles of hammers and sledgehammers must have a smooth surface and be made of hard and viscous wood;
- percussion instruments (chisels, crosscuts, barbs, punches, center punches, etc.) should not have cracks, burrs and work hardening. Chisels must be at least 150 mm long;
- files, chisels and other tools should not have a pointed non-working surface, they should be securely fixed on a wooden handle with a metal end on it;
- the power tool must have good insulation of current-carrying parts and reliable grounding.
2.3 Carefully inspect the workplace, put it in proper order. Remove all obstructions foreign objects. Check the condition of the floor in the workplace. The floor must be dry and clean. If the floor is wet or slippery, wipe it down or sprinkle it with sawdust.
2.4 Make sure that the workplace is sufficiently lit and the light does not blind the eyes.
2.5 Prepare bedding for working under the car (beds or special carts).
2.6 Do not allow unauthorized persons to your workplace.
2.7 When starting to repair the car, make sure that the fuel tanks and fuel lines are free from gasoline residues.
2.8 Before using the portable lamp, check if the lamp has a protective net, if the cord and insulating rubber tube are in good condition. Portable lamps must be connected to the mains with a voltage not exceeding 42 V.

3. Labor protection requirements during work

3.1. While working on the repair and maintenance of vehicles, the employee must:
3.1.1. All types of maintenance and repair of vehicles on the territory of the enterprise should be carried out only at places (posts) specially designed for this purpose.
3.1.2. Start maintenance and repair of the car only after it has been cleaned of dirt, snow and washed.
3.1.3. After placing the car at the maintenance or repair station, it is imperative to check whether it is braked by the parking brake, whether the ignition is turned off (if the fuel supply is shut off in a car with a diesel engine), whether the gearshift lever (controller) is set to the neutral position, whether the consumable and main valves on gas-balloon vehicles, whether special wheel chocks (shoes) (at least two) are placed under the wheels. In case of non-compliance with the specified security measures, do it yourself.
Hang a sign on the steering wheel "Do not start the engine - people are working!". On a car with a backup device for starting the engine, hang a similar plate next to this device.
3.1.4. After lifting the car with a lift, hang a sign on the lift control panel “Do not touch - people are working under the car!”, And when lifting with a hydraulic lift after lifting it, fix the lift with a stop against spontaneous lowering.
3.1.5. Car repairs from below outside the inspection ditch, overpass or lift should be carried out only on a sunbed.
3.1.6. For safe passage through the inspection ditches, as well as for work in front and behind the vehicle, use the transitional bridges, and for descending into the inspection ditch - ladders specially installed for this purpose.
3.1.7. Remove or install the wheel together with the brake drum using a special trolley. If the removal of the hubs is difficult, use special pullers to remove them.
3.1.8. All work on the maintenance and repair of the car to be carried out with the engine off, with the exception of work, the technology of which requires starting the engine. Such work should be carried out at special posts, where exhaust gas extraction is provided.
3.1.9. To start the engine and move the car, contact the driver, driver, foreman or mechanic appointed by order to perform this work.
3.1.10. Before starting the engine, make sure that the shift lever (controller) is in the neutral position and that no one is under the vehicle or near the rotating parts of the engine.
Inspection of the car from below is carried out only when the engine is not running.
3.1.11. Before turning the propeller shaft, check that the ignition is off, and for a diesel engine, that there is no fuel supply. Set the gearshift lever to neutral position and release the parking brake. After carrying out the necessary work, apply the parking brake again.
Turn the cardan shaft only with the help of a special tool.
3.1.12. Remove the engine from the car and install it on it only when the car is on wheels or on special stands - tragus.
3.1.13. Before removing the wheels, place under the suspended part of the car, trailer, semi-trailer traguses of the appropriate carrying capacity and lower the suspended part onto them, and install special wheel chocks (shoes) in the amount of at least two under the non-lifting wheels.
3.1.14. To drive the car to the parking lot inside the enterprise and check the brakes on the go, call an on-duty or assigned driver.
3.1.15. When disassembling and assembling and other fastening operations that require great physical effort, use pullers, wrenches, etc. Hard-to-remove nuts, if necessary, pre-moisten with kerosene or a special compound (Unisma, VTV, etc.).
3.1.16. Before starting work with the lifting mechanism, make sure that it is in good condition and that the weight of the lifted unit corresponds to the lifting capacity indicated on the stencil of the lifting mechanism, whether the test period has expired, and on removable load gripping devices, check for the presence of tags indicating the permissible weight of the lifted load.
3.1.17. To remove and install components and assemblies weighing 20 kg or more (for women 10 kg), use lifting mechanisms equipped with special devices (grabs), other auxiliary means of mechanization.
3.1.18. When moving parts manually, be careful, as the part (unit) can interfere with the view of the movement path, distract from observing the movement and create an unstable body position.
3.1.19. Before removing units and assemblies associated with power, cooling and lubrication systems, when liquid leakage is possible, first drain fuel, oil or coolant from them into a special container.
3.1.20. Before removing gas equipment, cylinders or tightening the nuts of the connections, make sure that there is no gas in them.
3.1.21. Before removing the spring, be sure to unload it from the weight of the car by raising the front or rear of the car and then installing the frame on the trestle.
3.1.22. When working on a tilting stand, securely fasten the car, first draining the fuel and coolant, close the oil filler tightly and remove the battery.
3.1.23. Repair and maintenance of buses and trucks with high bodies, use scaffolds or stepladders.
3.1.24. To carry out work under the raised body of a dump truck or dump trailer and when replacing or repairing the lifting mechanism or its units, first free the body from the load, it is imperative to install an additional inventory device (stop, clamp, bar).
3.1.25. Before repair, tank cars for the transportation of flammable, explosive, toxic, etc. cargo, as well as tanks for their storage, must be completely cleared of the remains of the above products.
3.1.26. Carry out cleaning or repairs inside the tank or tank from leaded gasoline, flammable and poisonous liquids in special clothing, with a gas mask, a rescue belt with a rope; a specially instructed assistant should be outside the tank.
The gas mask hose must be brought out through the hatch (manhole) and fixed on the windward side.
A strong rope is attached to the worker's belt inside the tank, the free end of which must be brought out through the hatch (hole) and securely fastened. The assistant, who is at the top, must watch the worker, hold the rope, insuring the worker in the tank.
3.1.27. Repair fuel tanks only after complete removal of fuel residues and neutralization.
3.1.28. Before carrying out maintenance and repair work on vehicles running on gas fuel, first raise the hood to ventilate the engine compartment.
3.1.29. Drain (release) the gas from the cylinders of the car on which the work related to troubleshooting is to be carried out gas system supply or its removal, in a specially designated place (post), and blow the cylinders with compressed air, nitrogen or other inert gas.
3.1.30. Work on the removal, installation and repair of gas equipment should be carried out only with the help of special devices, tools and equipment.
3.1.31. Check the tightness of the gas system with compressed air, nitrogen or other inert gases with the supply valves closed and the main valves open.
3.1.32. Fasten the hoses on the fittings with clamps.
3.1.33. Clean up spilled oil or fuel with sand or sawdust, which should be placed outdoors in metal boxes with lids after use.
3.1.34. During operation, position the tool so that there is no need to reach for it.
3.1.35. Correctly select the size of the wrench, preferably use box and socket wrenches, and in hard-to-reach places - wrenches with ratchet or with a hinged head.
3.1.36. Correctly apply the wrench to the nut, do not tighten the nut with a jerk.
3.1.37. When working with a chisel or other chopping tool, use goggles to protect your eyes from metal particles, and also put a protective washer on the chisel to protect your hands.
3.1.38. Press out tight pins and bushings only with the help of special tools.
3.1.39. Put the components and assemblies removed from the vehicle on special stable stands, and lay long parts only horizontally.
3.1.40. Check the alignment of the holes with a conical mandrel.
3.1.41. When working on drilling machines, place small parts in a vise or special devices.
4.1.42. Remove chips from drilled holes only after retracting the tool and stopping the machine.
3.1.43. When working on a grinding machine, you should stand on the side, and not against the rotating abrasive wheel, while using goggles or screens. The gap between the handpiece and the abrasive wheel should not exceed 3 mm.
3.1.44. When working with a power tool with a voltage of more than 42 V, use protective equipment (dielectric rubber gloves, galoshes, rugs) issued together with the power tool.
3.1.45. Connect the power tool to the mains only with a working plug connector.
3.1.46. In the event of a power outage or a break in operation, unplug the power tool from the mains.
3.1.47. Remove dust and chips from a workbench, equipment, or part with a basting brush or metal hook.
3.1.48. Clean the used cleaning material in metal boxes specially installed for this purpose and cover with a lid.
3.1.49. If gasoline or other flammable liquid has come into contact with the body and personal protective equipment, do not approach an open flame, do not smoke or light matches.
3.1.50. When working with leaded gasoline or engine parts running on leaded gasoline, observe the following requirements:
neutralize parts with kerosene;
immediately remove spilled gasoline, and neutralize this place with a solution of bleach;
pour leaded gasoline using a special tool.
3.1.51. Move units hung on lifting and transport mechanisms using hooks and braces.
3.2. The employee is prohibited from:
- perform work under a car or a unit hung only on a lifting mechanism (except for stationary electric lifts) without tragus support or other safety devices;
- lift the units with an oblique tension of the cable or chain of the lifting mechanism, as well as moor the units with a sling, wire, etc.;
- work under a raised body of a dump truck, dump trailer without a special inventory fixing device;
- use random stands and pads instead of a special additional stop;
- work with damaged or incorrectly installed stops;
- do any work gas equipment or cylinders under pressure;
- carry an electric tool, holding it by the cable, as well as touch the rotating parts with your hand until they stop;
- blow off dust and shavings with compressed air, direct a stream of air at people standing nearby or at yourself;
- store oiled cleaning materials at the workplace and store clean cleaning materials together with used ones;
- use leaded gasoline for washing parts, hands, etc.;
- suck gasoline with your mouth through a hose;
- wash units, components and parts, etc. with flammable liquids;
- block up the passages between the racks and exits from the premises with materials, equipment, containers, removed units, etc.;
- store used oil, empty containers from fuel and lubricants;
- take out special clothes contaminated with leaded gasoline from the enterprise, as well as enter the canteen and office premises in it;
- use ladders;
- release compressed gas into the atmosphere or drain liquefied gas to the ground;
- when opening and closing the main and consumable valves, use additional levers;
- use wire or other objects to fasten the hoses;
- twist, flatten and bend hoses and tubes, use oily hoses;
- use nuts and bolts with crumpled edges;
- hold small parts with your hands when drilling them;
- install gaskets between the jaw of the key and the edges of nuts, bolts, as well as increase the keys with pipes or other objects;
- use dry bleach to neutralize a sheet doused with leaded gasoline;
- push or pull the units hung on lifting mechanisms by hand;
- work when receiving a signal about the movement of the conveyor.

