Federal Agency for Education of the Russian Federation
SYKTYVKAR FOREST INSTITUTE
State educational institution
Higher professional education
"St. Petersburg State Forest Engineering Academy
them. CM. Kirov"
Faculty of Forest Transport
Department of Automobiles and Automobile Economy
COURSE PROJECT
Discipline: Vehicle maintenance
Subject: Organization of TO-1 car KAMAZ 53212
KP. BLTP. 190601.4 DO.061219. PZ
Made by Skorobogatykh P.A.
Checked by Malashchuk P.A.
Head Department of Chudov V.I. Ph.D.
Syktyvkar 2009
Introduction
Maintenance of machines is a set of preventive measures during the overhaul period aimed at preventing failures in units and assemblies and reducing the wear rate of parts. Maintenance includes control and diagnostic, fastening, lubricating, filling, adjusting, electrical and other types of work.
Vehicle maintenance has the following goals: to ensure the constant technical serviceability of units, components in the car as a whole; to maximize overhaul runs; guarantee traffic safety; ensure the minimum consumption of operating materials.
To achieve these goals in our country, a preventive maintenance system has been adopted, which provides for the mandatory implementation of a set of works at a given frequency in the process of using, storing and transporting vehicles. The technological process of car maintenance with a planned preventive 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 of special equipment installed on the vehicle is carried out, if possible, simultaneously with the maintenance of the chassis.
Depending on the scope 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 system of car maintenance, draw up a technological map, determine the number and placement of workers, as well as select technological equipment. Make a drawing of the car in two projections indicating the number and place of the maintenance operation. And a diagram of the technological layout of the post with the arrangement of equipment and workers.
The main technical characteristics of the car KAMAZ 53212
Weight parameters and loads:
Curb weight of the vehicle, kg 8500
Carrying capacity of a / m, kg 11000
Gross weight, kg 19650
Gross trailer weight, kg 14000
Gross train weight, kg 33650
Installed engines:
Model 740.31-240 (Euro-2)
Type: diesel turbocharged, air-to-air aftercooled
Maximum net power, kW (hp) 165 (225)
Rated power, gross, kW (hp) 176 (240)
at the frequency of rotation of the crankshaft, rpm. 2200
Max. useful torque, N m (kgf m) 912 (93)
at crankshaft 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:
Fuel tank capacity, l. 500
Electrical equipment:
Voltage, V 24
Batteries, V/A h 2×12/190
Generator, W/W 28/2000
Clutch:
Type friction, dry, two-disc
Hydraulic drive with pneumatic booster
Transmission:
Type mechanical, ten-speed
Mechanical control, remote
Gear ratios in gears:
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 pads, 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, high roof
Sleeper version
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")
Board height, mm * 500 or 725 ("euro")
Characteristics of a / m with a gross weight of 19650 kg:
Maximum speed, not less than, km/h 90
Climbing angle, not less than, % 25
External overall turning radius, m 9.8
The list of routine maintenance work for the KAMAZ 53212 car
Maintenance TO-1 for the KamAZ 53212 car presented below is carried out in accordance with the "Regulations on the current repair and maintenance of rolling stock". According to this provision, the first maintenance for trucks is carried out every 4000 km. These works include control and diagnostic, inspection, fixing and lubrication and cleaning works.
The list of works includes:
General inspection:
1. Inspect the car, check the condition of the cab, platform, windows, rear-view mirrors, plumage, license plates.
2. Mechanisms of doors, locks of the sides of the platform, towing (support-coupling) device.
3. Check the operation of the windshield wiper and washers, the operation of the heating and glass heating system (in the cold season), and the ventilation system.
Engine, including cooling systems, lubrication:
4. Visually check the tightness of the engine lubrication and cooling systems (including the starting heater).
5. Check the operation of the valve mechanism by ear.
6. Check the fastening of the parts of the exhaust tract (downpipe, muffler, etc.), oil sump.
7. Check motor mounting.
8. Check the condition and tension of the drive belts.
Clutch:
9. Check the free travel of the clutch pedal. Check the tightness of the hydraulic clutch release system.
10. Check the fluid level in the compensation tank of the master cylinder of the clutch release drive.
Transmission:
11. Check the fastening of the gearbox and its external parts.
12. Check the operation of the gearshift mechanism on a stationary vehicle.
Cardan gear:
13. Check the fastening of the cardan shaft flanges. Check the play in the hinged and splined joints of the driveline.
Rear axle:
14. Check the tightness of the connections of the rear (middle) axle.
15. Check the fastening of the gearbox housing, 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 levers of the pivot pins of the ball pins of the steering rods.
18. Check the play of the steering wheel and steering rod joints.
Brake system:
19. Check the condition and tightness of pipelines and devices of the brake system.
20. Check the stroke of the brake chamber rods.
21. Change the alcohol in the antifreeze.
Chassis.
22. Check the condition of the frame, components and suspension parts by inspection.
23. Check fastening of ladders and spring pins, fastening of 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 plumage.
25. Check the condition and operation of the locking mechanism, the stop-limiter and the safety device of the tipping cab.
26. Check the fastening of the platform to the vehicle frame,
27. Check the mounting, footpegs, mudguards. Inspect cab and platform surfaces; if necessary, clean corrosion spots and apply a protective coating.
Supply system.
28. Check by inspection the condition of the devices of the power system, their fastening and tightness of the connections.
Electrical equipment.
29. Check the operation of the horn, instrument panel lamps, lighting and signaling, headlights, sidelights, rear lights, brake light and light switch.
30. Check the condition and fastening of electrical wires.
31. Check the fastening 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 lugs 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 units with a chemotological map.
34. Clean the transmission and axle breathers.
Vehicle check after service:
35. After servicing, check the operation of the units, components and devices of the car on the go or at the diagnostic station.
