Typical technological maps for vehicle maintenance. Maintenance flow chart: simple things to achieve success
TECHNOLOGICAL MAPS FOR MAINTENANCE AND REPAIR OF KAMAZ VEHICLES (1989)
Introduction
Technological maps current repair of units was developed by Centravtotech of the Ministry of Automobile Transport of the RSFSR at the request of the production company KamAZAvtocenter of the KamAZ production association.
Technological maps are developed based on the following materials:
1. Regulations on maintenance and repair of rolling stock road transport. Part 1 (guide).
2. Regulations on the maintenance and repair of rolling stock of road transport. Part 2 (normative). Vehicles of the KamAZ family. Po-200-RSFSR-12-0115-87.
3. Operating manual for KamAZ 6x4 vehicles (5320-3902002Р7).
4. Operating manual for KamAZ vehicles type 6x6 (4310-3902002RE).
5. Manual for routine repairs of KamAZ-5320, KamAZ-5511, KamAE-4310 vehicles (shop work). RT-200-15-0066-82.
6. Catalogs and drawings of parts and assembly units of KamAZ vehicles.
When developing technological maps, equipment, instruments and tools were used, serially produced by the Rosavtospetsoborudovanie plants and non-standardized equipment, including those developed at KamAZ.
Technological maps contain standards for labor intensity of work, agreed upon with the “Tsentro-rgtrudavtotrans” of the Ministry of Autotrans of the RSFSR.
Technological maps have undergone experimental testing.
Technological maps are standard. In each individual case, it is necessary to link them to the specific conditions of enterprises.
The range of repaired units, assemblies, mechanisms and instruments was selected based on the typical and most frequently encountered work on routine repairs of KamAZ vehicles at enterprises.
The list of technological maps includes repairs of: engine, fuel equipment, gas equipment, electrical equipment, pneumatic equipment of the brake system, dump mechanism, transmission.
To make it easier to read technological maps, they contain diagrams and drawings.
The technological maps provide a complete list of disassembly, assembly and troubleshooting operations. Under operating conditions, the depth of disassembly and the scope of troubleshooting can be carried out until a defect is detected.
When organizing and performing work on routine repairs of units, components, mechanisms and instruments, it is necessary to be guided by the system of labor safety standards and the “Safety Rules for Motor Transport Enterprises”.
Current repairs of units, components, mechanisms and devices must be carried out in workshops or areas designated for this purpose.
When disassembling units, components, mechanisms and devices into parts, it is necessary to use pullers and devices that facilitate the work of performers and ensure the safety of work.
Maintenance workshops for units must be equipped with the necessary lifting and transport mechanisms. Units and assemblies that have a significant mass should be transported, removed and installed from stands using lifting and transport mechanisms equipped with devices that protect against possible falling of assemblies and assemblies.
Devices for securing units and assemblies on stands must prevent the possibility of units and assemblies moving or falling. Tools and accessories must be in good condition.
The procedure for carrying out routine repair work is set out in technological maps, which reflect the sequence of disassembly and assembly, troubleshooting and testing of units and components, equipment, devices and tools, technical conditions and instructions, labor intensity of work and qualifications of performers.
The technological process for routine repair of units should include: cleaning and washing work on the car; identifying faulty components on the car; removal of faulty units from the vehicle; transportation to the workshop; sub-disassembly; external washing (cleaning); disassembly;
washing; cleaning, drying, blowing parts; troubleshooting; picking; assembly; adjustment by test; ■ acceptance by quality control department; transportation to the post (warehouse); installation on the car.
Only persons who have undergone safety training and have been trained in safe labor techniques in special classes organized by the enterprise administration are allowed to work on the repair of units, components, mechanisms and instruments.
Shops or areas must have first aid kits stocked with medications necessary to provide first aid.
Federal Agency for Education of the Russian Federation
SYKTYVKA FOREST INSTITUTE
State educational institution
Higher professional education
"St. Petersburg State Forestry Academy
them. CM. Kirov"
Faculty of Forest Transport
Department of Automobiles and Automotive Industry
COURSE PROJECT
Discipline: Technical operation of vehicles
Subject: Organization of maintenance-1 of a KamAZ 53212 vehicle
KP. LTF. 190601.4 DO.061219. PZ
Completed by Skorobogatykh P.A.
Checked by Malashchuk P.A.
Head Department Chudov V.I. Ph.D.
Syktyvkar 2009
Introduction
Machine maintenance is a set of preventive measures during the overhaul period aimed at preventing failures in units and components and reducing the wear rate of parts. Maintenance includes inspection and diagnostic, fastening, lubrication, filling, adjustment, electrical and other types of work.
Vehicle maintenance has the goal of ensuring constant technical serviceability units, components in the car as a whole; maximize turnaround time; guarantee traffic safety; ensure minimal consumption of operating materials.
To achieve these goals, our country has adopted a planned preventative maintenance system, which provides for the mandatory implementation of a set set of works at a given frequency during the use, storage and transportation of vehicles. The technological process of servicing a car with a planned preventative system provides for a combination of mandatory work with work performed on demand, the need for which is determined as a result of checking the condition of the car. Maintenance special equipment installed on the vehicle is carried out, if possible, simultaneously with chassis maintenance.
Depending on the volume of work and the frequency of their implementation, maintenance is divided into the following types: control inspection, daily maintenance, maintenance No. 1 (TO-1), maintenance No. 2 (TO-2), seasonal maintenance (SO). The objective of this course project is to get acquainted with the vehicle maintenance system, draw up a technological map, determine the number and placement of workers, as well as select technological equipment. Draw a drawing of the car in two projections indicating the number and location of the maintenance operation. And a diagram of the technological layout of the post with the arrangement of equipment and workers.
Main technical characteristics of the KamAZ 53212 vehicle
Weight parameters and loads:
Vehicle curb weight, kg 8500
Car load capacity, kg 11000
Gross weight, kg 19650
Gross trailer weight, kg 14000
Gross weight of the road train, kg 33650
Installed engines:
Model 740.31-240 (Euro-2)
Type: diesel with turbocharging, with intercooling of charge air
Maximum net power, kW (hp) 165 (225)
Rated power, gross, kW (hp) 176 (240)
at rotation speed crankshaft, rpm 2200
Max. useful torque, Nm (kgfm) 912 (93)
at crankshaft rotation speed, rpm 1100-1500
Arrangement and number of cylinders V-shaped, 8
Working volume, l. 0.85
Cylinder diameter and piston stroke, mm 120/120
Compression ratio 16.5
Supply system:
Capacity fuel tank, l. 500
Electrical equipment:
Voltage, V 24
Batteries, V/Ah 2×12/190
Generator, V/W 28/2000
Clutch:
Type friction, dry, double-disc
Hydraulic drive with pneumatic booster
Transmission:
Type mechanical, ten-speed
Mechanical control, remote
Gear ratios:
7,82 4,03 2,5 1,53 1,000 7,38
6,38 3,29 2,04 1,25 0,815 6,02
Main gear:
Gear ratio 5.43
Pneumatic drive
Dimensions: drum diameter, mm 400
Brake lining width, mm 140
Total area of brake linings, cm2 6300
Wheels and tires:
Wheel type: disc
Rim size 7.5-20 (190-508)
Tire size 10.00 R20 (280 R508)
Over-engine type with high roof
Version with berth
Platform:
The platform is onboard, with metal folding sides, depending on the configuration, it is equipped with a frame and an awning
Internal dimensions, mm * 6100×2320 or 6114×2420 ("euro")
Side height, mm * 500 or 725 (“euro”)
Vehicle characteristics gross weight 19650 kg:
Maximum speed, no less, km/h 90
Climbing angle, not less, % 25
External overall turning radius, m 9.8
List of routine maintenance work for the KamAZ 53212 vehicle
Maintenance TO-1 for the KamAZ 53212 vehicle presented below is carried out in accordance with the “Regulations on routine repair and maintenance of rolling stock”. According to this provision, the first maintenance for trucks carried out every 4000 km. These works include control and diagnostic, inspection, fastening and lubrication and cleaning work.
The list of works includes:
General inspection:
1. Inspect the car, checking the condition of the cabin, platform, glass, rear-view mirrors, tail, license plates.
2. Door mechanisms, platform side locks, towing (fly-wheel) devices.
3. Check the operation of the windshield wiper and washers, the operation of the heating system and glass heating (in the cold season), and the ventilation system.