4. Labor protection requirements in emergency situations

4.1 In the event of accidents and situations that can lead to accidents and accidents, it is necessary:
4.1.1 Immediately stop work and notify the work manager.
4.1.2 Under the guidance of the work manager, promptly take measures to eliminate the causes of accidents or situations that can lead to accidents or accidents.
4.2 In the event of a fire, smoke:
4.2.1 Immediately inform the fire brigade by phone "01", notify the workers, notify the head of the unit, report the fire to the security post.
4.2.2 Open emergency exits from the building, turn off the power supply, close windows and close doors.
4.2.3 Start extinguishing the fire with primary fire extinguishing equipment, if this does not involve a risk to life.
4.2.4 Organize a fire brigade meeting.
4.2.5 Leave the building and be in the evacuation zone.
4.3 In the event of an accident:
4.3.1 Immediately organize first aid to the victim and, if necessary, deliver him to a medical organization.
4.3.2 Take urgent measures to prevent the development of an emergency or other emergency and the impact of traumatic factors on other persons.
4.3.3 Preserve prior to the investigation of the accident the situation as it was at the time of the incident, if it does not threaten the life and health of other persons and does not lead to a catastrophe, accident or other emergency circumstances, and if it is impossible to maintain it, record the current situation (draw up schemes, conduct other activities).

5. Labor protection requirements at the end of work

Upon completion of work, the employee must:
5.1.1 Disconnect electrical equipment from the mains, turn off local ventilation.
5.1.2 Tidy up the workplace. Remove fixtures and tools in the place provided for them.
5.1.3 If the car remains on special stands (tragus), check the reliability of its installation. It is forbidden to leave the car, the unit hung out only with a lifting mechanism.
5.1.4 Remove personal protective equipment and put them in the place intended for them.
5.1.5 Wash your hands with soap, and after working with parts and assemblies of an engine running on leaded gasoline, you must first wash your hands with kerosene.
5.1.6 Notify your immediate supervisor of all shortcomings found during work.

Instruction No.___

INSTRUCTIONS
on labor protection
for car repair and maintenance technicians

The instruction was drawn up in accordance with the "Typical instruction No. 2 on labor protection for mechanics for the repair and maintenance of a car" TOI R-200-02-95.

1. General safety requirements

1.1. The following employees are allowed to independently work on the repair and maintenance of vehicles:

• not younger than 18 years old;
• who have passed a preliminary (when hiring) and periodic (during work) medical examination and have no contraindications;
• having the appropriate qualifications;
• passed the introductory briefing and primary briefing at the workplace on labor protection;
• passed the test of knowledge on the management of load-lifting mechanisms.

1.2. A locksmith who has not undergone a timely re-instruction on labor protection (at least 1 time in 3 months) should not start work.

1.3. The locksmith must:

• comply with the internal labor regulations approved by the enterprise;
• observe fire safety rules, be able to use fire extinguishing means;
• smoking only in designated areas;
• during work, be attentive, not be distracted by extraneous matters and conversations;
• about observed violations of safety requirements at his workplace, as well as about malfunctions of devices, tools and personal protective equipment, the locksmith must inform his immediate supervisor and not start work until the observed violations and malfunctions are eliminated;
• follow the rules of personal hygiene. Before eating or smoking, wash your hands with soap and water, and when working with car parts that run on leaded gasoline, wash your hands with kerosene beforehand;
• for drinking, use water from devices specially designed for this purpose (saturators, drinking tanks, fountains, etc.).

1.4. The working time of a locksmith should not exceed 40 hours per week. The duration of daily work (shift) is determined by the internal labor regulations or shift schedules approved by the employer in agreement with the trade union committee.