Technological map of maintenance of the car KAMAZ 53212
Table 1
Technological map TO-1 of the KamAZ 53212
| No. of work performed | Name and content of works | Service Location | Number of service places | Devices, tools, fixtures, model, type | Technical requirements and instructions |
| General inspection | |||||
| 1 | Inspect the vehicle and check the condition of the cabin, platform, windows, rear-view mirrors, plumage, paint, license plates and rear-view mirrors | Top, front, back | - | - | Cabin glass, headlights, sidelights, direction indicators must be intact. Platform boards should not have cracks or breaks. The condition of license plates must comply with the requirements of the Rules of the Road. Rear view mirrors must be intact and properly adjusted |
| 2 | Check the serviceability of the cabin door locks, platform side locks, towing device | Top, back | - | The mechanisms of the doors, locks of the sides of the platform must be in good order. The towing device must be securely fastened to the frame, and its hinged bracket must be cottered | |
| 3 | Check the operation of the windscreen wipers, the windshield washer and the windshield blower and heater (in winter) | in the cockpit | 3 | - | The 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 must not touch the seal. The glass washing device must be in good working order and wash evenly the entire glass surface. |
| Engine, including cooling and lubrication systems | |||||
| 4 | Visually check the condition and tightness of the cooling systems, engine lubrication, cabin heating system and starting heater | Up and down | 4 | - | Oil leakage in the places where the oil filter and crankcase are attached is not allowed. Leakage of coolant in the pipes and radiator is not allowed |
| 5 | If necessary, eliminate leakage in the pipelines of the cooling system, engine lubrication, cabin heating system and starting heating | Same | 4 | Leakage of oil, coolant and fuel is eliminated by tightening nuts, clamps or replacing individual elements of parts | |
| 6 | Listen to the operation of the valve mechanism | Above | 1 | - | Start the engine to listen to its work, There should be no knocks in the valve mechanism with its correct adjustment |
| 7 | If necessary, adjust the clearances between the valves and rocker arms. | Same | 16 | Device for adjusting valves I801.14.000 (10), set of probes No. 2 (15) | Thermal gaps in the gas distribution mechanism are adjusted on a cold engine no earlier than 30 minutes after stopping. At each position, simultaneously adjust the valve clearances of the two cylinders in the order of operation: 1-5-4-2-6-3-7-8, turning the crankshaft 90 0 Adjust the thermal clearances in the following order: install the piston of the first cylinder in c. m.t. compression stroke, turn the crankshaft in the direction of rotation (counterclockwise, as viewed from the flywheel side) through an angle of 60 0 (turning the flywheel by an angular distance between two adjacent holes corresponds to between two adjacent holes corresponds to turning the crankshaft by 30 0 ), At the same time, the valves of the 1st and 5th cylinders are closed (the valve stems can be easily turned by hand), check the tightening torque of the nuts for fastening the rocker arms of the adjustable cylinders and, if necessary, tighten them, to adjust the gap, loosen the nut of the adjusting screw, insert a feeler gauge into the gap and, turning the screw with a screwdriver, set the required clearance. While holding the screw with a screwdriver, tighten the nut and check the clearance. The gap should be 0.25-0.3 mm for inlet valves and 0.35-0.4 mm for exhaust valves. |
| 8 | Check the fastening of the oil sump, exhaust pipes, flanges of the exhaust pipes of the muffler to the cylinder block and, if necessary, fix | Up and down | 3 | Auto mechanic set (large) I-148 (11), chisel (14), hammer (13). | Tighten the oil crankcase fastening 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 mounting and, if necessary, fix the engine to the frame | Above | 1 | Auto mechanic set (large) I-148 (11) | The nuts of the engine mounting bolts on the frame must be tightened and cottered. Tightening is carried out with a tightening torque of 5.5 - 6 kgf∙m |
| 10 | Check the condition and tension of the alternator and water pump drive belts | Above | 1 | Auto mechanic set (large) I-148 (11) | To ensure the tension of the belt by moving the generator, a 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 clutch pedal free play | in the cockpit | 1 | Ruler (16) | Pedal free play should be 6-12 mm |
| 12 | Adjust clutch pedal free play if necessary. | Same | 1 | Auto mechanic set (large) I-148 (11) | Pedal free play is set by adjusting the clearance between the piston and the master cylinder piston pusher. To adjust the clearance between the piston and the master cylinder piston pusher, pass the eccentric pin that connects the upper eye of the pusher to the pedal lever. Turn 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 cab and below | 1 | - | Fluid leakage in the main, working cylinder and pipeline is not allowed |
| 14 | If necessary, repair the tightness of the pipelines of the clutch release drive | Same | 1 | Auto mechanic set (large) I-148 (11) | Liquid leakage is eliminated by tightening the nuts and replacing individual elements |
| 15 | Check the fluid level in the compensation tank of the master cylinder of the clutch release actuator | front | 1 | - | |
| 16 | If necessary, add fluid to the expansion tank of the master cylinder of the clutch release actuator | 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 set (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 gearshift mechanism on a stationary vehicle | in the cockpit | 1 | - | Gear shifting should be done without jamming |
| cardan gear | |||||
| 19 | Check the fastening and, if necessary, fix the flanges of the cardan shafts, check the play in the hinged and splined joints of the cardan transmission | Bottom | 16 | Auto mechanic set (large) I-148 (11) | Backlash in hinged and splined joints is not allowed; tightening of flanges should be done 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 | Bottom | 2 | Auto mechanic set (large) I-148 (11) | Oil leakage is not allowed. Leakage should be eliminated by tightening the nuts or by replacing individual elements of the unit; tightening should be performed with a tightening torque of 1.5-1.7 kgf∙m |
| 21 | Check and fasten and, if necessary, fix the nuts for fastening the gearbox housing, axle shaft flanges | Bottom and top | - | Auto mechanic set (large) I-148 (11) | Tighten the reducer fastening nuts with a tightening torque of 16-18 kgf∙m |
| Steering and front axle | |||||
| 22 | Check the tightness of the power steering system | 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 set (large) I-148 (11) | Oil leakage is eliminated by tightening the nuts and replacing individual elements |
| 24 | Check fastening and splitting of the nuts of the pivot pin levers. Troubleshoot if necessary | Bottom | 3 | Auto mechanic set (large) I-148 (11), pliers (12) | The nuts for fastening the levers of the pivot pins must be tightened and cottered. Tighten the levers with a tightening torque of 36-40 kgf∙m. The levers must not have play in the socket and on the key |
| 25 | Check the fastening and cotter pin nuts of the ball pins of the longitudinal and transverse steering rods. Troubleshoot if necessary | Same | 3 | Auto mechanic set (large) I-148 (11), pliers (12) | The ball stud nuts must be tightened and cottered. Finger play in conical sockets is not allowed. tighten 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 an equipped car (without load) with the engine running at a speed of 600 - 1200 min -1, with normal tire pressure, set the front wheels straight, The free play of the wheel on a new car should not exceed 15 0. Maximum allowable play 20 0 |
| 27 | Check play in tie rod joints | Below and in the cab | 3 | - | The play in the joints of the steering rods must be checked by the relative movement of the ball pins and tips or heads of the rods when the steering wheel is turned sharply in both directions. Play is not allowed in the steering rod joints |
| Brake system | |||||
| 28 | External inspection and according to the readings of standard instruments, check the serviceability of the brake system | Below and in the cab | - | - | The pressure created by the compressor should be 6.2-7.5 kgf / cm 2. When you press the brake pedal, the pressure should drop sharply by no more than 0.5 kgf / cm 2 |
| 29 | Check the condition and tightness of pipelines and devices of the brake system and, if necessary, eliminate the malfunction | Up and down | - | Auto mechanic set (large) I-148 (11) | Depressurization of the brake system is not allowed. Depressurization is 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 | Bottom | 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 with its end resting on the brake chamber housing, mark the location of the extreme point. Press the brake pedal to the stop (pressure in the pneumatic actuator is not less than 6.2 kgf/cm 2 , the drums are cold, the parking brake system is off), mark the location of the same point. The difference between the obtained values is the value of the stroke of the rod. The stroke of the rod is adjusted by turning the axis of the worm of the adjusting lever, having previously unscrewed the lock by two or three turns. By rotating the axis, set the smallest stroke |
