CTY5/6,7,9-90

Explosion-proof special type battery electric locomotive

1Overview

1.1model, purpose and dimensions:

Locomotive Model and Usage See Table1, see outline drawing for outline and size14.

table1

Namesaid	type	usedway
Explosion-proof special type battery electric locomotive	CTY5/6,7,9-90	Suitable for coal mine underground return air lane road transport of mineral equipment or shunting

1.1.1Meaning of electric locomotive model

C T Y 5/6,7,9-90

Battery nominal voltage (90V)

Gauge600mm(7,9are respectively762mm,900mmGauge)

Locomotive viscosity5tons

one end of the cab

Explosion-proof special type

coal mine locomotive

1.2products

1.2.1this productMT491-901995General Technical Conditions for Coal Mine Explosion-proof Battery Electric Locomotive.

1.2.2technical specifications (see table2)

table2

Items	Namesaid	value
1	Viscosityt	5
2	rated voltage (battery nominal voltage)V	90
3	battery capacity (5 hour rate)Ah	385
4	Motor rated powerkW	7.5
5	Rated tractionkN	7.06
6	Rated speedkm/h	7
7	Wheelbasemm	850
8	minimum curve radiusm	6
9	Wheel rolling circle diametermm	520
10	Total transmission ratio	15.78
11	control mode	resistance speed regulation
12	transmission mode	Umbrella positive two-stage gear drive
13	braking mode	Mechanical brake
14	motorsTable	2

1.3locomotive:

Traction characteristics of locomotive, see Fig.1. Locomotives in3‰ downhill slope are shown in Fig.2.

2product structure and working principle

2.1:

General layout and main structure of this locomotive are shown in Fig.3shown in the figure, it can be divided into two parts: mechanical and electrical.

table3

Item times	Namesaid	Gaugegrid	Quantity
1	wheel	Rolling circle diameterφ520mm	2
2	bearing	30213	4
3	bearing	6216	2
4	axle		1
5	large spur gear	m=5 z=57 ζ=0.5	1
6	bearing	32307	2
7	small spur gear	m=5 z=13 ζ=0.6	1
8	bearing	NU205E	1
9	driven bevel gear	ms = 6 z = 36 β m = 20 ° Gleason system	1
10	driving bevel gear	ms = 6 z = 10 β m = 20 ° Gleason system	1
11	bearing	32008	2
12	coupling		1
13	traction motor	84V 7.5KW 1130r/m	1

2.2:

2.2.1Frame device: The frame is a high-quality steel plate welded structure with high strength, high rigidity and not easy to deform,are equipped with elastic buffers to reduce the impact and connect the mine car. The driver's cab ceiling device is installed at the front of the frame, and the battery box is installed at the rear. The side plate of the frame is notched, and both sides of the notch are equipped with guide plates to accommodate springs and bearing boxes in it to transmit weight and traction. The entire frame is supported on the bearing box of the running gear through the spring device.

2.2.2Walking device: it is composed of main parts such as reduction gearbox, wheelset, bearing box and suspension. Its structure is shown in the figure.6.

Each locomotive has2group, the gearbox shell is made of ductile iron, the transmission principle and main components are shown in the figure.4and tables3, the reduction gearbox is supported on the wheel axle with ball bearings, the bracket is connected with the reduction gearbox with bolts, and is elastically hung on the frame with rubber washers. The traction motor is installed on the bracket, and the rubber shell type elastic The coupling is connected with the active spiral bevel gear of the reduction gearbox to transmit torque. The two ends of each wheel set are equipped with tapered roller bearing boxes. The structure of the bearing box is shown in the figure5.

2.2.3Braking device: This braking device is a mechanical lever force transmission type, which can apply unilateral braking to two wheel pairs at the same time. The structure of the entire braking system is shown in the figure.7, the brake handwheel is located in the driver's compartment. The driver can rotate the handwheel clockwise to apply braking. Adjust the coupler to keep a certain gap between the brake shoe and the wheel flange. Adjust the spring plate with the adjusting screw to make the brake shoe working surface and the wheel flange The gap between the tread surfaces is uniform.