1.5. The mechanic must know that the most dangerous and harmful production factors affecting him during the maintenance and repair of vehicles are:

• the car, its components and parts (during the repair process, the suspended vehicle or the components and parts removed from it may fall, which leads to broadcasting);
• equipment, tools and fixtures (garage-repair and technological equipment, tools, fixtures - the use of faulty equipment, tools and fixtures leads to injury. The locksmith is prohibited from using tools, fixtures, equipment, with which he is not trained and instructed);
• electric current (if the rules and precautions are not followed, it can have a dangerous and harmful effect on people, manifested in the form of electrical injuries (burns, electric signs, electroplating of the skin), electric shocks);
• leaded gasoline (it has a toxic effect on the human body when inhaling its vapors, contaminating the body, clothing, ingesting it with food or drinking water);
• illumination of the workplace and the serviced (repaired) unit, unit (insufficient (excessive) illumination causes deterioration (overstrain) of vision, fatigue).

1.6. The locksmith must work in special clothing and, if necessary, use other personal protective equipment.

1.7. In accordance with the "Model industry standards for the free issue of special clothing, special footwear and other personal protective equipment to workers and employees", PPE is issued to the locksmith.

When performing work on disassembling engines, transporting, carrying and washing parts of engines running on leaded gasoline:

• viscose-dacron suit;
• rubber apron;
• rubber boots;
• rubber gloves.

When performing dismantling, repair and maintenance of vehicles and units:

• viscose-dacron suit;
• combined gloves.

When working with leaded gasoline additionally:

• rubberized apron;
• rubber gloves.

For outdoor work in winter additionally:

• cotton jacket with insulating lining;
• cotton trousers with insulating lining.

1.8. For non-compliance with the requirements of the Instruction, the locksmith is liable in accordance with current legislation.

2. Safety requirements before starting work

2.1. Before starting work, the mechanic must put on special clothes and fasten the cuffs of the sleeves.

2.2. Inspect and prepare your workplace, remove all unnecessary items without cluttering up the aisles.

2.3. Check the availability and serviceability of tools, devices, while:

• wrenches should not have cracks and nicks, the jaws of the keys should be parallel and not rolled up;
• sliding keys must not be loosened in moving parts;
• metalwork hammers and sledgehammers should have a slightly convex, not oblique and not knocked down, without cracks and work hardening, the surface of the striker, should be securely fastened to the handles by wedging with pointed wedges;
• the handles of hammers and sledgehammers must have a smooth surface;
• percussion instruments (chisels, crosscuts, barbs, cores, etc.) must not have cracks, burrs and work hardening. Chisels must be at least 150 mm long;
• files, chisels and other tools should not have a pointed non-working surface, be securely fixed on a wooden handle with a metal ring on it;
• the power tool must have good insulation of live parts and reliable grounding.

2.4. Check the condition of the floor in the workplace. The floor must be dry and clean. If the floor is wet or slippery, demand that it be mopped or sprinkled with sawdust, or do it yourself.

2.5. Before using a portable lamp, check whether the lamp has a protective net, whether the cord and the insulating rubber tube are in good condition. Portable lamps must be connected to the mains with a voltage not exceeding 42 V.

3. Safety requirements during operation

3.1. During work, the locksmith must:

3.1.1. All types of maintenance and repair of vehicles on the territory of the enterprise should be carried out only at places (posts) specially designed for this purpose.

3.1.2. Start maintenance and repair of the car only after it has been cleaned of dirt, snow and washed.

3.1.3. After placing the vehicle at a maintenance or repair station, it is imperative to check whether it is braked by the parking brake, whether the ignition is turned off (if the fuel supply is shut off in a car with a diesel engine), whether the gearshift lever (controller) is set to the neutral position, whether the consumable and main valves on gas-balloon vehicles, whether special wheel chocks (shoes), at least two, are placed under the wheels. In case of non-compliance with the specified security measures, do it yourself.

Hang a sign on the steering wheel “Do not start the engine! People are working." On a car with a backup device for starting the engine, hang a similar plate next to this device.

3.1.4. After lifting the car with a lift, hang a sign on the lift control panel “Do not touch! People are working under the car! ”, and when lifting with a hydraulic lift, after raising it, fix the lift with a stop against spontaneous lowering.

3.1.5. Car repairs from below outside the inspection ditch, overpass or lift should be carried out only on a sunbed.

3.1.6. For safe passage through the inspection ditches, as well as for work in front and behind the vehicle, use walkways, and for descending into the inspection ditch, use ladders specially installed for this purpose.

3.1.7. Remove or install the wheel together with the brake drum using a special trolley. If the removal of the hubs is difficult, use special pullers to remove them.

3.1.8. All work on the maintenance and repair of the car to be carried out with the engine off, with the exception of work, the technology of which requires starting the engine. Such work should be carried out at special posts, where exhaust gas extraction is provided.

3.1.9. To start the engine and move the car, contact the driver, driver, foreman or locksmith appointed by order of the enterprise to perform this work.

3.1.10. Before starting the engine, make sure that the shift lever (controller) is in the neutral position and that no one is under the vehicle or near the rotating parts of the engine.

Inspection of the car from below is carried out only when the engine is not running.

3.1.11. Before turning the propeller shaft, check that the ignition is off, and for a diesel engine, check that there is no fuel supply. Set the gearshift lever to neutral position and release the parking brake. After carrying out the necessary work, apply the parking brake again.

Turn the cardan shaft only with the help of a special tool.

3.1.12. Remove the engine from the car and install it on it only when the car is on wheels or on special stands - tragus.

3.1.13. Before removing the wheels, place under the suspended part of the car, trailer, semi-trailer traguses of the appropriate carrying capacity and lower the suspended part onto them, and install special wheel chocks (shoes) in the amount of at least two under the non-lifting wheels.

3.1.14. To drive the car to the parking lot inside the enterprise and check the brakes on the go, call an on-duty or assigned driver.

3.1.15. When disassembling and assembling and other fastening operations that require great physical effort, use pullers, wrenches, etc. If necessary, hard-to-turn nuts should be pre-moistened with kerosene or a special compound (Unisma, VTV, etc.).

3.1.16. Before starting work with the lifting mechanism, make sure that it is in good condition and that the weight of the lifted unit corresponds to the carrying capacity indicated on the stencil of the lifting mechanism, whether the test period has expired, and on removable load gripping devices - the presence of tags indicating the permissible weight of the lifted load.

3.1.17. For removal and installation of components and assemblies weighing 20 kg or more (for women 10 kg, lifting and moving weights when alternating with other work (up to 2 times per hour), if lifting and moving weights is carried out constantly during the shift - 7 kg.) use lifting mechanisms equipped with special devices (grabs), other auxiliary means of mechanization.

3.1.18. When moving parts manually, be careful, as the part (unit) can interfere with the view of the movement path, distract from observing the movement and create an unstable body position.

3.1.19. Before removing units and assemblies associated with power, cooling and lubrication systems, when liquid leakage is possible, first drain fuel, oil or coolant from them into a special container.

3.1.20. Before removing the gas equipment, cylinders or tightening the nuts of the connections, make sure that there is no gas in them.

3.1.21. Before removing the spring, be sure to unload it from the weight of the car by raising the front or rear of the car and then installing the frame on the trestle.

3.1.22. When working on a tilting stand, securely fasten the car, first draining the fuel and coolant, close the oil filler tightly and remove the battery.

3.1.23. When repairing and servicing buses and trucks with high bodies, use scaffolds or stepladders.

3.1.24. To carry out work under the raised body of a dump truck or dump trailer and when replacing or repairing the lifting mechanism or its units, first free the body from the load, it is imperative to install an additional inventory device (stop, clamp, bar).

3.1.25. Before repairing a tank car for the transportation of flammable, explosive, toxic, etc. goods, as well as tanks for their storage, completely clear the residues of the above products.

3.1.26. Carry out cleaning or repairs inside the tank or tank from leaded gasoline, flammable and poisonous liquids in special clothing, with a gas mask, a rescue belt with a rope; a specially instructed assistant should be outside the tank.