| 31 | Change the alcohol in the antifreeze | Above | 1 | Auto mechanic set (large) I-148 (11) | Drain the sediment from the filter housing. To fill in alcohol and control its level, release the draft handle to the lower position and fix it by turning it 90 0, unscrew the plug with a level indicator, pour in alcohol and close the filler hole, turn on the fuse |
| Chassis | |||||
| 32 | Check the condition of the frame, components and suspension parts by inspection | Bottom | - | - | Weakening of riveted joints, cracks and spars and cross members should not be |
| 33 | Check the fastening of the spring ladders | Above | - | Auto mechanic set (large) I-148 (11), wrench for spring ladder nuts model I-314 (7) | to tighten the stepladders with the tightening torque of the front ones - 25-30 kgf∙m, the back 95-105 kgf∙m |
| 34 | Check wheel alignment | Same | 30 | 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, 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 dispenser model TsKB S-401 (1) or tip with pressure gauge model 458 (2), pliers (12) | The tire should not have cracks, ruptures, swellings. The tire valve must have a cap. Air pressure 5.3-7.3 kgf / cm 2. The remaining depth of the tread pattern in the center of the tread 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, if necessary, fix | Same | - | Auto mechanic set (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, mudguards, fix if necessary | Same | - | Auto mechanic set (large) I-148 (11) | Tighten the footrests with a tightening torque of 1.5-2.5 kgf∙m, mudguards 1-2 kgf∙m |
| 39 | Inspect the surface of the cabin and platform, if necessary, clean the corrosion spots and apply a protective coating | Top, front, back | - | Metal brush | Rust, peeling paint, cracks are not allowed |
| Supply system | |||||
| 40 | Visually check the condition and tightness of the power supply system: low pressure fuel pump, fuel fine filter, fuel tank, fuel sediment filter, fuel line connections, high pressure fuel pump and fine filter | Above | - | - | Leakage of fuel in the instruments and fuel lines of the system is not allowed. Fuel lines must not be bent or cracked. |
| 41 | If necessary, eliminate leakage in the devices and connections of the fuel lines of the power supply system | Same | - | Auto mechanic set (large) I-148 (11), pliers (12) | Leakage of fuel from the devices and connections of the fuel lines of the power supply system is eliminated by tightening individual elements of the connections. to tighten with a tightening torque of 4.5-5.4 kgf∙m |
| electrical equipment | |||||
| 42 | Check the operation of the horn, headlights, sidelights, tail light, brake light, instrument panel lamps and direction indicators | In the cockpit and top, front, rear | - | - | All lamps should give light without flashing, and the sound signal should be sharp without rattling or wheezing. |
| 43 | If necessary, replace defective headlights, sidelights and taillight bulbs | In the front and in the back | - | Auto mechanic set (large) I-148 (11) sanding paper (19) | When replacing lamps, it is necessary to clean the contacts of the cartridges. |
| 44 | Check the condition and fastening of electrical wires | 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 electrical wires (up to 200 mm long) | Same | - | Pliers (12), assembly knife, insulating tape | Damaged electrical wires must be carefully insulated. |
| 46 | Check and, if necessary, fix the generator | Above | 1 | Auto mechanic set (large) I-148 (12) | - |
| 47 | Clean the surface of the battery from dust, dirt and electrolyte | Above | 1 | Rubber gloves (17), rags (20), ammonia or soda ash bath, 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 vent holes in the battery plugs | Same | 6 | Battery cap wrench (17), wooden stick Æ 1.5mm, rags (20), rubber gloves (17) | - |
| 49 | Check the electrolyte level of the electrolyte in the battery and top up with distilled water if necessary. | Same | 6 | Level tube (17), rubber gloves (17), rubber bulb (17) | The electrolyte level in the cells must be 10-15 mm higher than the upper edge of the safety grid |
| 50 | Check the fastening and condition of the wire lugs with the battery terminals | Same | 2 | Auto mechanic set (large) I-148 (11) | Lug terminals must make good electrical contact. |
| 51 | If necessary, clean and lubricate the battery terminals and cable lugs | Same | 2 | Rags (20), sandpaper (19) | Oxidized battery terminals and wire lugs should be cleaned and their non-contact surfaces should be greased with Litol 24 GOST 21150-87 |
| Lubrication and cleaning work | |||||
| 52 | Check the oil level in the crankcase | Above | 1 | Oil dipstick and rags (20) | Check the oil level with the engine off in the following order: remove and wipe the dipstick, insert it into the socket until it stops and remove it. The oil level must reach the top mark. |
| 53 | Top up crankcase oil if necessary | Same | 1 | Oil dispenser model 367MZ (4), rags (20) | Change oil M-10G 2 k, GOST 8581-78, in winter - M-8G 2 k, GOST 8581-78, all-weather - DV-ASp-10V |
| 54 | Check the oil level in the power steering pump reservoir | Same | 1 | - | The oil level must be between the marks on the dipstick. |
| 55 | Top up the oil in the power steering reservoir if necessary. | Same | 1 | Rags (20) | Add oil to the norm with the engine running at the minimum crankshaft speed. Oil for the hydraulic system of the car brand "P". |
| 56 | Check the oil level in the gearbox housing (KP) | Bottom | 1 | Auto mechanic set (large) I-148 (11), rags (20) | Unscrew and wipe the dipstick, insert into the socket until it stops and remove. The oil level must reach the top mark. |
| 57 | If necessary, add to the norm in the gearbox housing | Same | 1 | Auto mechanic set (large) I-148 (20), installation for filling car units with transmission oil model 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 crankcase of the rear (middle) axle | Same | 2 | Auto mechanic set (large) I-148 (11) | The oil in the rear axle housing should be at the level of the control hole |
| 59 | If necessary, top up the oil in the crankcase of the rear (middle) axle | Same | 2 | Auto mechanic set (large) I-148 (11), installation for refueling car units with transmission 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 gearbox and rear (middle) axle breathers | Bottom and top | 3 | Rags (20), wire 1.5 mm in diameter | - |
| 61 | Lubricate the front axle steering knuckles | Bottom | 4 | Solidolon blower model 390 (5) | Grease Litol - 24, GOST 21150 - 87. Substitutes: solid oil Zh, GOST 1033 - 79 or solid oil C, GOST 4366 - 76, Lubricate through grease fittings until fresh grease is squeezed out |
| 62 | Lubricate the front spring pins | front | 2 | Same | Same |
| 63 | Tie rod joints | Bottom | 4 | Same | Same |
| 64 | Lubricate brake adjusters | Same | 6 | Same | Same |
| 65 | Expander shaft bushings | Same | 6 | Same | Lubricant Litol - 24, GOST 21150 - 87. Substitutes: grease Zh, GOST 1033 - 79 or grease C, GOST 4366 - 76, Lubricate through grease fittings, making no more than five strokes with a syringe |
| Organizational work. Registration of documents and quality control of maintenance of the car | |||||
| 66 | Set the car to the maintenance post. | Fast | - | - | The car must be installed at the working post only after the repair of great labor intensity, cleaning and washing work, in a clean and dry condition. |
| 67 | Enter data on the performance of TO1 into the record sheet for maintenance and current repairs of the car. | office desk | - | - | - |
| 68 | Provide assistance and monitor the quality of the work of performers. | - | - | The operation is performed by a master or a senior locksmith. | |
Map-scheme of the arrangement of performers at the maintenance post
Table 2. Map-scheme of the arrangement of performers at the maintenance post
| Appointment of the post | The serial number of the performer and his qualifications | Place of execution |
Number of works and sequence of their execution | Notes |
| Control and inspection work, maintenance of the engine, electrical equipment, gearbox, switchgear, clutch, lubrication work. | No. 1, Car mechanic of the 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 executor jointly. |
| Lubrication, cleaning, refueling, maintenance of the running gear, transmission, cardan shafts and RU | No. 2, Car mechanic of the 2nd category | Bottom | 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 executor jointly |
| Organizational work, paperwork and quality control of service. | No. 3 Car repairman of the 4th category (foreman) | Above | 64, 65, 66 | The tasks of the foreman include paperwork, quality control and assistance in difficult situations. |
Table of basic and additional equipment
Table 3. Timesheet of the main and additional equipment
| No. p / p | Name of equipment | Model, type, GOST | Brief technical information | Manufacturer |
| 1 | Air dispensing automatic column | TsKB S-401 | Stationary, automatic; supply air pressure 5. .8 kgf / cm 2; measurement limits on a scale from 1.5 to 6.5 kgf / cm 2, scale division value 0.1 kg / cm 2 | Bezhetsk plant "Autospecial equipment" |
| 2 | Handpiece with pressure gauge for air hose | 458 | Manual, universal; pressure measurement limit 6 kg/cm 2 ; the price of division of the pressure gauge scale is 0.2 kg / cm 2. | Same |
| 3 | Transmission oil filling station | 3161 | Stationary, submersible, with automatic mode of operation; productivity through two sleeves not less than 12 l/min | Cherepovets plant of special equipment "Krasnaya Zvezda" |