Engine, including cooling systems, lubrication:
4. Inspect the tightness of the engine lubrication and cooling systems (including the starting heater).
5. Check by ear the operation of the valve mechanism.
6. Check the fastening of the exhaust tract parts (exhaust pipe, muffler, etc.) and the oil sump.
7. Check the engine mounting.
8. Check condition and tension drive belts.
Clutch:
9. Check the free play of the clutch pedal. Check the tightness of the clutch release hydraulic drive system.
10. Check the fluid level in the compensation tank of the clutch release master cylinder.
Transmission:
11. Check the fastening of the gearbox and its external parts.
12. Check the operation of the gear shift mechanism with the vehicle stationary.
Cardan drive:
13. Check the fastening of the cardan shaft flanges. Check the play in the articulated and splined joints of the cardan transmission.
Rear axle:
14. Check the tightness of the rear (middle) axle connections.
15. Check the fastening of the gearbox housing and axle shaft flanges.
Steering and front axle:
16. Check the tightness of the power steering system.
17. Check the fastening of the nuts of the steering axles of the ball pins of the steering rods into the cotter pins.
18. Check the play of the steering wheel and steering rod joints.
Brake system:
19. Check the condition and tightness of pipelines and brake system devices.
20. Check the stroke of the brake chamber rods.
21. Change the alcohol in the freeze protector.
Chassis.
22. Inspect the condition of the frame, components and suspension parts.
23. Check the fastening of the stepladders and spring pins, and the fastening of the wheels.
24. Check the condition of the tires and the air pressure in them: remove foreign objects stuck in the tread and between the paired wheels.
Cabin, platform (body) and tail.
25. Check the condition and operation of the locking mechanism, stop-limiter and safety device for the tilting cab.
26. Check the fastening of the platform to the car frame,
27. Check fastenings, running boards, mudguards. Inspect the surfaces of the cabin and platform; If necessary, clean the corrosion areas and apply a protective coating.
Supply system.
28. Inspect the condition of the power supply system devices, their fastening and tightness of connections.
Electrical equipment.
29. Check the operation of the sound signal, instrument panel lamps, lighting and alarm, headlights, sidelights, rear lights, brake light and light switch.
30. Check the condition and fastening of electrical wires.
31. Check the mounting of the generator and the condition of its contact connections.
32. Clean the battery from dust, dirt and traces of electrolyte; clean the ventilation holes, check the fastening and reliability of contact of the wire tips with the output pins; check the electrolyte level.
Lubrication and cleaning work:
33. Lubricate the friction units and check the oil level in the crankcases of the units with a chemical map.
34. Clean the breathers of the gearbox and axles.
Checking the car after service:
35. After servicing, check the operation of the vehicle’s units, components and devices while driving or at a diagnostic station.
Technological map of KamAZ 53212 vehicle maintenance
Table 1
Technological map TO-1 of the KamAZ 53212 vehicle
| No. of work performed | Title and content of work | Service location | Number of service locations | Devices, tools, devices, model, type | Technical requirements and instructions |
| General inspection | |||||
| 1 | Inspect the car and check the condition of the cabin, platform, glass, rear-view mirrors, tail, paint, license plates and rear-view mirrors | Top, front, back | - | - | The glass of the cab, headlights, sidelights, and direction indicators must be intact. The platform boards must not have cracks or kinks. The condition of license plates must meet the requirements of the Rules traffic. Rear view mirrors must be intact and correctly adjusted |
| 2 | Check the serviceability of the cab door locks, platform side locks, and towing device | Above, behind | - | The mechanisms of doors and platform side locks must be in good working order. The towing device must be securely fastened to the frame and its hinged bracket must be pinned | |
| 3 | Check the operation of the windshield wipers, the windshield washer and the windshield defogger and heating device (in winter) | In the cockpit | 3 | - | The windshield wiper blades must fit snugly along the entire length of the edge to the surface of the windshield and move without jamming or stopping. During operation, the brushes should not touch the seal. The glass washing device must be in good working order and wash the entire glass surface evenly |
| Engine, including cooling and lubrication systems | |||||
| 4 | Inspect the condition and tightness of the cooling systems, engine lubrication, cabin heating system and starting heater | Up and down | 4 | - | Oil leakage at mounting points oil filter and crankcase is not allowed. Leakage of coolant in the pipes and radiator is not allowed |
| 5 | If necessary, eliminate leaks in the pipelines of the cooling system, engine lubrication system, cabin heating system and starting heating | Same | 4 | Leakage of oil, coolant and fuel can be eliminated by tightening nuts, clamps or replacing individual parts. | |
| 6 | Check by ear the operation of the valve mechanism | Above | 1 | - | Let the engine listen to its operation. There should be no knocking in the valve mechanism if it is adjusted correctly. |
| 7 | If necessary, adjust the gaps between the valves and rocker arms | Same | 16 | Device for adjusting valves I801.14.000 (10), set of probes No. 2 (15) | Thermal clearances in the gas distribution mechanism are adjusted on a cold engine no earlier than 30 minutes after stopping. In each position, simultaneously adjust the valve clearances of two cylinders in the order of operation: 1-5-4-2-6-3-7-8, turning crankshaft at 90 0 Thermal clearances are adjusted in the following order: install the piston of the first cylinder in c. m.t. of the compression stroke, rotate the crankshaft in the direction of rotation (counterclockwise, when viewed from the flywheel side) through an angle of 60 0 (rotating the flywheel by the angular distance between two adjacent holes corresponds to between two adjacent holes corresponding to turning the crankshaft by 30 0 ), At the same time, the valves of the 1st and 5th cylinders are closed (the valve rods can be easily turned by hand), check the tightening torque of the nuts securing the rocker arms of the adjustable cylinders and, if necessary, tighten them, to adjust the gap, loosen the adjusting screw nut, insert a feeler gauge into the gap and, turning the screw with a screwdriver, set the required gap. Hold the screw with a screwdriver, tighten the nut and check the gap. The gap should be 0.25-0.3mm for intake valves and 0.35-0.4mm for exhaust valves. |
| 8 | Check the fastening of the oil sump, exhaust pipes, muffler intake pipe flanges to the cylinder block and secure if necessary | Up and down | 3 | Auto mechanic set (large) I-148 (11), chisel (14), hammer (13). | Tighten the oil sump mounting nuts with a tightening torque of 1.5-1.7 kgf∙m, exhaust pipes 4.5-5.4 kgf∙m, exhaust pipe flanges of the muffler 4.5-5.4 kgf∙m |
| 9 | Check the mounting and, if necessary, secure the engine to the frame | Above | 1 | Auto mechanic kit (large) I-148 (11) | The nuts of the engine mounting bolts on the frame must be tightened and cottered. Carry out tightening with a tightening torque of 5.5 - 6 kgf∙m |
| 10 | Check the condition and tension of the generator and water pump drive belts | Above | 1 | Auto mechanic kit (large) I-148 (11) | Ensure belt tension by moving the generator correctly tensioned belt when pressing on the middle of the belt with a force of 4 kgf, the deflection should be 15-22 mm. |
| Clutch | |||||
| 11 | Check the free play of the clutch pedal | In the cockpit | 1 | Ruler (16) | The pedal free play should be 6-12 mm |
| 12 | If necessary, adjust the free play of the clutch pedal | Same | 1 | Auto mechanic kit (large) I-148 (11) | The free play of the pedal is set by adjusting the gap between the piston and the master cylinder piston pusher. To adjust the gap between the piston and the master cylinder piston pusher, use the eccentric pin that connects the top eye of the pusher to the pedal lever. Rotate the eccentric pin so that the movement of the pedal from the top stop to the moment it touches the piston pusher is 6-12 mm, then tighten and cotter the castle nut. |
| 13 | Check the tightness of the hydraulic clutch release system | In the cabin and below | 1 | - | Liquid leakage in the main, working cylinder and pipeline is not allowed |
| 14 | If necessary, repair leaks in the clutch release piping | Same | 1 | Auto mechanic kit (large) I-148 (11) | Fluid leakage can be eliminated by tightening the nuts and replacing individual elements. |
| 15 | Check the fluid level in the compensation tank of the clutch master cylinder | Front | 1 | - | |
| 16 | If necessary, add fluid to the compensation tank of the clutch master cylinder | Same | 1 | - | The liquid level in the tank from the top edge should be 15-20mm |
