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 in 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, silencer exhaust pipe flanges 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, back | - | - | 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 points. 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.
Routing - this is a form of a technological document in which the entire process of influencing a car or its unit is recorded, the operations, professions and qualifications of performers, technological equipment and equipment, technical specifications (TU) and instructions and the norm of time or labor intensity are indicated in the established sequence.
Maps are divided into operational-technological, guard, workplace, route. Maps-diagrams of the arrangement and movement of performers at maintenance posts can also be developed.
Operational-technological maps(Form 1) - are the documentation of the general level and serve for the development of maps of guards and for the workplace. They contain lists of operations for units and systems indicating equipment and tools, specifications and labor intensity.
Guard cards(form 2) are drawn up for work performed only at this 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 the tools and equipment, specifications and instructions, the complexity of operations.
Route map(form 2) reflects the sequence of operations for the repair of the unit or mechanism of the car in one of the divisions of the current repair.
Operational-technological map car (unit).
Technological map No. . .
Labor intensity per person
Form 2
Post technological map car (trailer).
Number of specialized posts in the zone on line l And research institutes.
Total number of performers people General labor intensity pers.h
Post No. .
Labor intensity of work pers. Number of performers in the post people
(name of the unit, system or type of work)
Labor intensity per person
The initial data for the development of the technological map are:
- 1. General view drawing (assembly drawing or diagram) of a unit, mechanism or unit;
- 2. Specifications for assembly, adjustment, testing, control and acceptance of the product;
- 3. Characteristics of the equipment, fixtures and tools used
- 4. The complexity of operations.
Rationing the labor intensity of technological process operations
For each operation of TP TO and TR, a labor intensity norm must be established. Such a norm is necessary for calculating the number of performers and remuneration for their labor and for designing the technical process (even distribution of the amount of work among the performers, drawing up the optimal sequence of operations, etc.).
The general norm of time 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 the execution of this operation. It is determined by one of the methods discussed below.
The rest of the time norm is set in the form of allowances as a percentage of the operational time.
Thus, the norm of time for the operation TO, D, TR in minutes or hours:
where To - 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 man-hours or man-min is found by the formula:
Tn \u003d TV * R * Kp (2)
where P is the number of workers performing the operation, people; Kp is the operation repeatability coefficient, which characterizes the frequency of the operation during maintenance (D, TR).
For example, control and diagnostic operations are performed without gaps (mandatory for each service Кп=1). Adjusting and fastening operations may have Kp< 1, т.к. после проверки, если регулировочный параметр в норме или подтяжка крепежного соединения не требуется, они могут быть пропущены. Коэффициент повторяемости зависит от надежности конструкции автомобиля и качества выполнения предыдущего ТО или ТР, изменяется для различных операций, примерно в пределах Кп = (0,2-1), и определяется путем обработки соответствующих статистических данных или по данным типовых технологий ТО и ТР.
The complexity of maintenance and repair operations can be set in one of three ways:
- - using ready-made standards from standard technologies and standard norms of time for maintenance and repair of vehicles;
- - processing of data of chronometric observations of their implementation;
- - microelement regulation of operations.
The simplest and most desirable is the first method.
Standard norms of labor intensity are accepted according to
Typical norms of time (labor intensity) are subject to certain operating conditions. If the actual conditions for performing operations (other equipment, level of mechanization) differ from the average conditions specified for standard standards, they should be adjusted for the conditions of the designed process. So, for example, with the in-line method of organizing service, the standard labor intensity can be reduced by 15–25% of the typical norm. If the conditions for performing the operation differ sharply from the typical ones (new equipment, new vehicle design), then the labor intensity standard is set in other ways.
Timing observation method
The method of chronometric observations gives the most accurate results, but it is very laborious 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 method of time-keeping observations.
For timing, the 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 working shift (one hour after the start of work, stops one hour before lunch or the end of the working day).
The number of timing observations should 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 way the work is performed.
Table 2 - Required number of measurements during timing
Timing data are arranged in a variational series (from min to max). The stability and stability of the results of observations is checked by comparing the actual value of the stability coefficient of the chronological order with its normative (table) value (Table 3).