| 4 | Oil dispenser with pump unit | 376M3 | Stationary, submersible with automatic mode of operation; productivity 8-12 l/min | Same |
| 5 | Mobile brine blower with electric drive and hopper | 390 | Mobile, with electric drive; maximum developed pressure 400 kg/cm 2 ; productivity 150 g/min; useful capacity of the bunker | Kochubeevsky plant "Autospecial equipment" |
| 6 | Wheel nuts for trucks and buses | I-303M | Mobile, electromechanical, inertial-shock action; tightening torque of the nut at the first position of the load 50-60 kgf∙m | Gremyachinsky plant "Autospecial equipment" |
| 7 | Nut wrench for spring ladder nuts (ditch) | I-314 | Maximum torque 82 kgf∙m | Chita plant "Autospecial equipment" |
| 8 | Universal device for checking the steering of cars | NIIAT K-402 | Manual, mechanical, universal; measurement range; on the scale of the backlash meter 25 - 0 - 25 o, on the scales of the dynamometer up to 2 kgf | |
| 9 | balloon wrench | 535M | - | Kazan SEZ "Autospecial equipment" |
| 10 | Engine valve adjuster | I801.06.000 | Tubular wrench combined with a screwdriver | - |
| 11 | Auto mechanic set (big) | I-148 | Contains 44 items. Key sizes, mm - from 7 to 32 | Kazan SEZ "Autospecial equipment" |
| 12 | Combined pliers | Pliers 7814.0161 1X9 GOST 17438 - 72 | - | - |
| 13 | Locksmith steel hammer | Hammer 7850-0053 Ts 12XR GOST 2310-70 |
Rated weight 500g | - |
| 14 | Cold chisel | Chisel 2810-0189 GOST 7211-72 | - | |
| 15 | Probe set #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 | Ruler 1-150 |
- | - |
| 17 | Set of instrument and tool for battery maintenance | E-401 | Portable, consists of 15 pieces | Novgorod SEZ "Autospecial equipment" |
| 18 | hair brush | GOST 10597-70 | - | - |
| 19 | sandpaper paper | GOST 6456-75 | - | - |
| 20 | cleaning rags | GOST 5354-74 | - | - |
| 21 | locksmith workbench | ORG-1468-01-060A | - | Own production |
| 22 | Chest for cleaning materials | OG.03-000 | - | Same |
| 23 | waste bin | OG.16-000 | - | Same |
Conclusion
In the course of the work carried out, a scheme for carrying out maintenance at one post for the KamAZ 53212 vehicle was developed. A list of operations performed during the first maintenance was determined, which includes 35 items. During maintenance, fixing, refueling, adjustment, and inspection work is performed. A map-scheme of the arrangement of performers was drawn up. Compiled a timesheet of the main and additional equipment. 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 place 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. Technology for performing routine maintenance of the first and second maintenance of the GAZ 53A car.
2. Central design and technology bureau for the introduction of new technology and research work in road transport (TSENTRAVTOTECH). - M. Transport, 1978. - 136s.
3. Regulations on the maintenance and repair of the rolling stock of road transport Approved on 20.09.1984. M.: Transport, 1986. 73 p.
4. A practical guide to the maintenance and repair of KamAZ P69 type 6X4 / E.A. Mashkov. - M.: Mashinostroenie, 1994. - 243 p.: ill.
5. Report card of garage and technological equipment for motor transport enterprises of different capacities. S.A. Nevsky. - M.: Ed. TSENTRRUDAVTOTRANS, 2000. - 93s.
5. Technological map for the maintenance of engineering systems at facilities,managed by CJSC "Leader-Invest"
1.Thermal inputs:
1.1. Daily
Visual inspection.
Checking the condition of thermal insulation (including PPU and PPU control system)
Checking the condition of shut-off valves, thermometers, pressure gauges.
Temperature control at the thermal input. Recording of the main parameters in the Thermal Logbook.
1.2. Annually
Crimping of thermal input, elimination of leaks and leaks.
Preparation of the act of readiness for the heating season.
Restoration of thermal insulation if necessary.
2. Heat exchangers
2.1. Daily
Visual inspection.
2.2. Monthly
External inspection, checking for leaks.
Measurement of differential pressure across the heat exchanger.
Measurement of the temperature difference of the coolant on the heat exchanger.
2.3. Annually
Pressure testing of heat exchangers.
3. Pumps
3.1. Daily
External inspection, elimination of possible leaks.
Checking for extraneous noise and overheating of the pump motor
at work.
3.2 Monthly
Broaching contacts of electrical connections.
Assessment of the condition of the pump (if necessary, planning of repair work).
Checking the performance of fire pumps
3.3. Annually
Checking the presence and condition of grounding.
Pulling electrical connections.
Insulation resistance test.
Checking the current in operating modes.
Checking for extraneous noise and overheating of the pump motor
at work.
Pressure testing as part of a piping system.
Planning and carrying out repair and restoration works.
4. Drainage systems.
4.1. Daily
Checking (if necessary, cleaning) drainage channels.
Drain pump inspection.
Checking the absence of extraneous noise and overheating of the pump motor during operation.
4.2. Monthly
Measurement of pump operating current.
Checking the operation of signaling devices when overflowing and emptying the drainage pit.
4.3.Annually
Measurement of pump operating current.
Checking the presence and condition of the grounding of the drain pump.
Checking the insulation resistance of the drain pump motor.
Checking the condition and serviceability of the level sensors and overflow of the drainage pit.
Cleaning of drainage channels and drainage pit.
5. System automation
5.1.Monthly, weekly
Checking the condition of electrical connections and connectors.
Checking the condition and serviceability of the elements of light and sound alarms.
Checking the condition and reliability of fastening sensors of the automation and control system.
Checking the status and correct operation of the devices of the automation system.
Checking the settings of control devices.
Checking the serviceability and correct operation of control devices.
Checking the setting and operation of protective and safety devices.
5.2. Annually
Checking the presence and condition of grounding.
Checking the insulation resistance of power circuits.
Planning and carrying out repair and restoration work
6. Heating system.
6.1.Daily
External inspection of heating devices, fittings, pipelines.
6.2.Annually
Pressure testing, elimination of leaks and leaks.
Preparation of an act based on test results.
Planning and carrying out repair and restoration works.
7. PlumbingAndsewerage.
7.1. Daily
External inspection of plumbing fixtures, fittings, pipelines, flexible pipes, sewerage.
Check for leaks and fix.
7.2. Monthly
Planning and carrying out repair and restoration works.
Note:
- All operating parameters of the equipment, remarks on operation, the date of work and a description of the identified malfunctions are recorded in the operation log and confirmed by the signature of the Customer's representative.
- There is a daily and weekly detour of objects with an inspection of working systems, during the period from 8-30 to 17-30.
7.3. Twice a year
Checking for tightness of fire-fighting water supply networks.
6. Maintenance of equipment for heat energy metering units.
REGULATIONS
TECHNICAL MAINTENANCE DURING THE YEAR OF THERMAL ENERGY METERING UNIT (HUE) INSTALLED IN THE BUILDINGS OF CJSC "Leader-Invest"
| No. pp | Name of works | Frequency of execution |
| 1 | Gaining access to an object. | Upon arrival at the facility |
| 2 | Preparing for work: connecting a reader (printer) device | 2 times a month |
| 3 | Taking readings (printing a report). | 2 times a month |
| 4 | Preliminary analysis of results | 2 times a month |
| 5 | Analysis of errors and determination of their causes | 2 times a month |
| 6 | Checking compliance with technological parameters, comparing the readings T1 and T2 of the heat meter with the readings of thermometers | 2 times a month |
| 7 | Checking the integrity of seals on devices | 2 times a month |
| 8 | Issuing recommendations for the operation of internal networks | In the event of a deviation from the temperature schedule |
| 9 | Checking ground contacts | 1 time per month |
| 10 | Printout and final analysis of results | 1 time per month |
| 11 | Registration of a report on heat consumption for the reporting period in the subscriber's operation service | 1 time per month |
| 12 | Transfer of the report on heat consumption for the reporting period to the heat supply organization. | 1 time per month |
| 13 | Transfer of a report on heat consumption for the reporting period with a mark of the heat supply organization to the subscriber's operation service | 1 time per month |
| 14 | Cleaning the print head of a dot matrix printer | 1 time in 3 months |
| 15 | Checking the health of cable connections | 1 time per month |
| 16 | Dusting an external modem, printer, uninterruptible power supply (if available) | 1 time in 6 months |
| 17 | Maintenance of pressure measuring instruments - electrical pressure transducers, power supply | 1 time per month |
| 18 | Maintenance of devices for measuring the flow of coolant - primary electromagnetic flow converters | 1 time per month |
| 19 | Maintenance of temperature measuring devices - resistance thermocouples | 1 time per month |
7. Verification of heat meters.
Works are carried out according to the terms of verification and include:
Carrying out the dismantling of appliances
For the time of checking the heat meter, install the insert on the pipeline.