| Transmission | |||||
| 17 | Check the fastening of the gearbox and its external parts | Up and down | - | Auto mechanic kit (large) I-148 (11) | Tighten the gearbox mounting bolts with a tightening torque of 5.5-6 kgf∙m |
| 18 | Check the operation of the gear shift mechanism with the vehicle stationary. | In the cockpit | 1 | - | Shifting gears must be done without jamming |
| Cardan transmission | |||||
| 19 | Check the fastening and, if necessary, secure the flanges of the cardan shafts, check the play in the articulated and splined joints of the cardan transmission | From below | 16 | Auto mechanic kit (large) I-148 (11) | Play in hinged and splined joints is not allowed; flanges should be tightened with a tightening torque of 12.5-14 kgf∙m |
| Rear (middle) axle | |||||
| 20 | Check the tightness of the connections of the rear (middle) axle, if necessary, eliminate the leak | From below | 2 | Auto mechanic kit (large) I-148 (11) | Oil leakage is not allowed. Eliminate leakage by tightening the nuts or replacing individual elements of the unit; tighten with a tightening torque of 1.5-1.7 kgf∙m |
| 21 | Check the fastening and, if necessary, tighten the fastening nuts of the gearbox housing and axle shaft flanges | Below and above | - | Auto mechanic kit (large) I-148 (11) | Tighten the gearbox mounting nuts with a tightening torque of 16-18 kgf∙m |
| Steering and front axle | |||||
| 22 | Check the power steering system for leaks | Above | - | - | Oil leakage in the oil line and in the pump is not allowed |
| 23 | If necessary, repair the leakage of the power steering system | Same | - | Auto mechanic kit (large) I-148 (11) | Oil leakage can be eliminated by tightening the nuts and replacing individual elements. |
| 24 | Check the fastening and cotter pins of the steering axle arm nuts. Troubleshoot if necessary | From below | 3 | Auto mechanic set (large) I-148 (11), pliers (12) | The nuts securing the steering axle arms must be tightened and cottered. Tighten the levers with a tightening torque of 36-40 kgf∙m. The levers should not have play in the socket and on the key. |
| 25 | Check the fastening and cotter pins of the ball pin nuts of the longitudinal and transverse steering rods. Troubleshoot if necessary | Same | 3 | Auto mechanic set (large) I-148 (11), pliers (12) | The ball pin nuts must be tightened and cottered. Backlash of fingers in conical sockets is not allowed. tighten the ball pins with a tightening torque of 9-10 kgf∙m |
| 26 | Check steering wheel play | In the cockpit | 1 | Device model NIIAT K-402 (8) | The check is carried out on a loaded car (without load) with the engine running at a speed of 600 - 1200 min -1, with normal tire pressure, the front wheels set straight, the free play of the wheels on a new car should not exceed 15 0. Maximum permissible free play 20 0 |
| 27 | Check the play in the steering rod joints | Below and in the cockpit | 3 | - | Play in the steering rod joints must be checked by the relative movement of the ball pins and rod ends or heads when the steering wheel is sharply turned in both directions. Play in steering rod joints is not allowed. |
| Brake system | |||||
| 28 | Check the serviceability of the brake system using an external inspection and according to the readings of standard instruments. | Below and in the cockpit | - | - | The pressure created by the compressor should be 6.2-7.5 kgf/cm2. When you press the brake pedal, the pressure should drop sharply by no more than 0.5 kgf/cm2 |
| 29 | Check the condition and tightness of the brake system pipelines and devices and, if necessary, correct the malfunction | Up and down | - | Auto mechanic kit (large) I-148 (11) | Depressurization of the brake system is not acceptable. Depressurization can be eliminated by tightening the nuts or replacing individual elements of the system |
| 30 | Check and, if necessary, adjust the stroke of the brake chamber rods | From below | 6 | Auto mechanic set (large) I-148 (11), pliers (12), ruler (16) | The stroke of the rods should be no more than 40mm. Carry out the check in the following order: install a ruler parallel to the rod, resting its end against the brake chamber body, mark the location of the extreme point. Press the brake pedal all the way (pressure in the pneumatic drive is at least 6.2 kgf/cm2, the drums are cold, the parking brake system is turned off), mark the location of the same point. The difference between the obtained values is the stroke value of the rod. The stroke of the rod is adjusted by turning the worm axis of the adjusting lever, after unscrewing the lock two or three turns. Rotate the axis to set the smallest stroke |
| 31 | Change the alcohol in the freeze protector | Above | 1 | Auto mechanic kit (large) I-148 (11) | Drain sediment from the filter housing. To fill alcohol and control its level, release the rod handle to the lower position and fix it by turning it 90 0, unscrew the plug with the level indicator, pour alcohol and close the filling hole, turn on the fuse |
| Chassis | |||||
| 32 | Inspect the condition of the frame, components and suspension parts | From below | - | - | There should be no loosening of rivet joints, cracks, spars or cross members. |
| 33 | Check the fastening of the spring ladders | Above | - | Auto mechanic's set (large) I-148 (11), wrench for spring stepladder nuts model I-314 (7) | tighten stepladders with a tightening torque of the front ones - 25-30 kgf∙m, back 95-105 kgf∙m |
| 34 | Check wheel fastening | Same | 30 | Impact wrench for wheel nuts model I-303M (6) or wheel wrench 535M (9) | Tighten the nuts with a torque of 25 - 30 kgf∙m evenly, in one or two or three steps, starting from the top. |
| 35 | Check the condition of the tires and the air pressure in them, remove foreign objects stuck in the tread and between the paired wheels | Same | 10 | Air dispensing column model TsKB S-401 (1) or tip with pressure gauge model 458 (2), pliers (12) | The tire should not have cracks, tears, or swelling. The tire valve must have a cap. Air pressure 5.3-7.3 kgf/cm2. The remaining tread depth in the center of the treadmill must be at least 1.0 mm |
| Cabin and platform | |||||
| 36 | Check the condition and operation of the locking mechanism, stop-limiter and safety device | Above | - | - | The locking mechanism and safety devices must be in good condition |
| 37 | Check the fastening of the platform to the vehicle frame and secure if necessary | Same | - | Auto mechanic kit (large) I-148 (11) | tighten the platform fastening nuts with a tightening torque of 18-21 kgf∙m |
| 38 | Check the fastening of the footrests and mudguards, secure if necessary | Same | - | Auto mechanic kit (large) I-148 (11) | Tighten the footrests with a tightening torque of 1.5-2.5 kgf∙m, mudguards with a tightening torque of 1-2 kgf∙m |
| 39 | Inspect the surface of the cabin and platform, if necessary, clean areas of corrosion and apply a protective coating | Top, front, back | - | Wire brush | Rust, paint peeling, cracks are not allowed |
| Supply system | |||||
| 40 | Inspect the condition and tightness of the power supply system: fuel pump low pressure, fine fuel filter, fuel tank, fuel sump filter, fuel line connections, fuel pump high pressure and fine filter | Above | - | - | Fuel leakage in the instruments and fuel lines of the system is not allowed. Fuel lines must not be bent or cracked |
| 41 | If necessary, eliminate leaks in devices and connections of fuel lines of the power supply system | Same | - | Auto mechanic set (large) I-148 (11), pliers (12) | Fuel leakage from instruments and fuel system connections is eliminated by tightening individual connection elements. tighten with a tightening torque of 4.5-5.4 kgf∙m |
| Electrical equipment | |||||
| 42 | Check the operation of the sound signal, headlights, sidelights, rear light, brake light, instrument panel lamps and direction indicators | In the cabin and above, front, rear | - | - | All lamps must provide light without blinking, and sound signal- sharp without rattling or wheezing |
| 43 | If necessary, replace faulty headlight, sidelight and rear light bulbs | In the front and in the back | - | Auto mechanic kit (large) I-148 (11) sanding paper (19) | When replacing lamps, it is necessary to clean the contacts of the sockets. |
| 44 | Check the condition and fastening of electrical wires | In the cabin, front, top, rear | - | Auto mechanic set (large) I-148 (11), pliers (12) | Electrical wires must be in good condition and securely fastened |
| 45 | If necessary, insulate damaged areas of electrical wires (up to 200 mm long) | Same | - | Pliers (12), mounting knife, insulating tape | Damaged areas of electrical wires must be carefully insulated |
| 46 | Check and, if necessary, secure the generator | Above | 1 | Auto mechanic kit (large) I-148 (12) | - |
| 47 | Clean the surface of the battery from dust, dirt and electrolyte. | Above | 1 | Rubber gloves (17), rags (20), bath with a solution of ammonia or soda ash, brush (18) | The surface of the battery must be dry and clean. The electrolyte must be wiped with a rag soaked in a solution of ammonia or soda ash. |