2.2.4sand scattering device uses the principle of baffle cutting and falling sand. Two groups of sand boxes (two in each group) are respectively placed on both sides of the wheel set, which can scatter sand on the track in front of the load reduction wheel set during locomotive operation to increase the wheel and The adhesion between the rail surfaces prevents the wheels from idling when starting or accelerating. Sand box structure as shown in Fig.8.

2.2.5ceiling device and the front end of the frame form a cab. The ceiling is of thin steel plate welding structure, which can prevent rain and falling rocks and protect the safety of drivers. The front wall is provided with a lookout window, and the rear end is open. The driver control box, resistor and lighting lamp on the locomotive. Electrical equipment such as voltmeter and gas cut-off meter shall be installed in the ceiling.

2.2.6On the inner side of the frame wall plate, spring supports are welded on both sides of the bearing box notch.4supports the frame on the two-wheel pair bearing housing to transmit vertical loads and mitigate line impacts.

2.2.7buffer is used to reduce the impact of the trailer or the collision between the vehicles during operation. Its structure is shown in the figure.9.

2.3The working principle and structure of the electrical part

2.3.1working principle:

The electric locomotive adopts the direct control mode of resistance speed regulation, which adjusts the speed of the locomotive by changing the resistance value of the string in the motor circuit and changing the terminal voltage of the traction motor.

2.3.1.1pin into the seat according to the positive and negative polarity, and connect the battery power supply device and the locomotive control circuit.

2.3.1.2operate the reverse handle of the driver controller to point to the required running direction of the locomotive. At this time, the armature winding of the traction motor is switched on.

2.3.1.3Operate the driver controller, the main handle is0"Displacement to"1"bit~"3"position, the starting resistor is connected in series with two traction motors connected in series.

2.3.1.4continue to operate the main handle to move to4"position, the starting resistors are all shorted and the two motors run in series. "4"bit for economic operation.

2.3.1.5Operation Master Handle"4position continues to move forward, enterX1,X2,X3bit, this bit is the transition bit, the two motors are converted from series connection to parallel connection.

2.3.1.6main handle to"5","6"bit, the starting resistor is connected in series with two motors connected in parallel, and enters"7"position, the starting resistors are all shorted and the locomotive enters the highest speed."7"position is the economic operation position.

2.3.1.7"4"bit and"7" position is the economic operation position of the locomotive and can work for a long time. All other positions are connected with resistors and cannot work for a long time.

2.3.2structure

electrical circuit is mainly composed of battery power supply device, driver control box and traction motor. The structure and performance of each electrical equipment are detailed in their respective operating instructions.

3Locomotive Operation and Operation

3.1Inspection before the locomotive is put into operation: the driver shall carry out the following inspections before operating the locomotive:

3.1.1check whether the mechanical part and the electrical part of the locomotive are completely normal.

3.1.2check whether all movable covers and shields on the locomotive are properly covered, whether all fastening bolts, brackets, hanger bolts, bearing box bolts, etc. in the running gear are fastened and reliable, and whether there is enough lubricating oil at each lubricating place.

3.1.3Check whether the parts of the brake system are in good condition. When the brake shoe is worn to a thickness of less10mm, it should be replaced.Operationbrake hand wheelOperationis normal and flexible.

3.1.4check whether there is enough dry fine sand in the sand box, and check whether the sand spreading device works well in two directions.

3.1.5Check whether the connecting wires of each equipment in the electrical system are in good condition, and check whether the fixing of the battery box on the frame is reliable.

3.1.6Put the main handle in the zero position, press the lamp switch, and check whether the lamp is normal. Put the main handle in the running position, and check the over-discharge indicator. When the indicator flashes and gives an alarm, it should be charged. It should not be used reluctantly.

3.1.7the reverse handle in the "forward" or "reverse" position, pull the master handle to"1"position, the locomotive runs at a low speed in the established direction, and can check whether there is any problem with the electrical circuit of the locomotive, and verify whether the actual running direction of the locomotive is consistent with the reverse handle.

there is no fault or problem after the above inspection, indicating that the locomotive is in good condition before entering operation.