Delivery of the heat meter for verification to an organization or a specialized workshop licensed for this type of work.
Verification of a set of thermal converters.
Verification of the block and set of flowmeters.
Installing the heat meter after verification.
Adjusting the operation of the heat meter after installation.
Presentation of the heat meter to the heat supply organization for commercial registration (Heat meter sealing)
Presentation to the Customer of the original verification documents for the verified heat meter.
8. System of power supply and electric lighting.
(Order of the Ministry of Energy of the Russian Federation dated 13.01.2003 No. 6 Rules ...);
Carrying out technical inspections and scheduled repairs in accordance with the current "Rules for the installation of electrical installations of consumers", "Safety regulations for the operation of electrical installations of consumers", "Fire safety rules",
Development and implementation of plans for maintenance and repairs of electrical equipment of the building.
Accounting and control over the correct use and expenditure of electrical energy.
Maintenance and repair of electrical installations is carried out by electricians on duty at the facility around the clock according to the schedule.
Maintenance and repair of electrical installations in accordance with the requirements of the Rules for the technical operation of electrical installations of consumers, PPR schedules, job descriptions and labor protection instructions with the results reflected in the relevant logs (operational log, electrical equipment malfunction log, electricity consumption log).
The maintenance and repair of electrical equipment includes the following range of works:
Round-the-clock supervision of the operation of all electrical equipment and ensuring uninterrupted power supply to the Facility. Daily inspection of all electrical systems by an electrician on duty, with the obligatory recording of the results of the inspection in the operational log. Fulfillment of current requests for equipment repair. Implementation of the preventive maintenance schedule.
Maintenance of lighting fixtures (indoor and outdoor lighting):
Connection tightening,
dust cleaning,
Replacing burnt out lamps
Replacing chokes,
Starter replacement,
Ammo replacement,
Replacement of lighting fittings.
Maintenance and repair of electrical sockets, switches and unsoldered boxes:
Cleaning from dirt and dust,
Replacement of faulty sockets, switches and junction boxes.
Maintenance and repair of power equipment (including pump and fan motors):
Cleaning of electric motors from dirt,
Lubrication of motor bearings,
Tightening joints and fasteners,
Painting and marking of electric motors.
Maintenance and repair of lighting switchboards and power equipment:
Cleaning switchboards from dust and dirt,
Repair of automatic switches and starters,
Cleaning the contacts of circuit breakers, starters and buttons,
Coloring and marking of switchboards.
Maintenance and repair of automation and alarm panels:
Cleaning shields from dust and dirt;
Replacement of signal lamps,
Cleaning the contacts of the intermediate relays,
Adjustment of regulator settings,
Adjustment and repair of regulators,
Cleaning the contacts of buttons and switches,
Labeling of equipment for automation panels,
Switchboard painting.
Maintenance of outdoor lighting;
Overhaul, replacement of equipment, its adjustment and testing, as well as adjustment work on measurements of insulation resistance, resistance of grounding devices and phase zero loop of the entire building is carried out in agreement with the Customer on the basis of separate Supplementary Agreements;
Periodic monitoring of the absence of overheating and compliance of networks with actual loads;
Taking the necessary measures up to the immediate shutdown of networks in emergency situations.
9. Fire safety systems.
Fire-fighting plumbing, water, fire extinguishing systems.
Maintenance (inspection, cleaning of pipelines, shut-off valves, checking the condition and tightness of connections, etc.) of fire alarm systems, fire automation, water and fire extinguishing systems.
Checking the performance of the water fire extinguishing system.
Current repair (revision of choke-end connections, elimination of corrosion, performance check).
Inspection of the state of systems for readiness for use.
Control over compliance with the Rules of the fire regime in the Russian Federation, approved by the Decree of the Government of the Russian Federation of April 25, 2012 No. 390, and "Resolution 880-PP PPB in the city of Moscow."
Maintenance of hand-held fire extinguishers in good condition and ready for use.
Carrying out inspections of fire pumps, electric gate valves, fire water supply for tightness and water loss within the time limits established by regulatory documents with the preparation of the necessary documentation based on the results of the inspections.
Maintenance of the automatic smoke exhaust system:
Carrying out technical inspections and scheduled repairs in accordance with the current "Fire Safety Rules" and the requirements of the standards.
Development and implementation of plans for maintenance and repairs of the automation system.
Maintenance and current repair of installations is carried out by duty engineers located at the facility according to the schedule in accordance with the Regulations.
Maintenance and repair of the system includes the following complex of works:
Monitoring the operation of the system and ensuring its performance. Daily inspection of all components of the system by the engineer on duty, with the obligatory recording of the results of the inspection in the operational log.
Maintenance of SHA (automation cabinets):
Checking the performance of indicator lamps,
Checking the operation of the cabinet together with checking the controlled electric motor.
Maintenance of BSU units (control and signaling unit) and BUSO (power equipment control unit):
External examination for mechanical damage,
Light indication control,
Block performance check.
BBC 39.217
The collection of technological maps for the maintenance and current repair of the contact network has been revised, significantly expanded and prepared for publication by the Regulatory and Research Power Supply Station of the Design and Implementation Center for the Organization of Labor of the Ministry of Railways of the Russian Federation (NIS E PVC MPS RF).
When processing existing and developing new technological maps, materials from the Department of Electrification and Power Supply of the Ministry of Railways of Russia, VNIIZhT, and railways were used; developments of specialists, including and, as well as regulations on the device and operation of the contact network.
The collection is designed for a wide range of engineering and technical workers and electricians for the maintenance and current repair of the contact network, and can also be used in training for the power supply economy.
Technological maps of the collection are developed. B. C. Kravchenko,. took part in the preparation of the issue. The collection is prepared for publication under the general editorship.
Responsible for the release (CE Ministry of Railways of Russia) and (PVC of the Ministry of Railways of Russia).
With the release of this collection, all previously published technological maps for the maintenance and current repair of the contact network are canceled. Please send comments and suggestions on the collection to the address: 107228 Moscow, Novo-Ryazanskaya st., 12, room. 401, NIS E PVC of the Ministry of Railways of Russia.
ISBN -0 © CE MPS RF, 1998
Rented in a set January 15, 1999 Signed V print 03/23/99
Format 60x84/16. Circulation 5000 copies. Publishing house "Transizdat", LR No. 000 dated 01.22.98 Tel.: (0, Printing house IPO "Polygran", Moscow. Order No. 81
Printed from the finished original layout in the printing house of the IPO "Polygran" Moscow, Pakgauznoye sh., 1
MINISTRY OF COMMUNICATIONS OF THE RUSSIAN FEDERATION
Department electrification And electricity supply
APPROVE:
Head of the Department of Electrification and Power Supply
Ministry of Railways of Russia
V. V. MUNKIN
TECHNOLOGICAL CARDS
TO WORK
CONTACT NETWORK DEVICES
ELECTRIFIFIED
RAILWAYS
BOOKII
MAINTENANCE AND REPAIR
CE
№ 000-5/1-2
1999.