| 48 | Clean the ventilation holes in the battery plugs | Same | 6 | Plug wrench batteries(17), wooden stick Æ 1.5mm, rags (20), rubber gloves (17) | - |
| 49 | Check the electrolyte level in the battery and, if necessary, add distilled water | Same | 6 | Level measuring tube (17), rubber gloves (17), rubber bulb (17) | The electrolyte level in the cells should be 10-15mm above the top edge of the safety grid |
| 50 | Check the fastening and condition of the wire tips with the battery terminals | Same | 2 | Auto mechanic kit (large) I-148 (11) | The terminals of the lugs must make good electrical contact |
| 51 | If necessary, clean and lubricate the battery terminals and wire ends | Same | 2 | Rags (20), sanding paper (19) | Clean oxidized battery terminals and wire ends and apply non-contact surfaces with Litol 24 lubricant GOST 21150-87 |
| Lubrication and cleaning work | |||||
| 52 | Check the oil level in the engine crankcase | Above | 1 | Oil dipstick and rag (20) | Check the oil level with the engine not running in the following order: remove and wipe the dipstick, insert it into the socket until it stops and remove it. The oil level should reach the upper mark |
| 53 | If necessary, add oil in the crankcase to normal levels. | Same | 1 | Oil dispenser model 367МЗ (4), rags (20) | When using oil M-10G 2 k, GOST 8581-78, in winter - M-8G 2 k, GOST 8581-78, all-season - DV-ASp-10V |
| 54 | Check the oil level in the power steering pump reservoir | Same | 1 | - | The oil level should be between the marks on the indicator. |
| 55 | If necessary, add oil in the power steering reservoir to the correct level. | Same | 1 | Rags (20) | Add oil to the specified level with the engine running at minimum crankshaft speed. Oil for the hydraulic system of a car, grade "R". |
| 56 | Check the oil level in the gearbox housing | From below | 1 | Auto mechanic kit (large) I-148 (11), rags (20) | Unscrew and wipe the oil dipstick, insert it into the socket until it stops and remove it. The oil level should reach the upper mark |
| 57 | If necessary, top up the gearbox housing to the correct level. | Same | 1 | Auto mechanic kit (large) I-148 (20), installation for refueling car components transmission oil models 3161 (3) | TSp-15k, GOST 23652 - 79 (at temperatures not lower than minus 30 0 C), TM5-12RK, TU38.101.844 - 80 (at temperatures up to minus 50 0 C). |
| 58 | Check the oil level in the rear (middle) axle housing | Same | 2 | Auto mechanic kit (large) I-148 (11) | The oil in the rear axle housing should be at the level of the inspection hole |
| 59 | If necessary, add oil to the rear (middle) axle housing to the correct level. | Same | 2 | Auto mechanic kit (large) I-148 (11), installation for filling car units with gear oil 3161 (3) | TSp-15k, GOST 23652 - 79 (at temperatures not lower than minus 30 0 C), TN5-12RK, TU38.101.844 - 80 (at temperatures up to minus 50 0 C). |
| 60 | Clean the breathers of the gearbox and rear (middle) axle | Below and above | 3 | Rags (20), wire with a diameter of 1.5 mm | - |
| 61 | Lubricate the king pins steering knuckles front axle | From below | 4 | Solidolon blower model 390 (5) | Lubricant Litol - 24, GOST 21150 - 87. Substitutes: solid oil Zh, GOST 1033 - 79 or solid oil S, GOST 4366 - 76, Lubricate through grease nipples until fresh grease is squeezed out |
| 62 | Lubricate the front spring pins | Front | 2 | Same | Same |
| 63 | Steering rod joints | From below | 4 | Same | Same |
| 64 | Lubricate the brake adjustment levers | Same | 6 | Same | Same |
| 65 | Expansion fist shaft bushings | Same | 6 | Same | Lubricant Litol - 24, GOST 21150 - 87. Substitutes: solid oil Zh, GOST 1033 - 79 or solid oil S, GOST 4366 - 76. Lubricate through grease fittings, making no more than five strokes with a syringe |
| Organizational work. Preparation of documents and quality control of vehicle maintenance | |||||
| 66 | Place the vehicle at the service station. | Fast | - | - | The vehicle must be installed at the work station only after labor-intensive repairs, cleaning and washing work, and in a clean and dry condition. |
| 67 | Enter data on the completion of TO1 into the vehicle maintenance and current repair record sheet. | office desk | - | - | - |
| 68 | Provide assistance and monitor the quality of performers’ work. | - | - | The operation is performed by a master or senior mechanic. | |
Map of the arrangement of performers at the maintenance station
Table 2. Map of the arrangement of performers at the maintenance station
| Purpose of the post | The serial number of the performer and his qualifications | Location of execution |
Number of works and sequence of their execution | Notes |
| Inspection work, engine maintenance, electrical equipment, gearbox, switchgear, clutch, lubrication work. | No. 1, Car repair mechanic, 3rd category | Top, front, rear, cab | 3, 11, 12, 13, 14, 18, 26, 27, 28, 30, 42, 44, 45, 1-5,10, 22, 23, 6, 7, 36, 38, 39, 8, 9, 17, 21, 33, 34, 35, 40, 41, 43, 46-55, 15, 16 | Operation 42 is performed by the 1st and 3rd performers jointly. |
| Lubrication, cleaning, refueling work, maintenance work on the chassis, transmission, cardan shafts and control gear | No. 2, Car repairman, 2nd category | From below | 13, 14, 27-30, 4, 5, 8, 17, 19, 20, 21, 24, 25, 32, 56-61, 63-65 | Operations 27 and 30 Performed by the 1st and 2nd performer jointly |
| Organizational work, paperwork and quality control of service. | No. 3 Car repairman, 4th category (foreman) | Above | 64, 65, 66 | The tasks of the foreman include paperwork, quality control and assistance in difficult situations. |
Table of main and additional equipment
Table 3. Timesheet of the main and additional equipment
| No. | Name of equipment | Model, type, GOST | Brief technical information | Manufacturer |
| 1 | Automatic air dispenser | TsKB S-401 | Stationary, automatic; air supply pressure 5..8 kgf/cm2; measurement limits on a scale from 1.5 to 6.5 kgf/cm 2, scale division price 0.1 kg/cm 2 | Bezhetsk Automotive Equipment Plant |
| 2 | End piece with pressure gauge for air distribution hose | 458 | Manual, universal; pressure measurement limit 6 kg/cm 2 ; pressure gauge scale division price is 0.2 kg/cm 2. | Same |
| 3 | Gear oil filling installation | 3161 | Stationary, submersible, with automatic operation; productivity through two hoses is at least 12 l/min | Cherepovets Automotive Special Equipment Plant "Red Star" |
| 4 | Oil dispenser with pumping unit | 376M3 | Stationary, submersible with automatic operation; productivity 8-12 l/min | Same |
| 5 | Mobile solid oil blower with electric drive and hopper | 390 | Mobile, with electric drive; maximum developed pressure 400 kg/cm 2 ; productivity 150 g/min; useful hopper capacity | Kochubeevsky plant "Automotive special equipment" |
| 6 | Impact wrench for truck and bus wheel nuts | I-303M | Mobile, electromechanical, inertial-impact action; nut tightening torque at the first load position 50-60 kgf∙m | Gremyachinsky plant "Autospecial equipment" |
| 7 | Impact wrench for spring ladder nuts (ditch) | I-314 | Maximum torque 82 kgf∙m | Chita plant "Autospecial equipment" |
| 8 | Universal device for checking car steering control | NIIAT K-402 | Manual, mechanical, universal; measurement range; on the backlash meter scale 25 - 0 - 25 o, on the dynamometer scale up to 2 kgf | |
| 9 | Balloon wrench | 535M | - | Kazan SEZ "Automotive special equipment" |
| 10 | Engine valve adjustment tool | I801.06.000 | Tubular wrench combined with a screwdriver | - |
| 11 | Auto mechanic kit (large) | I-148 | Contains 44 items. Key sizes, mm - from 7 to 32 | Kazan SEZ "Automotive special equipment" |
| 12 | Combination pliers | Pliers 7814.0161 1Х9 GOST 17438 - 72 | - | - |
| 13 | Metalsmith's steel hammer | Hammer 7850-0053 Ts 12ХР GOST 2310-70 |
Nominal weight 500g | - |
| 14 | Cold chisel | Chisel 2810-0189 GOST 7211-72 | - | |
| 15 | Set of probes No. 2 | Probes No. 2 GOST 882-75 | The thickness of the probe plates is 0.02-0.10; 0.15-0.50mm | - |
| 16 | Measuring metal ruler | Line 1-150 |
- | - |
| 17 | Set of devices and tools for battery maintenance | E-401 | Portable, consists of 15 items | Novgorod SEZ "Automotive special equipment" |
| 18 | Hair brush | GOST 10597-70 | - | - |
| 19 | Sanding paper | GOST 6456-75 | - | - |
| 20 | Wiping cloth | GOST 5354-74 | - | - |
| 21 | Mechanic's workbench | ORG-1468-01-060A | - | Own production |
| 22 | Chest for cleaning materials | OG.03-000 | - | Same |
| 23 | Waste chest | OG.16-000 | - | Same |
Conclusion
In the course of the work carried out, a scheme for carrying out maintenance at one station for the KamAZ 53212 vehicle was developed. A list of operations performed during the first maintenance was determined, which includes 35 points. During maintenance, fastening, filling, adjustment, and inspection work is performed. A diagram of the arrangement of performers has been drawn up. A list of main and additional equipment has been compiled. The graphic part of the course project has been completed. The first part of which is a drawing of the car in two projections indicating the number and location of the maintenance operation. The second part is a diagram of the technological layout of the post with the arrangement of equipment and workers