Table 3 - Normative value of the coefficients of stability of the time series
The stability coefficient of the chronological series is found by the formula:
where t max, t min are the maximum and minimum values from the composition of the time series. A chronological series is considered stable if the actual "stability coefficient is less than or equal to the standard one: K Kn.
If this ratio is not observed, then the observations should be repeated. As an exception, due to the high cost of timing, it is allowed to correct the time series by discarding its extreme values (t max, t min).
The operational time in minutes to perform the operation is found as the average value of the members of the chronological sequence:
where ti is the value of the chronological series members , min; n is the number of members of the chronological series.
Timing and setting the norm can be carried out only after the introduction and debugging of a new technological process, i.e. it is impossible to design the norm of time (labor intensity) of operations at earlier stages of the development of TP.
Microelement method for designing normative complexity of operations
Microelement systems are currently widely used to determine the labor intensity of TP operations.
The essence of this method is that the most complex operations can ultimately be represented as a certain sequence of repeating simple elements, for example: move, install, fix, connect, etc. (Table 4).
If we divide the normalized operation into a number of such microelements and sum up the time available in the database for their execution, then we can find the operational time to complete the entire operation.
The main advantage of this method is the possibility of designing labor intensity norms "at the table" at the stage of TP development, which significantly reduces time and costs compared to the method of chronometric observations. Of course, this is possible with extensive experience and qualifications of process engineers (knowledge of the design of a given brand of car, the operation and capabilities of the technological equipment, fixtures and tools used, etc.).
The time values for the execution of microelements of the operation are “clean”, i.e. with their convenient implementation and free access to the service point. In real conditions, the convenience of performing work (working postures, table 4) and access to a service point (table 5) for each brand of car and operation will be different, therefore, in the operational time for the operation to be corrected by the appropriate coefficients.
Thus, the general equation for normalizing the labor intensity of car maintenance in man-min or man-hours with this method looks like this:
Tn \u003d (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 trace elements in the operation, incl. and taking into account their repetition; K1, K 2 - respectively, the coefficients taking into account the increase in time to perform the operation due to the deterioration of convenience and access during work (Tables 5 and 6); P is the number of executors of the operation; Kp - operation repeatability coefficient for maintenance and TR; A, B, C - allowances in% of the 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 arms, legs, inclination and rotation of the human body, transitions, i.e. an unchanging series (set) of repetitive movements.
One of the systems of microelement standards is the system of "standards" of Professor V.I. Ioffe. In this system, any handmade element consists of a combination of two microelements: take and move (combine, move, install, remove).
The degree of fragmentation of operations into microelements is of fundamental importance. The division of operations into 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 for the implementation of microelements (hundredths and thousandths of a minute) falls; the process of synthesizing an operation from elements becomes more complicated. Big mistakes are possible.
Taking into account this situation, at this stage, based on the collection and generalization of information on literary sources and normative and technical documentation, etc., a base was developed in the amount of 44 microelements (Table 4).
With the enlargement of microelements, their versatility decreases, since the probability of repetition in a large number of various operations and processes decreases. But it simplifies the process of designing operations in which they occur. Therefore, in our opinion, the base of microelements for TP TO and TR of cars should consist of two parts. The first part should contain elementary movements encountered in the operations of any labor processes. The second part - larger elements of operations of specialized maintenance and repair works (fastening, welding, etc.).
The base of trace elements presented in Table 4 is not sufficient, it needs to be improved and expanded. With its help, it is possible to design, mainly, the labor intensity standards for control, diagnostic and adjustment operations of maintenance and repair of cars, however, it allows us to demonstrate the possibility of the method under consideration.