A common part......................,......................... ................................................. ...............................6
1. MAINTENANCE
CHAPTER 1.1. DETOURS, DETOURS, INSPECTIONS
Map 1.1.1. Detour by inspection of the catenary .................................................................. ...........eleven
Map 1.1.2. Extraordinary detour with contact suspension inspection .............................................. 13
Map 1.1.3. Extraordinary detour with current collection check .............................................................. ....17
Map 1.1.4. Bypass with inspection to assess the condition and scope of repair of catenary suspension .............................................................. ................................................. ..........................................19
Map 1.1.5. Extraordinary detour with contact suspension inspection .............................................29
Map 1.1.6. Mounted inspection of the catenary .................................................................. ..............34
Map 1.1.7. Inspection of the transition of the power line through the contact network ... ... ... ... 38
Map 1.1.8. Inspection of a vertical safety shield on an artificial structure .............................................................. ................................................. .................................40
Map 1.1.9. Inspection of a horizontal protective shield on an artificial structure .............................................................. .............,.....,...................... .................................42
Map 1.1L0. Inspection of the electric traction track circuit .......................................................... ...........44
Map 1.1.11. Inspection of the grouping point of the docking station..............................................45
CHAPTER 1.2. DIAGNOSTIC TESTS AND MEASUREMENTS
Map 1.2.1. Diagnosis of control parameters of the contact suspension by a laboratory car with a scoring assessment of its condition ............................................................... ................................48
Map 1.2.2. Measurements of zigzags, offsets and height of the contact wire suspension from a removable insulating tower .................................................................. ................................................. .........50
Map 1.2.3. Measurements of zigzags, offsets and the height of the contact wire suspension from the railcar ............................................................................_... .......:~........................................ ...................................54
Map 1.2.4. Diagnosis of plate-type porcelain insulators located on the supports of the DC contact network from the side
way................................................. ................................................. .........................................57
Map 1.2.5. Diagnosis of plate-type porcelain insulators located on the supports of the AC contact network from the side
way..........g...................... .........................,......................... .........................................61
Map 1.2.6. Diagnosis of plate-type porcelain insulators of amplifying and supplying DC and AC wires located on independent supports or on the field side of the contact supports
networks ................................................. ................................................. .........................................65
Map 1.2.7. Diagnosis of plate-type porcelain insulators on
insulated flexible crossbar .............................................................. .........................................70
Map.1.2.8. Diagnostics of catenary insulators of alternating current with the electron-optical device "Filin-3" and ultrasonic flaw detector UD-8............................................................... ................................................. ................................................. ................75
Map 1.2.9. Diagnostics for heating of current-carrying clamps and contacts
disconnectors with devices of the IKD or IKT type .............................................. ...................77
Map 1.2.10. Measuring the dimensions of the supports.................................................... .................................80
Map 1.2.11. Measuring the wear of a contact wire with a hand measuring tool .............................................................. ................-................................ ...............................81
Map 1.2.12. Static performance measurement and condition check
current collectors of electric rolling stock .............................................................. .......................84
Map 1.2.13. Testing the contact suspension of the main tracks with a current collector having an increased static pressure .............................................................. ................................................. 89
Map 1.2.14, Preventive testing and measurements of transformers
current TFN-35 grouping point .............................................. .............................................91
Map 1.2.15. Preventive tests, measurements and adjustment of the protection equipment of the docking station (ZSS) .................................................................. ................................................. ..............98
Map 1.2.16. Preventive tests and measurements of 3.3/27.5 kV switchgear busbars
grouping point .......................................................... ...............................................109
Map 1.2.17. Switch preventive testing and measurements
Central Research Institute of the Ministry of Railways of the point of grouping .............................................. ...............................................
Map 1.2.18. Preventive testing and measurement of the MPS switch
3.3/27.5 kV grouping point .......................................... ................................................. ...117
Map 1.2.19. Preventive testing and measurement of circuit equipment
control, protection and own needs of the grouping point ..............................................
Map 1.2.20. Preventive testing, measurement and performance verification
equipment of the signal indicator "Lower pantograph" .................................................................. 122
Map 1.2.21. Measurements with a spark gap check
(IP) ........................: ..................... ..............................:..........."....... ...............................................127
Map 1.2.22. Measurements with a function check of the protective device in
group grounding circuits ...............: .............................. ................................................. ....129
Map 1.2.23. Measuring the resistance of the ground circuit of a support with individual grounding .............................................................. ................................................. ....................................133
Map 1.2.24. Group ground input resistance measurement
support ............................; .............. ................................................. .........................................141
Map 1.2.25. Measuring the individual resistance of the earth circuit
support united by a group grounding cable .............................................................. ...........
Map 1.2.26. Measurement of leakage currents from reinforcement of foundations and reinforced concrete supports .............................................................. ...............................:..................... ..:........ ………………………..148
Map 1.2.27. Measuring rail-to-ground potentials and compiling (adjusting) a potential diagram .............................................................. ......:...................................... .............
Map 1.2.28: Measurements to determine the degree of corrosivity of the soil in relation to steel reinforcement of reinforced concrete supports (foundations)............................................... ................................................. ................................................. ..............155
Map 1.2.29. Measurements with checking the insulation of the anchor from the guys of the support .............................................. ... .................... .....................:................................,..................158
Map 1.2.30. Measurements with verification of additional insulation in the grounding nodes of a support with a sectional disconnector or a horn arrester and
details of suspension fastening in an artificial structure ..............................................
Map 1.2.31. Measurements with checking the insulation of the suction line in DC sections .............................................................. ................................................. ...............................166
Map 1.2.32. Diagnosis of the state of the underground part of a centrifuged reinforced concrete support using the ADO device ....................................
Map 1.2.33. Diagnosis of the state of the underground part of a centrifuged reinforced concrete support using the DIACOR device ...................................174
Map 1.2.34. Ultrasonic diagnostics of a centrifuged reinforced concrete support with an assessment of its bearing capacity ........178
Map 1.2.35. Tests and measurements with verification of a special choke-transformer (DT) .............................................................. ................................................. ................................................. ..184
Map 1.2.36. Tests and measurements with checking the insulation of the motor drive, the control panel and the remote control circuits of the disconnector.................................................................................. .........................187
Map 1.2.37. Testing the scheme for melting ice or preventive heating of the catenary .................................................................................. ................................................. ...................192
2. CURRENT REPAIRS
CHAPTER 2.1. COMPLETE INSPECTION AND REPAIR
" Map 2.1.1. Comprehensive check of the condition and repair of the contact sub-
weights ................................................. ...............................................".......... ...................................197
Map 2.1.2. Comprehensive inspection of the condition and repair of non-insulating interface of anchor sections.................................................................................. .........„....................................... .........................213
Map 2.1.3. Comprehensive inspection of the condition and repair of the supply (suction line) or reinforcing wire .................................. , .........._.........................................................................220
Map 2.1.4. Comprehensive inspection, assessment of the condition and scope of repairs
underground part of the support (foundation) with excavation of soil .................................................................. ............224
Map 2.1.5. Comprehensive survey, assessment of the condition and volume of repair of the above-ground part of the reinforced concrete support .............................................................. ................................................. ...........228
Map 2.1.6. Comprehensive examination, assessment of the condition and scope of repairs,
forecasting the service life of a metal supporting structure .............................................. 231
Map 2.1.7. Comprehensive inspection of the condition and repair of rigid anchoring of the wire and its fasteners, attachment points of anchoring branches
wires to the compensating device............................................................... ...............................236
Map 2.1.8. Comprehensive check of the condition and repair of the support guy…………………239
Map 2.1.9. Comprehensive check. condition, and repair of the console.......................................241
Map 2.1.10. Comprehensive inspection of the condition and repair of brackets, racks and extensions for hanging reinforcing, supplying and other wires
contact suspension .............................................................. ................................................. ..............247
Map 2.1.11. Comprehensive inspection and repair of flexible crossbar
with stress relief .............................................................. ................................................. ...........251
Map 2.1.12. Comprehensive inspection and repair of the insulated flexible cross member without stress relief .............................................................................. ...................................................257
CHAPTER 2.2. CONDITION CHECK, ADJUSTMENT AND REPAIR
Map 2.2.1. Checking the condition, adjusting and repairing the insulating interface of the anchor sections and the neutral insert .................................................................. ...............................................263
Map 2.2.2. Checking the condition, adjusting and repairing the air arrow.... ……….270 Map 2.2.3. Checking the condition, adjustment and repair of the sectional insulator .............................................................. ................................................. ................................................. 277
Map 2.2.4. Checking the condition, adjustment and repair of contact suspension in artificial structures .............................................................. ................................................. ...........283
Map 2.2.5. Checking the condition, adjusting and repairing the compensating device .......................................................... ................................................. ............................................... 288 Map 2.2.6. Checking the condition, adjusting and repairing the sectional disconnector without de-energizing .............................................................. ................................................. ......................295
Map 2.2.7. Checking the condition, adjusting and repairing the sectional disconnector with stress relief .............................................................. ................................................. .........................305
Map 2.2.8. Checking the condition, adjusting and repairing the manual or motor drive and the control panel of the sectional disconnector.................................................................. .................................307
Map 2.2.9. Checking the condition, adjusting and repairing the horn gap without removing the voltage .............................................. ................................................. .......................................312
Map 2.2.10. Checking the condition, adjusting and repairing the horn arrester with voltage relief .............................................................. ................................................. .................317
Map 2.2.11. Checking the condition, adjustment and repair of the tubular arrester .............................................................. ....................,.,..............,........... ...................................................321
Map 2.2.12. Checking the condition and repair of individual grounding of a support of a contact network, a grouping point, an artificial and other metal structure …………………………………………………………………………………………….. 324
U Kart 2.2.13. Checking the condition and repair of individual grounding of a reinforced concrete support .............,………………….......................