Bibliography
1. Execution technology routine maintenance first and second maintenance of the GAZ 53A car.
2. Central design and technological bureau for the introduction of new technology and scientific - research work in road transport (CENTRAVTOTECH). - M. Transport, 1978. - 136 p.
3. Regulations on the maintenance and repair of rolling stock of road transport Approved on September 20, 1984. M.: Transport 1986, 73 p.
4. Practical guide for maintenance and repair of KamAZ P69 vehicles type 6X4/ E.A. Mashkov. - M.: Mechanical Engineering, 1994. - 243 pp.: ill.
5. Sheet of garage and technological equipment for motor transport enterprises of different capacities. S.A. Nevsky. - M.: Publishing house. CENTRTRUDAVTOTRANS, 2000. - 93 p.
Modern development of production places increased demands on the maintenance of the infrastructure of industrial enterprises. These include ensuring a continuous production process, introducing design and technological improvements finished products, reducing the time required to manufacture products and carry out repair work, increasing the efficiency of spending fixed and working capital of the enterprise. Systematic analysis manufacturing companies reveals two opposing trends: enterprises are introducing more and more new types of work, and at the same time, the qualifications of personnel are increasingly decreasing.
As a result, the capacity of the tasks being performed often exceeds the capacity of the workers. This directly leads to a decrease in productivity, deterioration in the quality of work and the occurrence of emergency situations, which can lead not only to equipment failure, but also to industrial accidents. And if a drop in productivity and quality is fraught with material losses, then a deterioration in the level of safety jeopardizes the activity of the enterprise as a whole.
To ensure compliance with increased requirements for infrastructure maintenance, enterprises create specialized units within their boundaries, and also attract specialized organizations to perform certain types of work. But, as practice shows, simply changing the staffing structure or attracting contractors is not enough to improve productivity and safety during work. Solving these problems requires the use of a number of special effective tools, one of which is technological maps that determine the procedure for performing standardized operations of the technological process.
What does the technological map contain?
A technological map is a unified document intended for enterprise employees engaged in the repair or maintenance of production equipment. The map contains a list necessary equipment, tools and personal protective equipment kits, a list of labor protection instructions. It specifies the sequence, frequency and rules for performing operations, types and quantities Supplies, time standards, material costs, as well as regulations, used in assessing the quality of work.
Technological maps are developed with the aim of systematizing and increasing the safety of the production process by streamlining the actions of personnel in repair processes or technological services equipment. Their implementation also contributes to solving problems of determining and optimizing material and technical costs per unit of product or service.
Advantages of implementing technological maps
The development of technological maps allows the company to obtain the full amount of information necessary for the high-quality and safe organization of the production process, replenishing the lack of knowledge about innovations in the field of equipment, technology for its repair and maintenance.
As practice shows, the use of technological maps helps reduce the rate of equipment wear by 15-20%, while repair costs are reduced by 13-14%, and the labor intensity of work is reduced by 16%. Compliance with the instructions set out in the documents ensures trouble-free operation of the equipment throughout the entire period between scheduled repairs and significantly reduces the risks of emergency situations and unscheduled shutdowns of the production process.
In addition, the surveys carried out during preparation make it possible to further plan the timing and costs of periodic repair and maintenance work, increase production efficiency and reduce the time required for scheduled repairs.
The presence of a technological map greatly simplifies the preparation of production schedules, preparation of planning and economic documentation, personnel training and systematization of the work of the supply service.
The introduction of technological maps contributes to a systematic reduction in the costs of repair and maintenance of equipment, providing significantly lower costs of funds and resources in comparison with the costs of technical re-equipment and reorganization of the production structure.
A challenge for professionals
When starting to develop technological maps, you must first familiarize yourself in detail with the objectives of the enterprise and its capabilities in terms of equipment, tools, personnel and logistics. Often, enterprises, trying to minimize costs, prefer to entrust this work to full-time technical employees. At the same time, they forget about the importance of a professional approach and familiarity with innovations in the field of industry quality and safety standards, which only a specialized organization can guarantee.
It is often beneficial to entrust the development of technological maps to external organizations. having high level competence in this area. In particular, it can provide services for the development of technological maps for enterprises in any industry. The preparation and transfer of documentation to the customer can be done either in standard paper form or using specialized software.
Involving our specialists has a number of advantages compared to independent development:
- objective and impartial assessment of opportunities and prospects by independent experts;
- access to regularly updated professional databases of regulatory documentation, equipment, tools and materials;
- regular retraining and training of personnel in connection with the emergence of new technologies and solutions;
- interest of company specialists in achieving results.
An additional advantage of cooperation with our company is our rich practical experience in the field of maintenance of infrastructure of industrial enterprises, implementation innovative technologies and modernization technological processes.
Over the course of several years, we have been developing our competencies in cooperation with the largest enterprises in the engineering, chemical, petrochemical and metallurgical industries. The company's experience allows us to talk about a real reduction in labor costs when using technological maps.
Routing - This is a form of technological document in which the entire process of influencing a car or its unit is recorded, operations are indicated in the established sequence, professions and qualifications of performers, technological equipment and accessories, technical conditions (TS) and instructions and norms of time or labor intensity.
Maps are divided into operational and technological, guard, workplace, and route maps. Scheme maps for the placement and movement of performers at maintenance posts can also be developed.
Operational and technological maps(form 1) - are general-level documentation and are used to develop maps of guards and on workplace. They contain lists of operations on units and systems, indicating equipment and tools, specifications and labor intensity.
Post cards(form 2) are compiled for work performed only at a given post (name of operations, number of performers, their specialty, place of performance, labor intensity).
Workplace map(form 2) contain operations performed by one worker in a strict technological sequence. They also indicate tools and equipment, specifications and instructions, and the complexity of operations.
Route map(Form 2) reflects the sequence of operations for repairing a vehicle unit or mechanism in one of the routine repair departments.
Operational and technological map vehicle (unit).
Technological map No. . .
Labor intensity person/hour
Form 2
Post technological map car (trailer).
Number of specialized posts in the zone on the production line And NI.
Total number of performers people Total labor intensity person/hour
Post no. .
Labor complexity of work person/hour Number of performers in office people
(name of the unit, system or type of work)
Labor intensity person/hour
The initial data for developing a technological map are:
- 1. Drawing general view(assembly drawing or diagram) of a unit, mechanism or assembly;
- 2. Specifications for assembly, adjustment, testing, control and acceptance of the product;
- 3. Characteristics of the equipment, devices and tools used
- 4. Labor intensity of operations.