Table 4 - Database on microelements of car maintenance operations
|
Name of microelement |
Time, min |
|
|
Step 1 |
||
|
Going 2 steps. |
||
|
Going 3 steps |
||
|
Going 4 steps |
||
|
Stretch out (remove, bend) a hand |
||
|
Take (put) a tool, device, part (take the handle, latch) |
||
|
Housing rotation 90° |
||
|
Housing rotation 180° |
||
|
Body tilt (straighten up) |
||
|
Body tilt 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 docking with the vehicle structure |
||
|
Rotate Tool |
||
|
Turn the handle, open the latch |
||
|
Press the latch |
||
|
Place (remove) foot (hand) on the pedal |
||
|
Press (release) the pedal with your hand |
||
|
Press (release) the pedal with your foot |
||
|
Go down into the inspection ditch |
||
|
Climb out of the inspection ditch |
||
|
Get up on the bumper |
||
|
Get off the bumper |
||
|
Open (close) the hood (with the latch open) |
||
|
Open (close) the cabin door (when the handle is turned) |
||
|
Tilt cab |
||
|
Put the tilt cab back in place |
||
|
Blow out the serviced element with compressed air from a hose |
||
|
Finger movements |
||
|
Screw (bait) the nut M8 - M24 |
||
|
Tighten the nut (bolt) M20 -- Ml 6 |
||
|
Tighten the nut (bolt) M20 -- M35 |
||
|
Look (glance) at an object or sign in sight |
||
|
Scale reading, cm |
||
|
Scale reading, mm |
||
|
Look closely at division |
||
|
One mind action with single digits |
||
|
One mental action with two digit numbers |
||
|
Setting the instrument to zero |
||
|
Preloading the indicator head |
||
|
Unscrew (wrap) the nut, bolt, fitting M8 M16 for a length of up to 20 mm |
||
|
Unscrew (wrap) the nut, bolt, fitting M8 -M16 for a length of up to 35 mm |
||
|
Unscrew (wrap) the nut, bolt, fitting M20 -M32 for a length of up to 25 mm |
||
|
Unscrew (wrap) the nut, bolt, fitting M20 -M32 for a length of up to 35mm |
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 in its maintenance.
Process impact points (sometimes called service points) are located on the side, bottom, and top of the vehicle. Therefore, when servicing a car, first of all, it is necessary to provide performers with access to service points. To reduce service time, it is better to provide simultaneous access to several workers from all sides.
In addition, it is necessary to provide the performer with the least fatigue and the greatest safety during work. Research has established that fatigue, and hence the productivity of a worker, significantly depends on the working posture he occupies. Table 5 shows data on changes in labor productivity depending on the working posture.
The conditions for performing operations directly in the area of service points are characterized by their availability, which also significantly affects the labor intensity of the work. The impact of access to places of technological impact during maintenance and repair of a car is presented in Table 5.
Table 5 - Influence of convenience of work on the complexity of maintenance and repair operations
Table 6 - Influence of access to service points on the complexity of the maintenance operation
- 13. Universal rack;
- 14. Recoil stop.
Specialized post SPP-1 for the replacement of power units and engines
- 1. Locksmith workbench;
- 2. Oil dispenser;
- 3. A set of keys;
- 4. Crane beam;
- 6. Oil distribution tank;
- 7. Footrest;
- 8. Lift;
- 10. Dynamometric handle;
- 11. Rack for aggregates;
- 12. Universal rack;
- 13. 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 appliances;
- 19. Mobile overpass for repair;
Specialized post SPP-2 for the replacement of suspension units and running gear
- 1. Locksmith workbench;
- 2. Wrench for wheel nuts;
- 3. Nut driver for spring ladder nuts;
- 4. Cassette for wheels;
- 5. Chest for cleaning materials;
- 6. Ruler for checking wheel alignment;
- 7. Transitional bridge;
- 8. Lift;
- 9. Mobile car mechanic post;
- 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 for braking systems of vehicles
- 1. Locksmith workbench;
- 2. Wrench for wheel nuts;
- 3. Cassette for wheels;
- 5. Lift,
- 6. Device for testing the pneumatic drive of the brakes;
- 7. Universal rack;
- 8. Stand for checking the brakes of three-axle vehicles;
- 10. Recoil stop;
- 11. Installation for refueling and pumping brakes;
Specialized post SPP-4 TR of low labor intensity
- 1. Bath for washing parts;
- 2. Locksmith workbench;
- 3. A set of wrenches;
- 4. Chest for cleaning materials;
- 5. Transitional bridge;
- 6. A set of socket keys;
- 7. Suspended pneumatic wrench:
- 8. Footrest;
- 9. Lift;
- 10. The post of a mobile mechanic-auto repairman:
- 11. Rack for components and parts:
- 12. Universal rack:
- 13. Recoil stop.