Map 2.2.14. Checking the condition and repair of group grounding supports ……………...331
Map 2.2.15. Checking the condition and repairing the point of connection of the suction line to the traction rail circuit .............................................................. ................................................. ...................336
Map 2.2.16. Checking the condition, adjustment and repair of transformers
currentTFN-35 grouping point .............................................. ..............,..............,........,......339
Map 2.2.17. Checking the condition, adjustment and repair of protection equipment
docking stations (ZSS).................................................. ................................................. ..
Map 2.2.18. Checking the condition, adjustment and repair of tires and disconnectors RU-3.3 / 27.5 kV of the grouping point .............................................. ................................................. .............344
Karga 2.2.19. Checking the condition, adjusting and repairing the switch of the Central Research Institute
IPU of the grouping point ..... „„ .......................................... .................... „...........,. „...........,.., 348
Map 2.2.20. Check of a condition, adjustment and repair of the MPS-switch
3.3/27.5 kV grouping point .......................................... ........ "………………... ...................355
Map 2.2.21. Checking the condition, adjusting and repairing interlocks, equipment and circuits for auxiliary needs of the grouping point………………………………………..................................361
CHAPTER 2.3. PARTS REPLACEMENT AND CLEANING
Map 2.3.1. Replacing the retaining clip....,……………….............,.,.................. ......364
Map 2.3.2. Replacing the contact wire butt clamp...............................................................367
Map 2.3.3. Replacing the supply, connection or adapter terminal ...............................
Map 2.3.4. Replacing the string clamp……………………………………………………378
Map, 2.3.5. Replacing the wedge clamp under tension .............................................., .............................. ....381
Map 2.3.6. Replacing the wedge clamp when de-energized.,............................,.,....,.185
Map 2.3.7. Replacement of the movable block of the compensator...............................................389
Map 2.3.8. Replacing the fixed block of the compensator............................................... ......392
Map 2.3.9. Clamp replacement .................................................................. ...............395
Map 2.3.10. Replacing the eyelet .................................................................. ................................................398
Map 2.3.11. Installing a shunt on a contact wire with local wear .... …………401
Map 2.3.12. Replacing a bolted butt joint of copper or aluminum (steel-aluminum) wires with an oval tubular connector……………………. 405
Map 2.3.13. Decontamination of the mortise insulator in the lower fixing cable, fixing guy or in the longitudinal wire .................................................................. ......................409
Map 2.3.14. Cleaning from contamination of insulators of the contact network located on supports and crossbars .............................................................. ......,..,........................................ ...............................412
Map 2.3.15. Cleaning From contamination of anchor insulators with insulated
flexible cross member without stress relief .............................................................. ...............„.„.415
Map 2.3.16. Decontamination of the suspension insulators and the second insulators from the support of the neutral insert of the lower fixing cable of the insulated flexible crossbar under tension............................................................... ................................................. ...............417
Map 2.3.17. Washing of catenary insulators with a mobile unit UPO.................................................................................. ................................................. ...............................421
Map 2.3.18. Decontamination of the lower above-ground part of supports and foundations, sealing of cracks and painting .................................................................. ................................................. .................424
GENERAL PART
This collection contains typical schemes of technological processes for maintenance (TO) and current repairs, (TR) of the contact network of direct and alternating current and points for grouping docking stations. The list of technological maps of the collection corresponds to the scope of work of Appendix 5 to the "Rules for the Design and Technical Operation of the Contact Network of Electrified Railways" (PUTEKSCE-197).
The collection is intended to guide the organization and performance of work. Technological maps provide for the performance of work by the personnel of contact network areas (ECC) and specialized teams of repair and inspection sites (RRU) of power supply distances (EC) equipped with vehicles, mechanisms, instruments and basic installation devices provided for in Appendix 4 to PUTEKS TsE-197. The maps reflect the current level of engineering and technology, organization of production and labor in the performance of work on the contact network, the components and structures of which correspond to standard designs and PUTEX.
The development of technological maps is based on:
Typical norms of time for maintenance and current repair of the contact network of electrified railways (Moscow, Transizdat, 1995).
Technological maps for work on the overhaul and current repair of the contact network (Moscow, Transport, 1973).
Rules for the design and technical operation of the contact network of electrified railways, TsE-197 (Moscow, Transport 1994).
Collection of technical instructions and information materials on the economy of power supply (Moscow, Transizdat, 1996).
Preventive testing of power equipment of traction substations. Collection of guidelines (Moscow, Transport, 1967).
Instructions for the protection of railway underground structures from corrosion by stray currents, TsE-3551 (Moscow, Transport, 1979).
Guidelines for the maintenance and repair of contact network support structures, K-146-96 (Moscow, Transizdat, 1996).
Instructions for grounding power supply devices on electrified railways TsE-191, (Moscow, 1993 p).
Faults and deviations from the established norms revealed during the maintenance or repair work, which can cause interruptions in the movement of trains, power outages or violating safety requirements, must be eliminated immediately, about which the work manager must report to the power dispatcher and then be guided by his instructions. Their implementation is carried out according to the relevant Technological maps and is additionally standardized, and in the absence of time standards - according to actual costs.
The technological maps define the categories of work in relation to safety measures, set out the basic requirements to ensure the safety of personnel when performing work in accordance with the "Safety Rules for the Operation of the Contact Network of Electrified Railways and Automatic Blocking Power Supply Devices", TsE / 4504 (Moscow, Transport 1988 .) and "Safety instructions for electricians of the contact network", TsE / 4816 (Moscow, Transport, 1992).
The cards indicate the sequence of operations that ensures the safety of personnel. The sequence must be strictly observed when performing work. The composition of the performers and the norms of time correspond to the "Typical norms of time for maintenance and current repairs of the contact network of electrified railways", approved by the Ministry of Railways of the Russian Federation on 06/07/95.