3.2General rules for starting operation of locomotives

This locomotive is for resistance speed regulation, the following regulations shall be observed during operation:

3.2.1insert the handle into the specified position, you can turn the reverse handle finger.the Forward or Backward position.

3.2.2fails during operation, the main handle should be quickly returned to the zero position to avoid damage to the equipment.

3.2.3In the starting operation, if the wheel is idling, sand should be sprinkled immediately to increase adhesion to eliminate idling, or the main handle should be returned to the zero position before restarting.

3.2.4When turning the handle, the handle should be moved gradually to ensure a stable start. In case of heavy load and low speed, the handle should be avoided to move quickly to avoid current impact. Except"4"bit and"7"position can work for a long time, other people are not allowed to stay for a long time.

3.2.5During operation, the battery box should be returned to the garage for inspection if it is seriously heated or has abnormal odor.

3.2.6During the operation of the locomotive, attention should be paid to whether there is abnormal sound and smell, and whether there is heat in each bearing part. If any problem is found, it should be stopped for inspection and eliminated.

3.3locomotive

3.3.1must stop the locomotive, the main handle should be returned to the zero position first, and then the brake hand wheel should be rotated clockwise to gradually increase the braking force to stop the locomotive.

3.3.2When braking, if the force is too strong, the brake shoe will lock the wheel and cause the phenomenon of sliding. At this time, the braking distance will increase instead. For this reason, the brake will be quickly released to stop the sliding, and then brake again. At the same time, sand should be scattered. Increase adhesion and stop sliding.

3.3.3finds that the mechanical brake works abnormally and cannot be reliably braked, it shall stop and check all parts of the brake system to eliminate the fault in time. If the brake system has a fault, the locomotive is not allowed to operate reluctantly.

3.3.4When operating the locomotive, the driver should control the speed of the locomotive according to the slope of the line, the traction weight and the required stopping distance to ensure the safe and reliable stop of the locomotive. When the locomotive is not stopped, it is not allowed to turn the reverse handle.

3.4Sanding Device

3.4.1When the locomotive is started and accelerated, sand can be scattered to increase adhesion and exert locomotive traction.

3.4.2In case of poor track adhesion conditions during operation, sand can be sprinkled when the wheels are idling to improve adhesion to terminate idling.

3.4.3During emergency braking, sand can be sprinkled to increase the braking effect.

3.5Inspection of locomotive shift change:

The inspection during shift change is the same as that before entering operation. At the same time, the successor driver should also check the heating of each bearing of the running gear, such as the temperature rise is higher55℃, should check the cause, to be excluded.

4Locomotive

4.1walking device

4.1.1walking device

4.1.1.1When the running gear must be separated from the car body, the following steps should be followed:

a)Pad up the carrier from under the body with a skid or rolling mount.

B)Remove the nut above the hanger rod connected with the car body, and remove the support plate below the bearing box and the motor wiring.

c)lift the frame out of the way.

4.1.1.2When only the traction motor needs to be taken out, the motor wiring, coupling, motor and anchor bolts are removed to lift the traction motor from above the car body.

4.1.1.3If only the gear or bearing in the reduction box is replaced, only the coupling and the bearing cover at the junction of the reduction box and the axle need to be disassembled, the lower box is held from below, and the connecting bolts of the upper and lower boxes are removed, and the upper box can be taken out from the upper part of the self-frame for maintenance.

4.1.2reduction gearbox

Internal structure of reduction gearbox is shown in figure10, when the parts are replaced, the assembly adjustment can be carried out according to the following steps:

4.1.2.1the driven bevel gear19installed in wheel center18, fasten with bolts and lock the nuts with anti-return washers (wheel center and wheel shaft20is a static fit connection), the bearing12is hot sleeved on the rotation shaft.20.

4.1.2.2adjusting bolt14precession bearing sleeve13, put in the inner cover15the bearing12pressed into bearing sleeve13.

4.1.2.3, feed the installed rotating shaft into the opening of the upper box, and then install the bearing13into the shaft hole from both sides, support the shaft, and bolt the bearing sleeve13is fastened to the box. Adjusting the adjusting bolt14, make the bearing12is in the pre-tightening state, and its tightness is suitable for applying axial force on the shaft without movement and being able to rotate flexibly.