- 14. Cabinet for tools and instruments:
Specialized post SPP-5 TR of electrical systems of vehicles
- 1. Locksmith workbench;
- 3. Motor tester;
- 4. Post of a mobile mechanic-auto electrician;
- 6. Device for checking and adjusting headlights;
- 7. Device for testing breakers-distributors;
- 8. Device for checking electrical equipment;
- 9. Rack for components and parts.
- 10. Universal rack;
- 11. Table for appliances;
- 12. Recoil stop;
- 13. Installation for accelerated charging of batteries;
- 14. Device for suction of exhaust gases;
- 15. Cabinet for tools and instruments;
Specialized post SPP-6 TR for devices of engine power systems
- 1. Bath for washing parts;
- 2. Locksmith workbench;
- 4. Set of wrenches,
- 5. Chest for cleaning materials;
- 6. The post of a mobile mechanic-auto repairman or carburetor;
- 7. Device for checking plunger pairs;
- 8. A device for checking fuel pumps of carburetor engines;
- 9. A device for checking the fuel priming pump and filters;
- 10. Device for checking injectors;
- 11. Universal rack;
- 12. Table for cutlery:
- 13. Recoil stop.
- 14. Device for suction of exhaust gases;
- 15. Cabinet for tools and instruments;
Specialized post for frame replacement SPP-7
|
from capsizing;
|
Special post SP-1 for the replacement of engines
- 1. Recoil stop.
- 2. Bath for washing parts;
- 3. Locksmith workbench;
- 4. Capture for the engine;
- 5. Oil dispenser;
- 6. A set of keys;
- 7. Crane beam;
- 8. Chest for cleaning materials;
- 9. Footrest;
- 10. Mobile locksmith's post;
- 11. Dynamometric handle;
- 12. Rack for engines;
- 13. Universal rack;
- 14. Device for detaching and holding the gearbox;
- 15. Device for suction of exhaust gases;
- 16. Device for draining used oils;
- 17. Device for draining coolant;
- 18. Cabinet for tools and instruments;
- 19. Mobile overpass for repair;
Special post SP-2, SP-3 for the replacement of rear suspension units of cars
- 1. Locksmith workbench;
- 4. Lift;
- 5. Rack for springs;
- 6. Universal rack;
- 7. Wheel chock
- 8. Device for dismantling and mounting springs:
- 9. Cabinet for tools and instruments;
Special post SP-4, SP-5 for the replacement of clutches and gearboxes
- 12. Recoil stop.
- 1. Locksmith workbench;
- 2. The track bridge is mobile;
- 3. Chest for cleaning materials;
- 4. Oil dispenser;
- 5. Monorail with a hoist;
- 6. Universal rack;
- 7. Rack for clutches and gearboxes;
- 8. Trolley for transportation of gearboxes and clutches;
- 10. Special device for disconnecting the gearbox;
Special post SP-6 for the replacement of rear axles and gearboxes for GAZ, ZIL vehicles
- 1. Locksmith workbench;
- 2. Nut driver for spring ladder nuts;
- 3. Multi-spindle hanging nut runner for wheel nuts and hub flanges,
- 4. Cassette for wheels;
- 5. Cantilever crane;
- 7. Oil distribution tank;
- 8. Lift;
- 9. Bridge rack;
- 10. Universal rack;
- 11. Trolley for removing and installing wheels;
- 12. Recoil stop.
Special post SP-7 for the replacement of gearboxes of KamAZ vehicles
- 1. Locksmith workbench;
- 2. Multi-spindle nut driver for hub flange nuts
- 3. Crane beam;
- 4. Chest for cleaning materials;
- 5. Oil dispensing tank;
- 6. Pneumatic wrench on suspension,
- 7. Rack for gearboxes;
- 8. Universal rack;
- 9. Recoil stop.
- 10. A device for draining used oils.