The gas mask hose must be brought out through the hatch (manhole) and fixed on the windward side.

A strong rope is attached to the worker's belt inside the tank, the free end of which must be brought out through the hatch (hole) and securely fastened. The assistant, who is at the top, must watch the worker, hold the rope, insuring the worker in the tank.

3.1.27. Repair fuel tanks only after complete removal of fuel residues and neutralization.

3.1.28. Maintenance and repair work refrigeration units on refrigerated vehicles, carry out in accordance with the current safety regulations for their repair.

3.1.29. Before carrying out maintenance and repair work on vehicles running on gas fuel, first raise the hood to ventilate the engine compartment.

3.1.30. Drain (release) the gas from the cylinders of the car, on which work is to be carried out related to the elimination of malfunctions of the gas supply system or its removal, on a specially designated bridge (post), and blow the cylinders with compressed air, nitrogen or other inert gas.

3.1.31. Work on the removal, installation and repair of gas equipment should be carried out only with the help of special devices, tools and equipment.

3.1.32. Check the tightness of the gas system with compressed air, nitrogen or other inert gases with the supply valves closed and the main valves open.

3.1.33. Fasten the hoses on the fittings with clamps.

3.1.34. Clean up spilled oil or fuel with sand or sawdust, which should be placed outdoors in metal boxes with lids after use.

3.1.35. During operation, position the tool so that there is no need to reach for it.

3.1.36. Correctly select the size of the wrench, preferably use box and socket wrenches, and in hard-to-reach places - ratchet or swivel head wrenches.

3.1.37. Correctly apply the wrench to the nut, do not tighten the nut with a jerk.

3.1.38. When working with a chisel or other chopping tool, use goggles to protect your eyes from metal particles, and also put a protective washer on the chisel to protect your hands.

3.1.39. Press out tight pins and bushings only with the help of special tools.

3.1.40. Put the components and assemblies removed from the vehicle on special stable stands, and lay long parts only horizontally.

3.1.41. Check the alignment of the holes with a conical mandrel.

3.1.42. When working on drilling machines, place small parts in a vise or special devices.

3.1.43. Remove chips from drilled holes only after retracting the tool and stopping the machine.

3.1.44. When working on a grinding machine, you should stand on the side, and not against the rotating abrasive wheel, while using goggles or screens. The gap between the handpiece and the abrasive wheel should not exceed 3 mm.

3.1.45. When working with a power tool with a voltage of more than 42 V, use protective equipment (dielectric rubber gloves, galoshes, rugs) issued together with the power tool.

3.1.46. Connect the power tool to the mains only with a working plug connector.

3.1.47. In the event of a power outage or a break in operation, unplug the power tool from the mains.

3.1.48. Remove dust and chips from a workbench, equipment, or part with a basting brush or metal hook.

3.1.49. Remove used cleaning material in metal boxes specially installed for this purpose and close with a lid.

3.1.50. If gasoline or other flammable liquid has come into contact with the body and personal protective equipment, do not approach an open flame, do not smoke or light matches.

3.1.51. When working with leaded gasoline or engine parts running on leaded gasoline, observe the following requirements:

• neutralize parts with kerosene;
• immediately remove spilled gasoline, and neutralize this place with a solution of bleach;
• pour leaded gasoline using a special tool.

3.1.52. Move units hung on lifting and transport mechanisms using hooks and braces.

3.2. The locksmith is prohibited from:

• perform work under a car or a unit hung only on a lifting mechanism (except for stationary electric hoists) without tragus stands or other safety devices;
• lift the units with an oblique tension of the cable or chain of the lifting mechanism, as well as moor the units with a sling, wire, etc.;
• work under a raised body of a dump truck, dump trailer without a special inventory fixing device;
• use random coasters and pads instead of a special additional stop;
• work with damaged or incorrectly installed stops;
• perform any work on gas equipment or cylinders under pressure;
• carry an electric tool, holding it by the cable, as well as touch the rotating parts with your hand until they stop;
• blow off dust and chips with compressed air, direct a stream of air at people standing nearby or at yourself;
• store oiled cleaning materials at the workplace and store clean cleaning materials with used ones;
• use leaded gasoline for washing parts, hands, etc.; suck gasoline with your mouth through a hose;
• wash units, components and parts, etc. with flammable liquids;
• clutter up the passages between the racks and exits from the premises with materials, equipment, containers, removed units, etc.;
• store used oil, empty containers from fuel and lubricants;
• take out special clothes contaminated with leaded gasoline from the enterprise, as well as enter the canteen and office premises in it;
• use ladders;
• release compressed gas into the atmosphere or drain liquefied gas to the ground;
• when opening and closing the main and supply valves, use additional levers;
• use wire or other objects to fasten hoses;
• twist, flatten and bend hoses and tubes, use oily hoses;
• use nuts and bolts with crumpled edges;
• hold small parts with your hands when drilling them;
• install gaskets between the jaw of the key and the edges of nuts, bolts, as well as build up the keys with pipes or other objects;
• use dry bleach to neutralize a sheet doused with leaded gasoline;
• units hung on lifting mechanisms to push or pull by hand;
• work when receiving a signal about the movement of the conveyor.

4. Safety requirements in emergency situations

4.1. The locksmith must immediately inform the employer about each accident that he witnessed, and provide the victim with first aid, call a doctor or help deliver the victim to a health center or the nearest medical facility.

If the accident occurred to the locksmith himself, he should, if possible, contact the health center, report the incident to the employer or ask someone around to do it.

4.2. In the event of a fire, immediately inform the fire brigade, the employer and start extinguishing the fire with the available fire extinguishing equipment.

5. Safety requirements at the end of work

5.1. At the end of the work, the locksmith must:

• disconnect electrical equipment from the mains, turn off local ventilation;
• tidy up the workplace. Remove fixtures, tools in the place provided for them;
• if the car remains on special supports (traguses), check the reliability of its installation. It is forbidden to leave the car, the unit hung out only by the lifting mechanism;
• remove personal protective equipment and put them in the place intended for them. Timely hand over special clothing and other personal protective equipment for dry cleaning (laundry) and repair;
• wash your hands with soap, and after working with parts and assemblies of an engine running on leaded gasoline, you must first wash your hands with kerosene;
• notify your immediate supervisor of any shortcomings discovered during work.

PROJECTS OF THE GROUP OF COMPANIES
"Regional Center for Innovative Technologies"
Instruction
auto coupler repair and maintenance
mobile railways
Chapter 1. GENERAL PROVISIONS

APPROVED:
Rail Transport Board
Member States of the Commonwealth
(minutes dated October 20-21, 2010)

put into action
by the order of JSC "Russian Railways"

2.1. Automatic coupler
2.1.
2.2. Draft apparatus
2.3. Traction clamps
2.4. Wedge, drawbar shaft, thrust plate, front and rear stops, support bar
2.5. Parts of the centering device
2.6. Release drive
2.7. Branding and painting of repaired and tested assemblies and parts of the coupler
2.8. Hitch Installation
3. External inspection
4. Checking the automatic coupler during the maintenance of wagons and locomotives
5. Hitch warranty period

Attachment 1:
Approximate list of equipment and recommended technological equipment for CPA and automatic coupler compartments
Application 2:
Templates (calibers) or other measuring instruments used in the repair and inspection of the coupler
Appendix 3:
List of defects, in the presence of which the parts of the coupler are not allowed for repair and are subject to scrapping
Appendix 4:
Sample form for reporting a self-uncoupling of a train
Appendix 5:
Sample form for reporting a broken traction collar on a train
Appendix 6:
Sample form for reporting a break in the body of an automatic coupler on a train
Appendix 7:
Manufacturer's warranty periods for coupler parts