Standardization of labor intensity of technological process operations
For each technical maintenance and repair operation, a labor intensity standard must be established. Such a norm is necessary for calculating the number of performers and remuneration for their labor and for designing a technical process (uniform distribution of work volumes among performers, drawing up an optimal sequence of operations, etc.).
General time limit for performing operations consists of operational, preparatory and final time, time for servicing the workplace and breaks for rest and personal needs.
Operational is the time spent directly on performing a given operation. It is determined by one of the methods discussed below.
The rest of the time standard is set in the form of allowances as a percentage of operational time.
Thus, the standard time for the operation of TO, D, TR in minutes or hours:
where To is operational time, min (h); A, B, C - respectively, the share of time for preparatory and final work, maintenance of the workplace, rest and personal needs, %. A + B + C = 12.5.
The complexity of operations in person-hours or person-minutes is determined by the formula:
Тн=Тв *Р *Кп (2)
where P is the number of workers performing the operation, people; Kp is the coefficient of repeatability of the operation, which characterizes the frequency of the operation during maintenance (D, TR).
For example, control and diagnostic operations are performed without omissions (in mandatory at each service Kp=1). Adjustment and fastening operations may have a manual< 1, т.к. после проверки, если adjusting parameter Normally, tightening of the fastening connection is not required; they can be skipped. The repeatability coefficient depends on the reliability of the vehicle design and the quality of the previous maintenance or repair work, varies for various operations, approximately within the limits Kp = (0.2-1), and is determined by processing the relevant statistical data or according to data from standard maintenance and repair technologies.
The complexity of maintenance and repair operations can be determined in one of three ways:
- - using ready-made standards from standard technologies and standard time standards for vehicle maintenance and repair;
- - processing data from time-lapse observations of their implementation;
- - microelement rationing of operations.
The simplest and most desirable is the first method.
Standard labor intensity standards are adopted according to
Standard standards of time (labor intensity) refer to certain conditions for performing operations. With differences real conditions operations (other equipment, level of mechanization) from the average specified for standard standards, they should be adjusted to the conditions of the designed process. So, for example, with the flow method of organizing maintenance, standard labor intensity can be reduced by 15 - 25% of the standard norm. If the operating conditions differ sharply from standard ones (new equipment, new design car), then the labor intensity standard is established in other ways.
Timing observation method
The method of time-lapse observations gives the most accurate results, but it is very labor-intensive and requires a long time to establish the complexity of operations due to the large number of observations and the complexity of processing the data obtained. Let us briefly consider the main provisions of the timing observation methodology.
For timing purposes, performers of maintenance and repair work are selected in a special way (work experience, qualifications, age, etc.).
Timing is carried out at certain hours of the work shift (an hour after the start of work, stops an hour before lunch or the end of the working day).
The number of time-lapse observations must be sufficient to reliably determine the average TO. Their minimum number is determined according to Table 2, depending on the duration of the operation and the method of performing the work.
Table 2 - Required number of measurements for timing
Timing data is arranged in a variation series (from min to max). The stability and stability of the observation results is checked by comparing the actual value of the chronosequence stability coefficient with its standard (tabular) value (Table 3).
Table 3 - Standard value of time series stability coefficients
The stability coefficient of the chronosequence is found by the formula:
where t max, t min are the maximum and minimum values from the chronosequence. A chronosequence is considered stable if its actual stability coefficient is less than or equal to the normative one: K Book.
If this ratio is not observed, then the observations should be repeated. As an exception, due to the high costs of timing, it is possible to correct the time series by discarding its extreme values (t max, t min).
The operational time in minutes to perform an operation is found as the average value of the members of the time series:
where ti is the value of the time series members , min; n is the number of members of the chronosequence.
Timing and establishment of standards can be carried out only after the implementation and debugging of a new TP, i.e. it is impossible to design the standard time (labor intensity) of operations at earlier stages of TP development.
Microelement method for designing normative labor intensity of operations
To determine the labor intensity of technological processes, systems of microelements are currently widely used.
The essence of this method comes down to the fact that the most complex operations can ultimately be presented in the form of a certain sequence of repeating simple elements, for example: move, install, secure, connect, etc. (Table 4).
If you divide the standardized operation into a number of such microelements and sum up the time available in the database for their implementation, you can find the operational time for completing the entire operation.
The main advantage of this method is the ability to design labor intensity standards “at the table” at the stage of technical development, which significantly reduces time and costs compared to the method of time-lapse observations. Of course, this is possible with extensive experience and qualifications of process engineers (knowledge of the design of a given car brand, the operation and capabilities of the technological equipment, devices and tools used, etc.).
The time values for performing microelements of the operation are “pure”, i.e. with convenient execution and free access to the service point. In real conditions, the convenience of performing work (working postures, Table 4) and access to the service point (Table 5) for each brand of car and operation will be different, therefore, during the operational time for performing the operation, adjustments must be made by appropriate coefficients.
Thus, the general equation for rationing the labor intensity of car maintenance in person-minutes or person-hours with this method looks like that:
Tn = (t1 + t2 + ... + tn) *K1 *K2 *(1+(A + B + C)/100) *P *Kp (5)
where t1 is the time to complete the microelements that make up the operation; n - the number of microelements in the operation, incl. and taking into account their repetition; K1, K2 - respectively, coefficients that take into account the increase in time to perform an operation due to deterioration in convenience and access during work (Tables 5 and 6); P is the number of performers of the operation; Kp is the coefficient of repeatability of the operation during maintenance and repair; A, B, C - allowances as a percentage of operational time.
Microelements are understood as elements of operations consisting of labor movements of the worker. It has been established that any physical work includes: movement of the arms, legs, tilting and turning of the human body, transitions, i.e. an unchanging series (set) of repeated movements.
One of the systems of microelement standards is the system of “standards” of Professor V.I. Ioffe. In this system any element self made consists of a combination of two microelements: take and move (combine, move, install, remove).
The degree of fragmentation of operations into microelements is fundamentally important. Breaking down operations down to elementary movements makes it possible to obtain a universal base of microelements suitable for designing labor intensity standards for any technological process. However, at the same time, the accuracy of determining the time to complete microelements (hundredths and thousandths of a minute) decreases; The process of synthesizing an operation from elements becomes more complicated. Big mistakes are possible.
Taking this situation into account, at this stage, based on the collection and synthesis of information from literary sources, regulatory and technical documentation, etc., a database of 44 microelements was developed (Table 4).
With the enlargement of microelements, their versatility decreases, since the likelihood of repetition in a large number of different operations and processes decreases. But the process of designing operations in which they occur is simplified. Therefore, in our opinion, the base of microelements for technical maintenance and technical repair of cars should consist of two parts. The first part should contain elementary movements found in the operations of any labor processes. The second part is larger elements of specialized maintenance and repair operations (fastening, welding, etc.).
The micronutrient base presented in Table 4 is not sufficient; it requires improvement and expansion. With its help, it is possible to design, basically, labor intensity standards for control, diagnostic and adjustment operations of vehicle maintenance and repair, but it allows one to demonstrate the possibility of the method under consideration.