- 11. Cabinet for tools and instruments,
Special post SP-8 for the replacement of the rear and middle axles of KamAZ vehicles
- 1. Locksmith workbench;
- 2. Wheel nut wrench multi-spindle suspended;
- 4. Cassette for wheels;
- 5. Track bridge;
- 6. Chest for cleaning materials;
- 7. Oil distribution tank;
- 8. Monorail with a hoist;
- 9. Mobile lift;
- 10. Bridge rack;
- 11. Universal rack;
- 12. Device for draining used oils;
- 13. Device for holding the car in a suspended state
- 14. Cabinet for tools and instruments;
Special post SP-9 for the replacement of front axles and beams
- 1. Locksmith workbench;
- 2. Wheel nut wrench multi-spindle suspended,
- 3. Multi-spindle multi-spindle nut driver;
- 4. Cassette for wheels; a chest for cleaning materials;
- 5. Monorail with a 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 the pins
- 12. Cabinet for tools and appliances;
Special post SP-10 for the replacement of steering units
- 1. Bath for washing parts;
- 2. Locksmith workbench;
- 3. Chest for cleaning materials;
- 4. Grease blower;
- 5. Post mobile locksmith-auto repairman;
- 6. Steering tester;
- 7. Universal rack;
- 8. Recoil stop.
- 9. Device for draining used oils;
Special post SP -11 TR brake systems with hydraulic drive
- 1. Locksmith workbench;
- 2. Wrench for wheel nuts;
- 3. Cassette for wheels;
- 4. Chest for cleaning materials;
- 5. Lift for trucks;
- 6. Universal rack;
- 7. Trolley for removing and installing wheels;
- 8. Recoil stop.
- 9. Installation for refueling and pumping brakes;
- 10. Cabinet for tools and appliances;
Special post SP-12 TR for braking systems of KamAZ vehicles
- 1. Locksmith workbench;
- 2. Wrench for wheel nuts;
- 3. Cassette for wheels
- 4. Chest for cleaning materials;
- 5. Lift;
- 6. A device for testing the pneumatic drive of car brakes;
- 7. Universal rack;
- 8. Trolley for removing and installing wheels;
- 9. Recoil stop.
- 10. Device for pumping receivers with compressed air;
Special post SP-13 for the replacement of cabs and platforms of KamAZ vehicles
- 1. Locksmith workbench;
- 2. Capture for cabins;
- 3. Capture for platforms;
- 4. Crane beam;
- 5. Chest for cleaning materials;
- 6. Shelving for cabins and platforms;
- 7. Trolley for moving cabins and platforms;
- 8. Emphasis
- 9. Cabinet for tools and instruments;
Special post for the replacement of CPG engines SP-14
- 1. Recoil stop.
- 2. Bath for washing parts;
- 3. Locksmith workbench;
- 4. Oil dispenser;
- 5. Picking trolley;
- 6. Chest for cleaning materials;
- 7. Mobile post of a car mechanic;
- 8. Pneumatic wrench on suspension;
- 9. Footrest;
- 10. Lift;
- 11. Universal rack;
- 12. Device for suction of exhaust gases;
- 13. Device for draining used oils;
- 14. Cabinet for tools and instruments;
- 15. Mobile overpass for repair;
Special post SP-15 TR and adjustment of ignition system instruments
- 1. Locksmith workbench;
- 2. Chest for cleaning materials;
- 3. Post of a mobile mechanic-auto electrician;
- 4. A device for welding electrical equipment of cars;
- 5. Device for checking and cleaning spark plugs;
- 6. Device for testing breakers-distributors;
- 7. Universal rack;
- 8. Mobile electronic stand;
- 9. Table for instruments;
- 10. Recoil stop;
- 11. Device for suction of exhaust gases;
- 12. Cabinet for tools and appliances;
Special post SP-16 TR of power system devices
carburetor engines
- 1. Bath for washing parts;
- 2. Locksmith workbench;
- 3. A set of tools for the carburetor adjuster;
- 4. Chest for cleaning materials;
by car;
- 5. Mobile carburetor locksmith post
- 6. Instrument for testing fuel pumps of carburetor engines
- 7. Universal rack;
- 8. Recoil stop.
- 11. Cabinet for tools and appliances;
Special post SP-17 TR for diesel engine power system devices
- 1. Bath for washing parts;
- 2. Locksmith workbench;
- 3. Chest for cleaning materials;
- 4. Post of a mobile diesel mechanic;
- 5. Device for checking plunger pairs;
- 6. A device for checking the fuel priming pump and filters;
- 7. Device for checking nozzles;
- 8. Universal rack;
- 9. Recoil stop.