OPEN JOINT STOCK COMPANY
"RUSSIAN RAILWAYS"

ORDER
dated December 28, 2010 N 2745r

ABOUT COMMISSIONING INSTRUCTIONS
FOR REPAIR AND MAINTENANCE OF AUTOCOUPLE DEVICE
ROLLING STOCK OF RAILWAYS

On the basis of the order of the President of Russian Railways JSC V.I. Yakunin of November 23, 2010 N 2387r and in accordance with the "Order" of the Ministry of Transport of the Russian Federation of November 18, 2010 N 257 is announced for guidance and execution from January 1, 2011 "Instructions for the repair and maintenance of the automatic coupling device of the rolling stock of railways" (hereinafter referred to as the Instruction) (not given), approved by the decision of the fifty-third meeting of the Council for Railway Transport of the Commonwealth Member States (minutes of October 20 - 21, 2010, clause 34.6):

1. To the heads of the departments: D.N. Losev for carriage facilities, A.B. Head of the Traction Directorate Mishin S.P., Chiefs: Central Directorate for Repair freight wagons Bochkarev N.A., Directorate for the repair of traction rolling stock Lubyagov A.M., Central Directorate for the repair of the track Bunin A.I., heads of railways and regional directorates to ensure compliance with the requirements of the Instruction.

2. To the director of the design bureau of the carriage economy Sokolovsky M.S. ensure replication, distribution to roads, regional directorates and placement of the Instruction on the website of Russian Railways.

3. Heads of railways, heads of regional directorates:
3.1. Organize the study of the Instruction by the involved managers and specialists.
3.2. Make changes and additions to the regulatory and technological documentation.

4. Instructions for the repair and maintenance of the automatic coupler of the rolling stock of the railways of the Russian Federation (TsV-VNIIZhT-494 of September 16, 1997) should not be applied from January 1, 2011.

Vice President of Russian Railways
A.V. VOROTILKIN

1. GENERAL PROVISIONS

1.1 Repair and check of the automatic coupler of the rolling stock are carried out at the control points of the automatic coupler (CPA) of the depot and the departments for the repair of the automatic coupler of car and locomotive repair plants, as well as in specialized divisions of enterprises for the repair of rolling stock of any form of ownership that have a certificate of the established form issued by the railway administration .

1.2 The placement of technological equipment at the points of repair of the automatic coupler must ensure compliance with the requirements of this Instruction, as well as safety and industrial sanitation.

1.3 Checkpoints of automatic couplers of depots and departments of repair plants must have the necessary technological equipment, at least two sets of test templates in accordance with Annexes No. 1 and No. 2 of this Instruction. Templates must comply with current specifications approved by the infrastructure owner. Templates are checked at repair enterprises at least once a year with the date of verification set in accordance with RD 32 TsV 088-2007 "Guidelines. Control of a set of templates T416.00.000 for checking automatic couplers during repair."

1.4 Changes in the norms, tolerances and additions to the requirements of this Instruction are agreed and approved in a manner similar to the approval of the Instruction. The procedure for applying templates, depending on the type of rolling stock repair, is specified in Appendix No. 2 of this Instruction.

1.5 To maintain the coupler in good condition, the following types of inspection have been established: full inspection, external inspection, checking the coupler during maintenance of the rolling stock.

1.6 A complete inspection of the automatic coupler is carried out during the overhaul and depot repairs of cars, overhaul locomotives and cars of diesel and electric trains, current repairs of TR-2, TR-3 diesel locomotives, electric locomotives and cars of diesel and electric trains, lifting repairs of steam locomotives and special rolling stock. External inspection is carried out during the current uncoupling repair of cars, a unified technical audit of passenger cars, washing repairs of steam locomotives, current repairs of TR-1 diesel locomotives, electric locomotives and cars of diesel and electric trains. They check the automatic coupler during maintenance during the inspection of cars in trains at maintenance points (PTO), when preparing cars for loading and during maintenance of TO-2, TO-3 locomotives, as well as in other cases established by the organizational and distribution documents of the owner infrastructure. Routine inspection of elastomeric draft gear is carried out during depot or major repairs of rolling stock. The routine inspection of the elastomeric apparatus (RO) is carried out in accordance with the period of the next RO, indicated on the cantilever part of the end beam in the top line "RO 00 (month). 00 (year)" during the next scheduled repair of the car. After the RO or installation of a new device, the date of the next RO in 4 years is indicated. Repair in the service center (SR) of the apparatus is carried out in accordance with the period of the next SR indicated on the cantilever part of the end beam in the bottom line "SR 00.00" during the next scheduled repair of the car. After the installation of a new or repaired device in the service center, the date of the next SR is indicated after 16 years.

1.7 During a complete inspection, the removable units and parts of the automatic coupler are removed from the rolling stock, regardless of their condition, and sent to the CPA or the automatic coupler repair department of the plant for inspection and repair in accordance with the requirements set forth in Chapter 2 of this Instruction. For each body of the automatic coupler and each traction yoke, an act is drawn up in the form established by the railway administration, which indicates the part number, year of manufacture, reference number of the manufacturer, reference number of the repair company, date of complete inspection, type and place of repair by welding and / or surfacing . The non-removable parts of the coupler include: impact socket, front and rear stops located on the center beam, parts of the uncoupling drive (fixing bracket, bracket and uncoupling lever). Repair and inspection of non-removable parts is carried out on the rolling stock, with the exception of cases requiring their dismantling.

1.8 During external inspection, as well as when checking the automatic coupler during maintenance, the components and parts are examined in accordance with the requirements set forth in chapters 3 and 4 of this Instruction, without removal from the rolling stock. Only defective components and parts are removed and replaced with serviceable ones.

1.9 Parts of the automatic coupler, removed from the rolling stock and subject to inspection and repair, must be cleaned of dirt with the means available to the repair point. After cleaning, the body of the automatic coupler, the traction collar, the wedge (roller) of the traction collar, the pendulum suspension of the centering device, the bolts of the locomotive socket must be subjected to non-destructive testing. The coupling bolt of the draft gear is subjected to non-destructive testing only after its repair by welding.

1.10 Non-destructive testing is carried out in accordance with the guidelines adopted by the railway administration.

1.11 Parts with defects specified in Appendix No. 3, or without a readable manufacturer's mark, are not subject to repair and are handed over to scrap metal. At the same time, for each body of the automatic coupler and each traction yoke, an act is drawn up in the form established by the railway administration, which indicates the part number, year of manufacture, reference number of the manufacturer, reference number of the repair company, date of disposal, defect in accordance with Appendix No. 3.

1.12 All welding and surfacing works during the repair of the automatic coupler are carried out in accordance with the requirements of the instructions: "Instruction for welding and surfacing during the repair of freight cars", approved by the Council for Railway Transport of the Commonwealth Member States of May 30, 2008, TsL-201-03 "Instruction for welding and surfacing of components and parts during the repair of passenger cars", TsT-336-96 "Instruction for welding and surfacing during the repair of diesel locomotives, electric locomotives, electric trains and diesel trains" and approved changes to them.

1.13 Locksmith, machine work and straightening of curved parts are carried out in accordance with the current technological instructions for the production of these works and with the requirements of the Standard technological maps for the repair of an automatic coupler.