The composition of the performers does not include signalmen for fencing the place of work. Their number is determined by the "Instructions for ensuring the safety of train traffic during work on the contact network from insulating removable towers", TsE / 4373 (Moscow, Transport, 1987), taking into account local conditions and is specified in the work order. The number of signal accessories and portable radio stations required for them is not provided for in section 3 of the technological maps and is determined additionally.
In * a number of technological maps (for work not included in the collection of Model Time Standards) time standards are indicated, adopted on the basis of statistical and calculated data. In the future, it is planned to develop technically justified time standards for these works.
The time standards given in the technological maps take into account only operational time and should be adjusted in accordance with the instructions of the general part of the "Typical time standards for maintenance and current repairs of the contact network of electrified railways" (Moscow, 1995!). The performance of additional operations during the TS that are not provided for by the technological map is normalized according to the actual costs.
It is allowed to combine several works, if the composition of the performers, their qualifications and the category of work in relation to security measures are the same in the technological maps for these works. In these cases, the time limit for performing combined work must be reduced by multiplying by K \u003d 0.925 - when performing work from an isolating removable tower and by K \u003d 0.936 - for work without an isolating tower.
PART 1. MAINTENANCE
CHAPTER 1.1. DETOURS , BYPASSES , INSPECTIONS Technological map № 1.1.1.
DETOUR WITH INSPECTION OF THE CONTACT SUSPENSION 1. Composition of performers
Head of the district, electrician or electrician of the 6th category Conditions for the performance of work
The inspection tour is carried out:
2.1. From the front cab of an electric locomotive or electric train.
2 2. By order and notification of the energy dispatcher, indicating the time of the detour, the name of the section to be bypassed, and the number of the train from which the detour will be made..
3. Mechanisms, devices, assembly; fixtures, tools, protective equipment and signal accessories
Notepad for writing with writing utensils, butt
4. The norm of time for 1 km of the way is 0.05 people. h.
5. Preparatory work
5.1. Receive an order to perform work and instructions from the person who issued it.
5.2. Notify the energy dispatcher about the upcoming detour, indicating the track number, the name of the stage, station (or section), the start time of the detour and the number of the train from which the detour will be made.
5.3. Arrive at the station (stop) from which the detour will begin.
6. Diagram of a sequential technological process
Name of operations | ||
Performing an Inspection | 6.1.1. When driving around, carefully monitor the condition of the contact suspension, identify visible damage to its individual elements, violations of their adjustment or position, as well as deviations from the technical requirements and standards set forth in PUTEX (TsE-197). When driving, pay special attention to: The position of the supports (tilt and deflection are not allowed), the reliability of their fastening in the ground (there should be no subsidence, landslides or soil erosion near the supports), serviceability of the grounding; Compliance of the position of the clamps with air temperature or technical standards, the distance between the contact wire and its main rod, the lower fixing cable or fixing guy (it is unacceptable to reduce this distance - preload), the serviceability of inclined strings or rigid struts, as well as lift limiters; The magnitude of the sag of the longitudinal wires and their relative position, the preload of the wires to the grounded structures, the presence of dangling wires, the sagging of the wires of the middle anchors or the anchoring branches of the mates of the anchor sections; The condition of the insulators, the presence of damaged insulating parts or the presence of bending of the connecting fittings, as well as the preload of the suspension insulators of the garlands to grounded structures; The condition of the compensatory devices (breaks in the cores of the cables are not allowed, the distances between the blocks, as well as from the bottom of the compensator weights to the ground and from the top of the cargo bar to the fixed compensator block must correspond to the air temperature); The condition of the cable and strings (breaks of strings and cores on the cable are not allowed, the slope of the strings along the path should not exceed 30 ° to the vertical); Condition and adjustment of arresters, sectional insulators, air arrows; Condition of disconnectors, loops and drives; The presence of mechanical vibrations ("dancing") of the wires of the contact network; Interaction of pantographs of oncoming trains and contact suspension along the adjacent track; The voltage level on the instruments in the driver's cab. Sharp fluctuations of the kilovoltmeter needle during movement indicate a violation of the current collection. 6.1.2. Inspection results l all identified deviations from technical standards should be recorded in a notebook indicating their location (name of change |
rut or station, track number, support, span, etc.). 6.1.3. If deviations are detected that can cause disturbances in the movement of trains, take measures through the energy dispatcher to eliminate them, organize the passage of trains at this place with the pantographs lowered or with a speed limit. |
Basic information, elements of the technological map (TC):
1. List of works
2. Technical requirements
3. Tool, equipment
4. Operating materials (brand, volume)
5. Norm of time (person-min.)
6. Scheme, drawing or photograph
7. Checkpoints
Technological map (Table 1).
Type of examination:
Sedan Daily Maintenance: NISSAN PRIMERA Brands
Performer: owner of the car.
Table 1. Technological map of daily car maintenance
|
Name of procedure (operation) |
Technical requirements, instructions, notes (diagnostic signs) |
Tool, equipment, fixture |
Operating materials (brand, volume) |
Norm of time (person min.) |
Scheme, drawing or photograph |
Control points |
|
|
Daily external inspection of the car body |
Check for chips, scratches |
||||||
|
Checking the good condition of all doors |
Make sure the door latches are working properly. |
by opening / closing |
|||||
|
Checking the reliability of opening and closing the hood of the engine compartment |
Make sure all latches lock securely. Make sure the second latch prevents the hood from closing when the primary latch is lowered. |
by opening / closing |
|||||
|
Visual inspection of the engine compartment |
Check for traces of oil, brake and coolant leaks |
visually |
|||||
|
Checking the windshield washer fluid |
Check if there is enough fluid in the washer reservoir |
visually |
|||||
|
Checking the engine coolant level |
On a cold engine, check the coolant level. |
visually |
The coolant level must be at the max mark. |
||||
|
Checking the engine oil level |
Remove the dipstick from the engine, wipe it with a dry cloth and reinsert completely in the same place. Now take it out and check the oil level. |
Control oil dipstick, rags |
The level must be between the max and min marks. |
||||
|
Checking the fluid level in the hydraulic booster reservoir |
Unscrew the reservoir cap, look at the fluid level |
visually |
The level must be between the max and min marks |
||||
|
Check the condition of pipelines |
Pay attention to the tightness of the union nuts, signs of leakage and the presence of cracks. |
visually |
|||||
|
Checking the level of brake fluid and clutch hydraulic fluid |
Make sure that the brake fluid level is between the min and max marks, which are marked on the wall of the master brake cylinder barrel and the clutch fluid reservoir. |
visually |
The brake fluid level must be at the max mark. |
||||
|
Battery check |
Check the electrolyte level in each section of the battery |
visually |
the electrolyte level must be between the min and max marks |
||||
|
Daily external inspection of the luggage compartment of the car |
|||||||
|
Checking the good condition of all doors, including the trunk lid |
Check that the latches on the trunk lid are working properly. |
by opening/closing |
|||||
|
Checking the presence of a spare wheel, jack, wheelbrace, pump |
visually |
||||||
|
Checking the presence of a driver's bag |
visually |
||||||
|
Daily tire inspection |
visually |
||||||
|
Check for cuts, damage, excessive wear |
Carefully check for damage, signs of heavy wear |
visually |
|||||
|
Tire pressure check |
Visually or with a pressure gauge |
manometer MD-214 GOST 9921 |
2.0-2.3 kg/cm2 |
||||
|
Daily inspection of lighting fixtures |
|||||||
|
Checking headlights, brake lights, position lights, direction indicators |
Check the reliability of fastening and serviceability of all lighting devices |
visually |
|||||
|
Daily Inspection of Windshield Wiper Blades |
|||||||
|
Checking the wiper blades |
Check the quality of glass cleaning, inspect the brushes, pay attention to the presence of cracks and signs of wear of the rubber elements |
visually |
Total daily service - 20 people-min.