- 10. Device for suction of exhaust gases;
- 11. Cabinet for tools and appliances;
Special post SP-18 for the replacement of frames of KamAZ vehicles
shih oils; 8. Device for draining cooling soup liquid; 9. Device for suction flue gases;
|
Suspended pneumatic wrench
from capsizing; 26. Cabinet for tools and instruments; |
Special post SP-19 for the replacement of frames of GAZ, ZIL cars
flue gases 17. Device for draining cooling soup liquid; |
18. Device for draining spent shih oils;
from capsizing;
|
engine shop
- 1. Locksmith workbench;
- 2. Crane - beam.
- 3. Chest for cleaning materials;
- 4. Fire extinguisher;
- 5. Stand for engines;
- 6. A 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. Tool for removing and installing piston rings;
- 11. Device for installing the piston in the block;
- 12. Sink;
- 13. Wooden lattice under the feet;
- 14. Hand dryer;
- 15. Mesh basket;
- 16. Machine for grinding valves;
- 17. Machine for boring engine cylinders;
- 18. Machine for honing (polishing) of engine cylinders;
- 19. Valve grinding machine;
- 20. Rack for storage of oil and water pumps, compressors, fans, filters;
- 21. Rack for storing instruments and fixtures;
- 22. Stand for testing oil pumps;
- 23. Stand for running and testing of compressors;
- 24. The stand for check of tightness of blocks and heads of the block of cylinders of the engine;
- 25. Stand for disassembly-assembly of engine cylinder heads;
- 26. Stand for disassembly-assembly of engines;
- 27. Stand for grinding the necks of the crankshaft;
- 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 run-in and test department
- 1. Fuel tank;
- 2. Crane - beam;
- 3. Fire extinguisher;
- 4. Extraction of exhaust gases;
- 5. Stand for running and testing engines;
- 6. Installation for cooling engines.
Aggregate shop
|
|
Carburetor shop
|
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Fuel equipment shop (diesels)
Electrical shop
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Battery section
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Mednitsky workshop
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19. Box with sand; |
Tire shop
Vulcanization shop
paint shop
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wallpaper shop
Forging shop
Welding and tinsmith shop
Properly apply protective equipment when performing individual operations. The general system of measures for labor safety during car repair 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 the organization of technological processes and hygienic requirements for production ...
Therefore, in the project, it is necessary to develop measures for the implementation of a preventive maintenance system for car maintenance at JSC Balezinoagropromkhimiya. 2. Improving car maintenance 2.1 Types and frequency of car maintenance Knowledge and pattern of changes in the parameters of the technical condition of 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 these works on the TR together with the SW. 3. DEVELOPMENT OF THE TECHNOLOGICAL PROCESS OF THE EO GAZ-53 CAR Maintaining the car in good condition and proper form is achieved by maintenance and repair based on the recommendations of the preventive maintenance ...
On the move of the car through the holes on the sidewalls of the body and the perforated upholstery of the ceiling. 3. MAINTENANCE 3.1. Features of operation Seats For a more comfortable individual fit in the GAZ 3110 car, the front seats are adjustable. To move in a horizontal direction, turn the handle and release it when the seat is set to one of the nine...
- 1. Complete car wash.
- 2. Determining the technical condition of vehicle systems, which includes:
- - technical condition of the power unit: checking the components - the crank mechanism, gas distribution, cooling system, power supply and clutch systems.
- - power supply systems.
- - ignition systems.
- - the condition of the gearbox, cardan drive and differential.
- - steering.
- - carrier system.
- - power supply and alarm and control devices.
- 3. Elimination of identified defects and adjustment work.
- 4. Vehicle assembly.
- 5. Delivery of the finished car to the customer.
List of works during maintenance:
Power unit: calibrated tightening of the nuts for fastening the head, pan, neck supports, eliminating knocks in the engine, adjusting and restoring the tightness of the valves, checking the tension of the alternator-fan belt, checking the tightness and filling level of the cooling system, the technical condition of the pump, flushing and adjusting the carburetor, checking operation of the fuel pump, checking the fuel level in the carburetor, checking the ignition system - the condition of the high-voltage wires, the condition of the distributor, the condition of the candles, the operation of the clutch - the reliability of operation, the condition of the clutch parts, the oil is changed at a certain mileage.
Braking system: tightness of the system, production of pads and discs, brake fluid level.