1.14 Compliance with the current regulatory and technical requirements for the repair of an automatic coupler is checked by the heads of the wagon, passenger and locomotive services, directorates for the repair of freight wagons, regional directorates for passenger service, heads of departments for wagon, locomotive facilities and passenger communications of departments, heads of the wagon (locomotive) depot or their deputies in accordance with personal standards, and at repair plants - the chief engineer and head of the technical control department (OTK) with an entry in the repair log. For enterprises that are not part of the structural divisions of the railways, the inspection is carried out by persons authorized in this area. 1.15 The assemblies and parts of the automatic coupler that are not presented in this Instruction are serviced and repaired in accordance with the requirements of the repair and operational documents of the manufacturers.

Instructions for the repair and maintenance of the automatic coupler of the rolling stock of railways
Approved by order of December 28, 2010 N 2745r

MINISTRY OF TRANSPORT

RUSSIAN FEDERATION

INSTRUCTIONS
FOR REPAIR AND MAINTENANCE OF AUTOMATIC

ROLLING STOCK DEVICES

RAILWAYS OF THE RUSSIAN FEDERATION
(As amended by the Instructions of the Ministry of Railways dated 09.06.1999 N K-1018u,

dated October 19, 2001 N P-1742u, dated August 16, 2002 N A-737u,

dated 21.01.2003 N P-50u)
Chapter 1

GENERAL PROVISIONS

1.1. Repair and inspection of the automatic coupler of the rolling stock are carried out at the automatic coupler checkpoints (CPA) of the depot and the automatic coupler repair departments of the car and locomotive repair plants that have special certificates of the established form issued by the Department of Carriage Facilities (CV) of the Ministry of Railways of Russia.

1.2. The placement of technological equipment at the points of repair of the automatic coupler must ensure the fulfillment of the requirements of this Instruction, as well as safety and industrial sanitation.

1.3. The control points of the automatic coupler of the depot and the departments of repair plants must have the necessary technological equipment, two sets of test and one set of control templates in accordance with Annexes 1 and 2 of this Instruction. The templates must comply with the current technical requirements approved by the Central Committee of the Ministry of Railways. Templates are checked at repair facilities at least once a year with the date of verification set in accordance with the Methodological Instructions for Controlling the SDK for Automatic Couplers of Cars RD 32 TsV-TsL 027-91.

1.4. Changes in the norms and tolerances specified in this Instruction can be made only with the permission of the Central Committee of the Ministry of Railways. The procedure for applying templates, depending on the type of rolling stock repair, is specified in Appendix 2 of this Instruction.

1.5. To maintain the coupler in good condition, the following types of inspection have been established: full inspection, external inspection, checking the coupler during the maintenance of rolling stock.

1.6. A complete inspection of the automatic coupler is carried out during the overhaul and depot repairs of cars, the overhaul of locomotives and cars of diesel and electric trains, current repairs of TR-2, TR-3 diesel locomotives, electric locomotives and cars of diesel and electric trains, lifting repairs of steam locomotives. During the overhaul of group refrigerated rolling stock on the end cars, the SA-D automatic coupler is replaced by the SA-3 automatic coupler.

External inspection is carried out during the current uncoupling repair of cars, a unified technical audit of passenger cars, washing repairs of steam locomotives, current repairs of TR-1 diesel locomotives, electric locomotives and cars of diesel and electric trains.

They check the automatic coupler during maintenance during the inspection of cars in trains at maintenance points (PTO), when preparing cars for loading and during maintenance of TO-2, TO-3 locomotives, as well as in other cases specially established by the Ministry of Railways.

1.7. Upon a complete inspection, the removable units and parts of the automatic coupler are removed from the rolling stock, regardless of their condition (except for the cases specified in paragraphs 2.2.7 and 2.2.20 of this Instruction) and sent to the CPA or the automatic coupler repair department of the plant for inspection and repair in in accordance with the requirements set forth in Chapter 2 of this Instruction. The non-removable parts of the coupler include: impact socket, front and rear stops located on the center beam, parts of the uncoupling drive (fixing bracket, bracket and uncoupling lever). Repair and inspection of non-removable parts is carried out on the rolling stock, with the exception of cases requiring their dismantling.

1.8. During external inspection, as well as when checking the automatic coupler during maintenance, the components and parts are examined in accordance with the requirements set forth in chapters 3 and 4 of this Instruction, without removal from the rolling stock. Only defective components and parts are removed and replaced with serviceable ones.

1.9. Parts of the automatic coupler, removed from the rolling stock and subject to inspection and repair, must be cleaned of dirt with the means available to the repair point. After cleaning, the body of the automatic coupler, the traction collar, the wedge (roller) of the traction collar, the pendulum suspension of the centering device, the bolts of the locomotive socket must be subjected to non-destructive testing. The draft gear coupling bolt, the base plate of the PMK-110A and PMK-110K-23 draft gears are subjected to non-destructive testing only after their repair by welding.

1.10. Non-destructive testing is carried out in accordance with the Technological Instructions for Tensile Testing and Non-Destructive Testing of Car Parts.

1.11. Parts with defects listed in Appendix 3, or without the manufacturer's marking, are not subject to repair and are handed over for scrap. At the same time, an act is drawn up for each utilized body of the automatic coupler.

1.12. All welding and surfacing works during the repair of the automatic coupler are carried out in accordance with the requirements of the Instruction for welding and surfacing during the repair of wagons and containers RTM 32 TsV-201-88.

1.13. Locksmith, machine work and straightening of curved parts are carried out in accordance with applicable specifications Ministry of Railways for the performance of these works and with the requirements of Standard technological maps for the repair of an automatic coupler, approved by the Ministry of Railways.

1.14. Compliance with the current regulatory and technical requirements for the repair of an automatic coupler is checked by the heads of the wagon, passenger and locomotive services, the heads of departments of the wagon, locomotive facilities and passenger transportation departments, the heads of the wagon (locomotive) depot or their deputies in accordance with personal standards, and at repair plants - chief engineer and head of the technical control department (OTC) with an entry in the repair log.

Chapter 2

FULL INSPECTION

The requirements specified in this chapter relate to the inspection, testing and repair of the automatic coupler during the overhaul and depot repairs of cars, the overhaul and current repairs of TR-2, TR-3 diesel locomotives, electric locomotives and cars of diesel and electric trains, hoisting repairs of steam locomotives.
2.1. AUTO HITCH
Coupler body
2.1.1. The width of the mouth of the automatic coupler body is checked with an impassable template 821r-1 along the entire height of the toe of the large tooth. The template is applied with one end to the corner of the small tooth (Fig. 2.1), and the other end is brought to the toe of the large tooth. If the edge of the template passes by the toe of a large tooth, then the pharynx is expanded and must be corrected.

2.1.2. The length of the small tooth (Fig. 2.2, a) of the body and the distance between the shock wall of the throat and the traction surface of the large tooth (Fig. 2.2, b) are checked with templates 892r, 893r and 884r, depending on the types of rolling stock repair (Appendix 2). The check is carried out in the middle part along the height of the teeth at a distance of 80 mm up and down from the longitudinal axis of the housing. At the same time, the zone of the traction surface of the large tooth, located opposite the window for the lock holder paw, is not checked, since the shock wall of the throat has a casting slope.

Pictures not shown - approx. ed.
If the impact wall of the throat was built up and machined, then the distance from the traction surface of the large tooth to the impact wall of the throat should be checked in this area with a template 884p.