4.1.2.4Bearings11inner ring hot sleeve to driving bevel gear10, and use the gear ring21fix it on the axle, and then fix the bearing3pressed into the bearing sleeve9, against the raised edge.

4.1.2.5the bearing sleeve9is sleeved on the driving bevel gear, the bearing3is hot sleeved on the driving bevel gear, and then the bearing3is pressed in with the bearing cover1and bolt the bearing sleeve9and bearing covers1fastening, by adding or removing gaskets between them83is suitable for applying axial force on the shaft without movement and being able to rotate flexibly. After that, the oil seal cover2oil seal7loading, coupling half6installation, with anti-return washer4and round nuts5lock, and pay attention to make the bearing cover1and bearing sleeves9oil return gap is located below.

4.1.2.6Assembled driving bevel gear10and bearing sleeves9Gasket8are installed into the upper shell of the reduction gearbox. At this point, the assembly of the reduction gearbox and the adjustment of the bearing clearance have been completed, so that the bearing is in a micro-preload state when there is no load. When the force is applied, a small axial clearance will appear on one bearing. The reserved axial clearance has good supporting rigidity and improves the bearing life. However, the preload should not be too large, otherwise it will cause heat generation and reduce the bearing life.

4.1.2.7the following spiral bevel gear meshing performance should be adjusted. First adjust the flank clearance. Turn the shaft simultaneously for this purpose20adjusting bolts at both ends14(keep the adjusted bearing clearance intact)20moves along its axial direction so that the tooth side clearance reaches this0.15-0.40mm, the measurement of the backlash is shown in Fig.11, the contact of the wire meter is vertically pressed on the large end tooth surface of the large gear, the small gear is fixed, and then the large gear is swung. The swing range of the pointer of the wire meter is the tooth gap of the gear.

4.1.2.8side is adjusted, apply a thin layer of red Dan powder adjusted by oil on the tooth surface of the driving bevel gear, and then rotate for tens of turns to observe the contact spots on the tooth surface. The good contact spot area should be located in the middle of the tooth. Slightly smaller end, as shown in the figure12shown. When the contact area is not required, it should be adjusted, the driving bevel gear10can be increased or decreased gasket8, the driven bevel gear moves while rotating the adjuster bolt14reached. After all adjustments are made, use anti-heat tablets.16the adjusting bolt14locked.

4.1.2.9After the above steps are completed, clean it with kerosene, hold the upper box and the lower box on the wheelset and fasten it with bolts. Pay attention to making the oil return gap of the bearing located below, connect the bracket and the lower box, install the motor on the bracket, adjust the coupling clearance and concentricity, install the coupling, and complete the assembly of the traveling device. The disassembly of the reduction gearbox can be carried out in the reverse order of the assembly process.

4.1.3reduction gearbox

4.1.3.1bearing and gear adjustment to the appropriate state is an important factor to ensure the normal operation of the gearbox, so after a certain period of operation to be checked, adjust to the appropriate state to ensure reliable operation, improve life.

4.1.3.2the reduction gearbox heats up during work, first check the bearing clearance. If it is too loose or too tight, it should be adjusted. Then check the dirt degree of lubricating oil. If it is serious, replace it with new oil. If necessary, disassemble the reduction gearbox and check the bearing working surface. If there is wear and peeling, pitting and other phenomena, the bearing should be replaced.

4.1.3.3New bearings must be washed with gasoline or kerosene to remove oil wax and debris before assembly.

4.1.3.4The lubricating oil in the reduction gearbox must be replenished and replaced regularly. When replacing, open the lower screw plug to drain oil, and inject new oil from the upper part (mechanical oil can be usedN46).

4.1.3.5When the oil leakage at the half coupling of the reduction gearbox and the axle is serious, check the oil seal at this part. If it is severely worn or burned, replace it with a new oil seal. Before installing the new oil seal, scrub the surface of the sealed shaft diameter and apply a little. A layer of lubricating oil before installation. The installation operation should be careful and the oil return gap should be located below.