Table 4 - Database on trace elements of vehicle maintenance operations
|
Name of trace element |
Time, min |
|
|
Go 1 step |
||
|
Go to 2 steps. |
||
|
Go to 3 steps |
||
|
Go to 4 steps |
||
|
Extend (remove, bend) your hand |
||
|
Take (put down) a tool, device, part (take by the handle, latch) |
||
|
Rotate the housing 90° |
||
|
Rotate the body 180° |
||
|
Body tilt (straighten up) |
||
|
Bend the body below the waist |
||
|
Deliver (take away) a tool, device, part "," |
||
|
Installation (removal) of a tool, device, part is simple |
||
|
Installation (removal) of a tool, device, part with connection to the vehicle structure |
||
|
Rotate tool |
||
|
Turn the handle, open the latch |
||
|
Press the latch |
||
|
Place (remove) your foot (hand) on the pedal |
||
|
Press (release) the pedal by hand |
||
|
Press (release) the pedal with your foot |
||
|
Go down into the inspection ditch |
||
|
Climb out of the inspection ditch |
||
|
Stand on the bumper |
||
|
Get off the bumper |
||
|
Open (close) the hood (with the latch open) |
||
|
Open (close) the cabin door (with the handle turned) |
||
|
Recline the cab |
||
|
Reinstall the tilt cab |
||
|
Blow off the serviced element with compressed air from a hose |
||
|
Movements of the fingers of the hand |
||
|
Screw (fasten) the M8 - M24 nut |
||
|
Tighten the nut (bolt) M20 -- Ml 6 |
||
|
Tighten the nut (bolt) M20 - M35 |
||
|
Look (take a glance) at an object or sign in the field of view |
||
|
Scale reading, cm |
||
|
Scale reading, mm |
||
|
Look closely at the division |
||
|
One mental action with single digit numbers |
||
|
One mental action with two-digit numbers |
||
|
Setting the device to zero |
||
|
Creating indicator head preload |
||
|
Unscrew (tighten) the nut, bolt, fitting M8 M16 to a length of up to 20 mm |
||
|
Unscrew (tighten) the nut, bolt, fitting M8 -M16 to a length of up to 35 mm |
||
|
Unscrew (tighten) the nut, bolt, fitting M20 - M32 to a length of up to 25 mm |
||
|
Unscrew (tighten) the nut, bolt, fitting M20 - M32 to a length of up to 35 mm |
The labor intensity and complexity of the work are largely determined by the characteristics of the object of labor. A car is a complex object of labor when servicing it.
Process impact points (sometimes called service points) are located on the side, bottom and top of the vehicle. Therefore, when servicing a vehicle, it is first necessary to provide the performers with access to service points. To reduce service time, it is better to provide simultaneous access to several performers from all sides.
In addition, it is necessary to ensure the least fatigue for the performer and the greatest safety during work. Research has established that fatigue, and therefore the productivity of a worker, significantly depends on the working posture he occupies. Table 5 shows data on changes in labor productivity depending on working posture.
The conditions for performing operations directly in the area where service points are located are characterized by their accessibility, which also significantly affects the labor intensity of the work. The influence of access to places of technological influence during vehicle maintenance and repair is presented in Table 5.
Table 5 - Influence of ease of use on the labor intensity of maintenance and repair operations
Table 6 - Impact of access to service points on the complexity of the maintenance operation
- 13. Universal rack;
- 14. Recoil stop.
Specialized post SPP-1 for replacement power units and engines
- 1. Metalworking workbench;
- 2. Oil dispenser;
- 3. Set of keys;
- 4. Crane beam;
- 6. Oil distribution tank;
- 7. Footrest;
- 8. Lift;
- 10. Torque handle;
- 11. Rack for units;
- 12. Universal rack;
- 13. Anti-recoil stop.
- 15. Device for draining used motor oils;
- 16. Device for draining used transmission oils;
- 17. Device for draining coolant;
- 18. Cabinet for tools and equipment;
- 19. Mobile overpass for repairs;
Specialized post SPP-2 for replacing suspension units and chassis
- 1. Metalworking workbench;
- 2. Impact wrench for wheel nuts;
- 3. Impact wrench for the nuts of the spring ladders;
- 4. Cassette for wheels;
- 5. Chest for cleaning materials;
- 6. Ruler for checking wheel alignment;
- 7. Transitional bridge;
- 8. Lift;
- 9. Mobile auto repairman station;
- 10. Universal rack;
- 12. Trolley for removing and installing springs;
- 13. Trolley for removing brake drums with hubs;
- 14. Recoil stop.
Specialized post SPP-3 TR braking systems cars
- 1. Metalworking workbench;
- 2. Impact wrench for wheel nuts;
- 3. Cassette for wheels;
- 5. Lift,
- 6. Device for checking the pneumatic brake drive;
- 7. Universal rack;
- 8. Stand for checking the brakes of three-axle vehicles;
- 10. Recoil stop;
- 11. Installation for filling and bleeding brakes;
Specialized post SPP-4 TR low labor intensity
- 1. Bath for washing parts;
- 2. Metalworking workbench;
- 3. Set of wrenches;
- 4. Chest for cleaning materials;
- 5. Transitional bridge;
- 6. Set of socket wrenches;
- 7. Suspension-mounted pneumatic torque wrench:
- 8. Footrest;
- 9. Lift;
- 10. Mobile auto repairman station:
- 11. Rack for components and parts:
- 12. Universal rack:
- 13. Anti-recoil stop.
- 14. Cabinet for tools and devices:
Specialized post SPP-5 TR electrical systems cars
- 1. Metalworking workbench;
- 3. Motor tester;
- 4. Mobile auto electrician's station;
- 6. Device for checking and adjusting headlights;
- 7. Device for testing circuit breakers;
- 8. Device for testing electrical equipment;
- 9. Rack for components and parts.
- 10. Universal rack;
- 11. Cutlery table;
- 12. Recoil stop;
- 13. Installation for accelerated charging of batteries;
- 14. Device for exhaust gas suction;
- 15. Cabinet for tools and equipment;
Specialized post SPP-6 TR for engine power supply system devices
- 1. Bath for washing parts;
- 2. Metalworking workbench;
- 4. Set of wrenches,
- 5. Chest for cleaning materials;
- 6. Mobile station for a car repairman or carburetor mechanic;
- 7. Device for checking plunger pairs;
- 8. Testing device fuel pumps carburetor engines;
- 9. Device for checking the fuel pump and filters;
- 10. Device for checking injectors;
- 11. Universal rack;
- 12. Cutlery table:
- 13. Anti-recoil stop.
- 14. Device for exhaust gas suction;
- 15. Cabinet for tools and equipment;
Specialized post for replacing SPP-7 frames
|
from capsizing;
|
Special post SP-1 for engine replacement
- 1. Anti-recoil stop.
- 2. Bath for washing parts;
- 3. Metalworking workbench;
- 4. Engine grip;
- 5. Oil dispenser;
- 6. Set of keys;
- 7. Crane beam;
- 8. Chest for cleaning materials;
- 9. Footrest;
- 10. Mobile post for a car repairman;
- 11. Torque handle;
- 12. Rack for engines;
- 13. Universal rack;
- 14. Device for disconnecting and holding the gearbox;
- 15. Device for exhaust gas suction;
- 16. Device for draining used oils;
- 17. Device for draining coolant;
- 18. Cabinet for tools and equipment;
- 19. Mobile overpass for repairs;
Special post SP-2, SP-3 for replacing units rear suspension cars
- 1. Metalworking workbench;
- 4. Lift;
- 5. Rack for springs;
- 6. Universal rack;
- 7. Recoil stop
- 8. Device for dismantling and installing springs:
- 9. Cabinet for tools and equipment;
Special post SP-4, SP-5 for replacing clutches and gearboxes
- 12. Anti-recoil stop.
- 1. Metalworking workbench;
- 2. Mobile track bridge;
- 3. Chest for cleaning materials;
- 4. Oil dispenser;
- 5. Monorail with hoist;
- 6. Universal rack;
- 7. Rack for clutches and gearboxes;
- 8. Trolley for transporting gearboxes and clutches;
- 10. Special device for disconnecting the gearbox;
Special post SP-6 for replacement rear axles and gearboxes for GAZ, ZIL vehicles
- 1. Metalworking workbench;
- 2. Impact wrench for the spring ladder nuts;
- 3. Multi-spindle suspended impact wrench for wheel nuts and hub flanges,
- 4. Cassette for wheels;
- 5. Console crane;
- 7. Oil distribution tank;
- 8. Lift;
- 9. Bridge rack;
- 10. Universal rack;
- 11. Trolley for removing and installing wheels;
- 12. Anti-recoil stop.
Special post SP-7 for replacing gearboxes of KamAZ vehicles
- 1. Metalworking workbench;
- 2. Multi-spindle impact wrench for hub flange nuts
- 3. Crane beam;
- 4. Chest for cleaning materials;
- 5. Oil distribution tank;
- 6. Pneumatic impact wrench on suspension,
- 7. Rack for gearboxes;
- 8. Universal rack;
- 9. Anti-recoil stop.
- 10. Device for draining used oils.