2.1.3. The contour of the engagement of the body is controlled by a through-flow template 827r (Fig. 2.3), which is moved in the engagement contour along the entire height so that the guide tube 1 of the template is located rounded at the point where the small tooth passes into the shock wall 2 of the throat, and the flat part passes through the throat and covers small tooth. The contour is valid if the template passes freely through it along the entire height of the body head.

2.1.4. If the surfaces of the engagement contour of the automatic coupler body or one of them do not meet the requirements of checking with templates 892р, 893р or 827р, the automatic coupler must be repaired to landscape dimensions according to template 914р-m with a profile bar 914/24-1m with a non-going probe 914р/21а , pass-through templates 914r / 22 and 914r / 25, non-passage 884r and through-pass 827r templates, template 822r.

When equipping the automatic coupler with brackets from self-uncoupling according to the design of PKB TsV M1695, instead of templates 914r-m 914r / 22-m, use templates 914r-2M and 914r / 22-2M.

(As amended by the Directive of the Ministry of Railways dated 09.06.1999 N K-1018u)
2.1.5. Template 914r-m checks the impact surface of the small tooth and the shock wall of the throat. The template is installed in the body so that the stops c (Fig. 2.4, a) are pressed against the shock wall of the throat, and the lower part of the p base rests on the lower bridge of the small tooth. Springs c1, resting on the edges of the window for the lock, press the supports and bases of the template against the inner wall of the small tooth.

After installing the template, the condition of the impact surfaces of the contour is checked using the 914r / 24-1m profile bar and the 914r / 21a impassable probe (Fig. 2.4, d).

The profiles of the working surfaces of the strap ribs correspond to the vertical profiles of the impact surfaces of the walls of the pharynx and the small tooth.

The edge 1 of the profile bar 3 with the inscription Zev checks the impact surface of the throat wall, and the edge 2 with the inscription "Small tooth" - the impact surface of the small tooth.

To check the impact surface, the profile strip is applied to the contour sheets of the template so that the plane of the strip is perpendicular to the surface being checked. Then the bar is moved along the edges of the contour sheets, as if along copiers, over the entire width of the surface to be checked, and the probe plate is inserted into the gap between the edge of the profile bar and the surface of the engagement contour to be checked.

If the profile bar 3 is adjacent to the upper 4 and lower 5 contour sheets at the same time (Fig. 2.4, b), then the surface to be checked is suitable. The surface to be checked will be unusable (Fig. 2.4, c) if the profile bar fits snugly against the lower 5-contour sheet, but does not adhere to the upper 4-contour sheet, or vice versa.

The checked surface of the automatic coupler is suitable (Fig. 2.4, d, pos. 7) if the probe b does not pass between the profile bar and the impact surface of the small tooth.

The body of the coupler is rejected if the non-going probe over its entire width passes all the way into the tide of the handle into the gap between the profile bar, tightly pressed at the ends to the contour sheets of the template, and the surface to be checked (pos. II).

The difference between the gaps between the profile bar and the impact surfaces of the small tooth and throat at the top and bottom should not exceed 2 mm.

The gap between the profile bar and the shock wall of the throat in the area below the toe of the large tooth is not controlled.

2.1.6. Templates 914r/22-m and 914r/25 check the traction surfaces of the small and large teeth of the body. In this case, the 914r/22-m template should be freely put on the small tooth until it stops against its lateral surface (Fig. 2.5, a), and the 914r/25 template should freely pass between the shock wall of the throat and the traction surface of the large tooth in zone 3 until it stops limiters (Fig. 2.5, b) into the lateral surface of this tooth, while the protrusion 1 of the template should rest on the edge of the large tooth 2.

2.1.7. If, when checking the body, it is established that the profile bar does not adhere tightly to the contour surfaces of the template with its ends, or the pass-through template for a small tooth does not completely find it, or the pass-through template for a large tooth does not go all the way into its side surface, then there is a excess metal, which must be removed until the profile strip fits tightly to the contour surfaces or until the free passage of the through-going templates on the small and large teeth.

If it is necessary to weld the impact surfaces of the throat and the small tooth of the automatic coupler body, then the thickness of the deposited layer is determined by the gaps a and b (Fig. 2.6) between the deposited surface and the edge of the profile bar 914r / 24-1m.

To determine the maximum allowable thickness of the surfacing of the traction surface of the small tooth, it is necessary to subtract the value of the gap a previously determined using the template 914r-m from the value of the gap between the edge of the template 914r/22-m, tightly pressed against the impact surface of the small tooth, and the traction surface.

To determine the thickness of the hardfacing layer of the traction surface of a large tooth, it is necessary to subtract the value of the gap b previously determined using the template 914r-m from the value of the gap r between the edge of the template 914r/25, tightly pressed against the impact surface of the throat, and the traction surface.

2.1.8. After repair, the surfaces of the engagement contour of the body must be parallel to the edges of the template 827p.

2.1.9. The corners of the throat and small tooth of the body are checked with a template 822r (Fig. 2.7).

2.1.10. When repairing the surfaces of the engagement contour of the body, it is not allowed to apply welds closer than 15 mm to the places of rounding (Fig. 2.8, a). The transition from the deposited shock surface of the throat wall to the non-wearing one must be smooth over a length of at least 15 mm for unhindered sliding of automatic couplers over each other at the moment of coupling. The edge of the angle formed by the welded impact surface of the small tooth and the surface to which the lock adjoins must be without rounding along the entire height (Fig. 2.8, b). The hardness of the deposited metal of shock-traction surfaces for freight cars and locomotives must be at least HB 250, for refrigerator and passenger cars and cars of electric trains - at least HB 450.

2.1.11. The width of the pocket for the lock in the case is considered to be increased if, during the rotation of the lifter shaft, the lock lifter passes the lower shoulder of the fuse without touching it with its upper wide finger. In this case, a washer of such thickness must be welded coaxially with the small hole for the lifter shaft so that the width of the corrected pocket meets the requirements of checking with a non-passing template 845p and a through-going 848p.

To check, the 845r template is inserted into the pocket of the coupler body through a large hole for the lifter roller until it stops against the inner wall of the pocket so that the template touches the body wall with the entire end surface (Fig. 2.9, a). In this case, the cylindrical part of the template should not pass between the walls of the pocket. Template 848p is inserted into the head of the case through the lock window and passed between the pocket walls. The width of the pocket is recognized as correct if the measuring strip of the template passes freely between the walls along the entire width of the pocket (Fig. 2.9, b).

The 845p template also controls the distance from the leading edge of the hole for the elevator roller to the wall of the hole for the locking bolt (Fig. 2.10). To do this, the template is installed so that the straight surface a of its impassable bar enters the groove for the locking bolt, while the semicircular surface b of the template should not pass by the front edge of the hole for the lift roller (position 7). If surface b extends past the leading edge of the lifter shaft hole (position II), then the wall of the locking bolt slot must be welded on and then machined flush with the surface of the trailing edge of the lifter shaft hole.

After processing, the hole is checked with a template 845p with the installation of a locking bolt, which should freely enter its place and be easily removed.

2.1.12. Diameters and coaxiality of small and big holes for the lift roller, they are checked with a template 797r (Fig. 2.11), and the position of the holes relative to the contour of the automatic coupling engagement - with templates 937r and 797r (Fig. 2.12). The body is considered fit if the passage part of the template 797r freely enters the corresponding hole, and the non-going part of the template does not enter the hole until it stops against the end face of the body boss.