4.1.3.6When parts are not replaced and only gears and bearings are adjusted, the reduction gearbox may not be disassembled, but the work shall be done carefully, the tools used shall be clean, and sundries shall not be dropped into the box. When disassembling and reassembling, all parts should be scrubbed clean. If the lubricating oil in the box is mixed with impurities, it will cause early wear of gears and bearings.

4.1.4wheelset bearing

Single row radial ball bearing with reduction gearbox on wheelset216and bearing housing7213, bearing box structure (see figure5),7213bearing can be carried out as follows:

4.1.4.1Install the bearing cover without gasket, and tighten the bolts so that the bearing box can rotate flexibly but there should be no axial gap, and then use a feeler gauge to measure the gap between the bearing cover and the bearing box "T".

4.1.4.2the measured"T"plus0.05~0.20mm, select the gasket according to this value, then remove the bearing cover, pad the selected gasket, and tighten the bolt.

4.1.4.3bearing216after the reduction gearbox is engaged on the axle is the same as above.

4.1.5wheelset

4.1.5.1When checking the locomotive every day, pay attention to whether the wheels are loose and whether the bearing box is hot.

4.1.5.2During regular maintenance, check the wear of wheel tread and wheel flange. When the depth on the rolling circle surface is greater3mm, length greater5mm, the wheel should be removed to rotate on the lathe, and the diameter deviation of any two rolling circles on the locomotive should not be greater1mm.

4.1.5.3When the diameter of the wheel rolling circle is less500mm, or the rim is radially higher from the rolling surface12mmis less13mm.

4.1.5.4The bearing box should be cleaned regularly, the grease should be replaced, the bearing clearance should be adjusted, and the grease should be added to the guide plate groove.

4.1.6coupling and traction motor suspension system.

4.1.6.1should regularly check all fastening parts, such as loose should be timely fastening.

4.1.6.2Coupling Structure See Fig.13, should regularly check the rubber tire shell, permanent deformation and crack should be replaced. If the deviation of the two axes is too large due to the displacement of the traction motor, the position of the motor should be adjusted so that the deviation is not greater0.5mm.

4.1.6.3The traction motor is in the horizontal position in normal state. When it deviates, the nut on the hanger rod can be adjusted to restore the horizontal position. During assembly, all rubber shock-absorbing washers shall be in a compressed state. When the washers are seriously deformed, aged, worn and cracked, they shall be replaced.

4.2braking device

4.2.1brake device7. The braking device shall be checked before each locomotive operation, and must be replaced and repaired if there is any fault, damage or serious wear.

4.2.2is in the relief state, the brake shoe is in the concentric position with the wheel tread, and the spring is adjusted in time to achieve the non-concentric position.

4.2.3The coupling should be adjusted frequently according to the degree of wear of the brake shoe, so that the gap between the brake shoe and the wheel tread is maintained2~3mmrange.

4.2.4Sludge should be removed frequently, and lubricating oil should be added to the screw rod, bearing and pin to maintain flexibility and reduce wear.

4.2.5When the brake shoe is worn to the thickness10mm, the new brake shoe shall be replaced. When replacing, the coupler shall be removed and the inclined pin on the brake shoe holder shall be punched out to remove the brake shoe. After replacing the new brake shoe, the coupling and spring should be adjusted accordingly to meet the above requirements.

4.3Sanding device

4.3.1Sand box structure as shown in Fig.8, the sand box should be in the open position when the pedal is stepped on, and the sand can flow out smoothly. After the pedal is not stressed, the recovery spring should be able to return the sand box to the closed position. When it cannot be reset, the length of the spring should be adjusted to increase the recovery force, and Check whether the system is stuck and eliminate it. Add lubricating oil at each hinge pin to make the operation flexible.

4.3.2When the sand cannot fall on the track correctly, the position of the sand discharge pipe should be checked and adjusted to the correct position.

4.3.3When the sand pin returns to the closed position, if there is sand leakage, check the distance between the sand outlet of the sand box and the support, remove the large sand particles stuck between them, and adjust the gap0.5-1mm.

4.3.4shall regularly check the movable joints, add lubricating oil, and remove the accumulated soil and sand in the sand pipe.

4.4spring suspension device

4.4.1spring system must be checked frequently, and fragments and cracks must be replaced.