- 11. Cabinet for tools and equipment,
Special post SP-8 for replacing rear and middle axles of KamAZ vehicles
- 1. Metalworking workbench;
- 2. Multi-spindle suspended impact wrench for wheel nuts;
- 4. Cassette for wheels;
- 5. Track bridge;
- 6. Chest for cleaning materials;
- 7. Oil distribution tank;
- 8. Monorail with hoist;
- 9. Mobile lift;
- 10. Bridge rack;
- 11. Universal rack;
- 12. Device for draining used oils;
- 13. Device for holding the car suspended
- 14. Cabinet for tools and equipment;
Special post SP-9 for replacing front axles and beams
- 1. Metalworking workbench;
- 2. Multi-spindle suspended wheel nut wrench,
- 3. Multi-spindle impact wrench for stepladder nuts;
- 4. Cassette for wheels; chest for cleaning materials;
- 5. Monorail with hoist;
- 6. Mobile lift;
- 7. Rack for front axles and beams;
- 8. Universal rack;
- 9. Trolley for removing and installing wheels;
- 10. Recoil stop.
- 11. Installation for pressing out pins
- 12. Cabinet for tools and equipment;
Special post SP-10 for replacing steering units
- 1. Bath for washing parts;
- 2. Metalworking workbench;
- 3. Chest for cleaning materials;
- 4. Lubrication pump;
- 5. Mobile auto repairman station;
- 6. Steering tester;
- 7. Universal rack;
- 8. Anti-recoil stop.
- 9. Device for draining used oils;
Special post SP -11 TR brake systems with hydraulic drive
- 1. Metalworking workbench;
- 2. Impact wrench for wheel nuts;
- 3. Cassette for wheels;
- 4. Chest for cleaning materials;
- 5. Truck lift;
- 6. Universal rack;
- 7. Trolley for removing and installing wheels;
- 8. Anti-recoil stop.
- 9. Installation for filling and bleeding brakes;
- 10. Cabinet for tools and equipment;
Special post SP-12 TR for brake systems of KamAZ vehicles
- 1. Metalworking workbench;
- 2. Impact wrench for wheel nuts;
- 3. Wheel cassette
- 4. Chest for cleaning materials;
- 5. Lift;
- 6. Device for testing the pneumatic drive of car brakes;
- 7. Universal rack;
- 8. Trolley for removing and installing wheels;
- 9. Anti-recoil stop.
- 10. Device for pumping receivers with compressed air;
Special post SP-13 for replacing cabs and platforms of KamAZ vehicles
- 1. Metalworking workbench;
- 2. Grip for cabins;
- 3. Platform grip;
- 4. Crane beam;
- 5. Chest for cleaning materials;
- 6. Rack for cabins and platforms;
- 7. Trolley for moving cabins and platforms;
- 8. Emphasis
- 9. Cabinet for tools and equipment;
Special post for replacing the CPG of SP-14 engines
- 1. Anti-recoil stop.
- 2. Bath for washing parts;
- 3. Metalworking workbench;
- 4. Oil dispenser;
- 5. Picking trolley;
- 6. Chest for cleaning materials;
- 7. Mobile station for an auto repairman;
- 8. Suspension-mounted pneumatic impact wrench;
- 9. Footrest;
- 10. Lift;
- 11. Universal rack;
- 12. Device for exhaust gas suction;
- 13. Device for draining used oils;
- 14. Cabinet for tools and equipment;
- 15. Mobile overpass for repairs;
Special post SP-15 TR and adjustment of ignition system devices
- 1. Metalworking workbench;
- 2. Chest for cleaning materials;
- 3. Mobile auto electrician's station;
- 4. Device for welding electrical equipment of cars;
- 5. Device for checking and cleaning spark plugs;
- 6. Device for testing circuit breakers;
- 7. Universal rack;
- 8. Mobile electronic stand;
- 9. Cutlery table;
- 10. Recoil stop;
- 11. Device for exhaust gas suction;
- 12. Cabinet for tools and equipment;
Special post SP-16 TR for power supply system devices
carburetor engines
- 1. Bath for washing parts;
- 2. Metalworking workbench;
- 3. A set of tools for a carburetor adjuster;
- 4. Chest for cleaning materials;
by car;
- 5. Mobile carburetor mechanic station
- 6. Device for testing fuel pumps of carburetor engines
- 7. Universal rack;
- 8. Anti-recoil stop.
- 11. Cabinet for tools and equipment;
Special post SP-17 TR for diesel engine power system devices
- 1. Bath for washing parts;
- 2. Metalworking workbench;
- 3. Chest for cleaning materials;
- 4. Mobile station for a diesel mechanic;
- 5. Device for checking plunger pairs;
- 6. Device for checking the fuel pump and filters;
- 7. Device for checking injectors;
- 8. Universal rack;
- 9. Anti-recoil stop.
- 10. Device for exhaust gas suction;
- 11. Cabinet for tools and equipment;
Special post SP-18 for replacing KamAZ vehicle frames
low oils; 8. Device for draining cooling liquid; 9. Device for exhaust suction free gases;
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Pneumatic impact wrench on suspension
from capsizing; 26. Cabinet for tools and equipment; |
Special post SP-19 for replacing frames of GAZ, ZIL vehicles
low gases 17. Device for draining cooling liquid; |
18. Device for draining waste low oils;
from capsizing;
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Engine shop
- 1. Metalworking workbench;
- 2. Crane - beam.
- 3. Chest for cleaning materials;
- 4. Fire extinguisher;
- 5. Engine stand;
- 6. Device for checking and straightening connecting rods;
- 7. A device for checking the elasticity of valve springs and piston rings;
- 8. Device for heating pistons;
- 9. Device for assembling a connecting rod with a piston;
- 10. Device for removing and installing piston rings;
- 11. Device for installing the piston into the block;
- 12. Sink;
- 13. Wooden grate for feet;
- 14. Hand dryer;
- 15. Mesh basket;
- 16. Machine for grinding valves;
- 17. Machine for boring engine cylinders;
- 18. Machine for honing (polishing) engine cylinders;
- 19. Valve grinding machine;
- 20. Rack for storing oil and water pumps, compressors, fans, filters;
- 21. Rack for storing instruments and accessories;
- 22. Stand for testing oil pumps;
- 23. Stand for running in and testing compressors;
- 24. Stand for checking the tightness of engine blocks and cylinder heads;
- 25. Stand for disassembling and reassembling engine cylinder heads;
- 26. Stand for disassembling and reassembling engines;
- 27. Stand for grinding crankshaft journals;
- 28. Table;
- 29. Chair;
- 30. Tool cabinet;
- 31. Installation for washing engines and parts;
- 32. Cabinet for storing parts of the crank mechanism;
- 33. Cabinet for storing parts of the gas distribution mechanism;
- 34. Box with sand;
Engine running and testing department
- 1. Fuel tank;
- 2. Crane - beam;
- 3. Fire extinguisher;
- 4. Exhaust gas suction;
- 5. Stand for running in and testing engines;
- 6. Installation for cooling engines.
Aggregate shop
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Carburetor shop
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Fuel equipment workshop (diesel engines)
Electrical workshop
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Battery section
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Mednitsky workshop
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19. Box with sand; |
Tire shop
Vulcanization shop
Painting shop
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Wallpaper shop
Forging and spring shop
Welding and tin shop
Correctly use protective equipment when performing individual operations. The general system of occupational safety measures during car repairs must comply with GOST 12.3.017-79 “Repair and maintenance of cars.” GOST 12.2.003-74 “Production equipment”, SI 1042-73 “Sanitary rules for organizing technological processes and hygienic requirements production...
Therefore, the project needs to develop measures for the implementation of a planned preventative system for vehicle maintenance at Balezinoagropromkhimiya OJSC. 2. Improving vehicle maintenance 2.1 Types and frequency of vehicle maintenance Knowledge and patterns of changes in parameters technical condition components, assemblies and...
There will be a need to repair electrical equipment (17.9%) and brakes (1.5%). Therefore, it is necessary to provide for the possibility of carrying out this work according to the TR together with the SW. 3. DEVELOPMENT OF A TECHNOLOGICAL PROCESS FOR THE EO VEHICLE GAZ-53 Maintaining the vehicle in good condition and in proper form is achieved by maintenance and repair based on the recommendations of the preventive maintenance...
While the car is moving through the holes on the sides of the body and the perforated headliner. 3. MAINTENANCE 3.1. Features of operation Seats For a more comfortable individual seating, the GAZ 3110 has adjustable front seats. To move in a horizontal direction, you should turn the handle and release it when setting the seat to one of nine...