If the non-going parts of the template enter the corresponding holes, then the walls of the holes are worn out and they must be repaired by surfacing with subsequent processing. After repair, the position of the holes is checked with templates 937r and 797r (see Fig. 2.12). To check, the template 937r is inserted into the case pocket, and the template 797r is passed through the hole of this template. Then, pressing the template against the inner wall and the lower bridge of the small tooth, move it in the direction of the arrow A, while checking the gap a between the stop 7 and the shock wall 2 of the throat. The position of the holes is recognized as correct if this gap is not more than 4 mm.

2.1.13. The dimensions of the spike for the lock holder and its position relative to the engagement contour of the automatic coupler body are checked using templates 849r-1.806r and 816r.

Template 849r-1 controls the height of the spike (Fig. 2.13). If the passage part of the template passes into the space between the wall on the side of the small tooth and the end of the stud and the impassable part does not pass, then the height of the stud meets the requirements. If the non-passing part of the template passes into this space (short spike) or the passable part (long spike) does not pass, then the spike must be repaired. The check is carried out over the entire surface of the end face of the spike.

The diameter and condition of the edge of the end of the spike is checked with a template 806r (Fig. 2.14). To this end, the template is firmly pressed against the end of the spike and moved along the handle (shown by arrows), sequentially turning the handle in zone A. If at the same time the spike passes into the through cutout of the template and does not pass into the through cut, then it is considered serviceable (good). Otherwise, the spike must be repaired.

The position of the front surface of the spike relative to the contour of the coupling of the automatic coupling is checked with a template 816p (Fig. 2.15). To check, the template is inserted into the pocket of the automatic coupler body and set so that the supports 4 are pressed against the inner wall of the small tooth, the supports 5 rest against the impact wall of the throat, and the inner support 3 with its lower flat part rests on the top of the spike for the lock holder. Holding the template in this position, raise the pointed end of the arrow 7 until the protrusion 2 at its other end rests against the front of the tenon surface.

The position 7 of the spike is considered correct if the pointed end of the arrow 7 does not go beyond the control cutout b in the template sheet. The spike is invalid if the point of the arrow extends beyond the notch (position II).

If the spike does not meet the requirements for checking at least one of the templates 849p-1, 806p and 816p, then it must be repaired and then checked in the above order. But in this case, a more stringent requirement is imposed on the spike: the end of the arrow 7 should not go beyond the deeper cutout of the template.

In addition, you need to check the position of the repaired spike relative to the hole for the lift roller using a 938r template (Fig. 2.16). This position is considered correct if the template with hole a is put on the spike, and with protrusion b it enters the small hole for the elevator roller. Both at the hole and at the tenon, the template must lie against the plane of the housing pocket.

2.1.14. The position of the shelf for the upper arm of the fuse in the housing relative to the spike for the lock holder and the engagement contour is checked with a template 834r (Fig. 2.17), after it is established that the spike for hanging the lock holder meets the requirements of verification with templates 849r-1.806r and 816r.

To check, the template 834r must be taken by the base b, inserted into the pocket of the case and installed so that the stops 3 and the protrusions 4 are tightly pressed against the non-wearing part of the shock surface of the throat and the inner wall of the small tooth, and the rectangular support 1 rests on the spike for the lock holder.

After such installation of the template, the vertical position of the shelf is checked by turning the arrow 2, the pointed end of which is lifted up until its rear end rests against the upper surface of the shelf. The horizontal position of the shelf is checked using the slider 5, which is moved all the way to the front edge of the shelf. If the tip of the arrow 2, resting with its other end on the working surface of the shelf, is located outside both steps of the control cutout b, then the vertical position of the shelf is incorrect (pos. A). If the pointer of the slider 5, resting against the shelf, is located outside both steps of the control cutout d, then this indicates an incorrect horizontal position of the shelf (pos. B).

For the correct indication of the template, when checking the vertical position of the shelf, it is necessary to turn the arrow 2 with the slider 5 fully extended towards itself, and check the horizontal position of the shelf at the lowest position of the arrow pointer 2.

A shelf that does not meet the requirements of the 834p test must be repaired or replaced with a new one.

A new or repaired shelf is also checked with the 834p template as described above. But at the same time, they present increased requirements, namely: the position of the shelf is considered correct when the pointers of the arrow and the slider are located respectively within the deeper cuts a and b.

2.1.15. The thickness of the jumper of the shank of the CA-3 automatic coupler must meet the requirements of checking with an impassable template 897r-1 or 898r-1 (Fig. 2.18, i), depending on the type of repair of the rolling stock (Appendix 2) both from the upper and from the lower plane. The jumper is considered good if the template is not put on it completely (pos. 7); if the template reaches the stop in the jumper, then it is unusable (pos. II).

The jumper, worn out by the wedge of the traction clamp and having dimensions less than permissible, is subject to surfacing. The worn end part of the shank is restored by surfacing if the length of the shank of the automatic coupler is less than 645 mm, and for the SA-3M * 1 automatic coupler - less than 654 mm.

The thickness of the web of the shank of the SA-ZM automatic coupler, measured in the middle part, must be at least 44 mm for all types of periodic repairs of the rolling stock. The measurement is made with a caliper equipped with a measuring bar.

2.1.16. The jumper of the shank of the SA-3 automatic coupler from the side of the wedge must be processed in such a way as to obtain a flat cylindrical surface with a radius of curvature of at least 16 mm and not more than 20 mm, with a smooth transition to side surfaces hole walls.
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* The SA-ZM automatic coupler is installed on 8-axle and some special cars, as well as 8-axle shunting locomotives. During repairs, it is allowed to replace the SA-ZM automatic coupler with the SA-3 automatic coupler with a vertical movement limiter while replacing the draft device (traction collar, draft gear, traction collar wedge) in accordance with the design of Design Bureau TsV N M 1497.00.000.

After repair, the shank jumper is checked with impassable 900r-1 (Fig. 2.18, b) and 46g through passage (Fig. 2.18, c) templates.

The surfaces of the body shank in contact with the traction collar, centering beam, walls of the impact socket and the traction collar wedge (side walls of the hole), worn to a depth of more than 3 mm, must be deposited and then machined flush with the casting surface.

2.1.17. The bent shank of the automatic coupler must be straightened if its bending r (Fig. 2.19), measured from the original longitudinal axis of the body in the middle part, exceeds 3 mm.

The marking of the body to determine the bend in the horizontal plane is made, as shown in fig. 2.19, a. First, the middle of the shank is found and marked at a distance of 20 mm from the head stop, as well as at the end and in the middle part. After that, the points are connected with a line, indicating the middle of the shank at the beginning and at the end. The bend is defined as the deviation of the specified line from the middle of the shank in its middle part.

Bend g in vertical plane count in the middle part of the shank from the original longitudinal axis of the body, which is a continuation of the casting seam on the large tooth (Fig. 2.19, b).

It is not allowed to straighten an automatic coupler shank with welded or non-welded cracks in the area of ​​straightened places.

2.1.18. Cracks in the shank of the automatic coupler body up to 5 mm deep can be cut down with a smooth transition to the casting surface without subsequent welding. Small cracks (netted) with a depth of not more than 8 mm in the shank web are allowed to be cut down with subsequent welding, provided that after their cutting, the thickness of the web will be at least 40 mm.

2.1.19. Limiters of vertical movements of passenger cars, cars of electric trains, refrigerated, eight-axle and other freight cars, on which the installation of limiters is provided, should not have bends, wear of more than 5 mm. The distance from the longitudinal axis (casting seam) of the automatic coupler body to the horizontal shelf of the limiter should be 280 + 5 mm (Fig. 2.20, a). Automatic couplers of wagons for the transport of dangerous goods must have both a lower and an upper limiter (Fig. 2.20, b).