4.4.2the spring plate should be lubricated frequently, dust and soil should be removed, and lubricating oil should be poured on the side of the spring plate to make the oil flow between the plates along the side of the spring plate. Grease should be added regularly at the spring ear and bearing fulcrum.

4.5Electrical equipment and electrical wiring

4.5.1The use and maintenance of each electrical equipment is shown in the respective product manual.

4.5.2During the daily operation of the locomotive, during the shift change, all components of the electrical circuit should be checked. If the fault is found, it should not be used reluctantly. The fault location should be found according to the electrical equipment wiring diagram, and then repaired according to the instruction manual of the component to eliminate the fault.

4.5.3shall regularly check the condition of the connecting wire of the electrical circuit. If the wire insulation is damaged, insulation aging and corrosion, it shall be handled or replaced in time to avoid short circuit damage to electrical equipment.

4.5.4The electric locomotive must be wired strictly according to the wiring diagram. Battery power must be used when testing electrical wiring.

4.5.5In the rainy season, the insulation of electrical lines should be checked. When there is water in the electrical equipment and trunking, it should be removed in time, and attention should be paid to the timely removal of dust and coal dust in the electrical equipment to avoid short circuit caused by this.

4 .. 5.6Maintenance of battery box

4.5.6.1The cover of the battery box cannot be opened at will during operation, and heavy objects are prohibited from being placed on the cover.

4.5.6.2The ventilation holes on the battery box and box cover shall not be blocked by coal dust and dirt, and shall be cleaned in time.

4.5.6.3is charging, it should be carried out in strict accordance with the steps specified in the battery manual. And pay attention not to the sulfuric acid liquid splash leakage in the box body, after charging, the application of clean water rinse, avoid leakage caused by the short circuit between the poles, prolong the service life of the box body.

4.5.6.4transportation should be reasonably arranged to avoid excessive discharge of the battery to extend its life.

4.6locomotive

4.6.1Lubrication parts and requirements of the locomotive are listed in the table6

table6

Components Name	Lubrication point number Number of lubrication points	Lubricant Name	lubrication system	Lubricant	addition amount
spring device	1/4	leaf spring	Monthly1times	mechanical oilN46	right amount
	1/12	plate spring support point	Monthly1times	calcium-sodium base grease	right amount
axle box	2/4	bearing	half year1times	calcium-sodium base grease	right amount
	2/8	Axle box guide groove	Weekly1times	calcium-sodium base grease	right amount
reduction gearbox	4/3	gear bearing	half year1times	mechanical oilN46	5kg
Braking device	5/3	brake screw coupling thread	Weekly1times	mechanical oilN46	right amount
	5/13	Bearing Hole Pin	Weekly1times	mechanical oilN46	right amount
Sanding device	6/12	Pin support point	Weekly1times	mechanical oilN46	right amount

Note: (1) Wet Tropical Type Use Lithium Grease3

(2) It is allowed to substitute oils with similar performance, but it is not allowed to be mixed.

5. Spare parts, tools and documents

5.1Spare parts and tools except for items in the table below,is specified in the electrical equipment instruction manual.

Itemtimes	Namesaid	Code	quantity
1	Utype oil seal	5.370.093	4
2	rubber washer	8.280.097	4
3	oilseal	5.370.094	2
4	rubber tireshell	8.280.098	2
5	driving bevel gear	8.242.112	1
6	driven bevel gear	8.242.131	1
7	special nut	8.948.243	1
8	bombspring	8.282.1015	2
9	small spur gear	8.240.460	1
10	oilpot	specifications are0.5Kg	1
11	power supply unit	DXT90/385	1

1. 2. file

Serial Number	Namesaid	Quantity	equipmentNote
1	Electric locomotive certificate	1
2	Operating Instructions for Electric Locomotive	1
3	Traction motor instructions	1

6Quality Assurance

accordingMT491-1995to the provisions of the standard, this product from the date of arrival.10months6months, if there is a failure, the factory is responsible for free repair or replacement after analysis of the quality problems of the factory.

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Xiangtan Shuangmali Material Trading Co., Ltd.