Gearbox: check the level and quality of the oil, the oil is changed at a certain mileage, check for extraneous noise, smooth gear shifting, reliability of fixing speeds, condition of the bearings, condition of the differential - condition of gears, satellites, bearings, condition of the driveline: determination of the technical condition according to backlash in the connection, the external state of the node.
Carrying system: checking the operation of shock absorbers, springs, rods, the condition of ball bearings and dampers, checking the camber and toe-in, checking the wear of the wheels, the condition of the wheel bearings, wheel balancing.
Control system: checking the steering wheel play, wheel play, changing the oil in the gearbox.
Power supply system: checking the condition of the generator, the condition of the collector, brushes, rectifier, the condition of the contacts, the output voltage and current, replace the bearing grease, the condition of the starter, the condition of the brushes and the collector, the developed torque, the condition of the contacts, the condition of the battery, the level and density of the electrolyte, the condition terminals, checking and correct readings of instrumentation, checking lighting and alarm systems.
Body: to lubricate the hinge points, the reliability of operation and fixing of locks, the condition of the body, to re-preserve the body.
Lubricate in accordance with the lubrication chart of the units.
Periodic maintenance and current repairs ensure the maintenance of trouble-free and reliable operation of vehicles. Maintenance is divided into three periods:
daily, TO-1, TO-2. Maintenance allows you to keep the mechanisms of the car working between repairs. Maintenance is an integral part of maintenance. It is designed to restore the performance of the unit.
To perform maintenance and current repairs, a set of devices and instrumentation is used. This kit is in stock.
When a car arrives at a car repair shop for maintenance or current repairs, it is necessary to perform a list of mandatory works:
- 1. Wash the car from operational pollution.
- 2. Check the technical condition of the vehicle components and assemblies.
- 3. Draw up a technical condition map indicating defective components and assemblies.
The reliability and durability of the operation of units and assemblies depends on the quality of lubricants and keeping the terms of their replacement, determined by the manufacturer of the car and component units.
We will consider the types of work performed and their frequency using the example of a Gazelle car
Table 4. Periodic maintenance of a Gazelle car (TO-1, TO-2, CO)
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Periodicity |
Technical requirements |
Tools and materials |
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Engine |
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Check: |
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Condition and tightness of cooling, power, lubrication systems |
Leakage of coolant, fuel, oil is not allowed |
Visually |
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Ignition timing ZMZ-4025, -4026, UMZ-4215. |
Adjust if necessary |
stroboscope |
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Check fastening: |
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Cylinder heads (4215, ZMZ-4025, 4026) |
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oil sump |
Tighten loose nuts |
Key 13 mm |
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Settling filter (UMZ-4215), fuel fine filter (UMZ-4215) |
Tighten loose nuts |
Key 13 mm |
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Radiator and water pump, thermostat housing, water pump pulley and idler** |
Tighten loose nuts |
Key 13 mm |
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Generator and starter |
Tighten loose nuts |
Key 17 mm, 19 mm |
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Carburetor air and throttle actuators |
Tighten loose fitting |
Wrench 10 mm, screwdriver |
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Adjust: |
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Belt tension (belts ** 4215, ZMZ-4025, 4026) drive units |
Ruler with dynamometer, wrenches 12, 13 mm |
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Minimum idle speed and carbon monoxide (CO) and hydrocarbon (CH) content |
Tachometer, screwdriver, gas analyzer |
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Gap between spark plug electrodes |
The gap should be 0.8-0.95 mm (ZMZ-4025, 4026); 0.7-0.85 mm (ZMZ-4061, 4063, UMZ-4215) |
Feeler gauge, spark plug wrench |
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Gap between valves and rocker arms (4215, ZMZ-4025, 4026) |
Wrench 13 mm, screwdriver, probe |
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Clear: |
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Carburetor Air Filter Housing and Blow Out Filter Element |
Blow through the inside of the corrugation, and then outside |
Compressed air source |
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Carburetor Air Filter Housing and Replace Filter Element |
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Fuel filter housing and its filter element (in autumn) |
After installing the housing in place, make sure that there are no fuel leaks. |
Wrenches 10, 12 mm, pliers, |
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Settling glass of the fine fuel filter (for UMZ-4215 engines) and rinse the mesh filter element. Replace paper filter element*** |
After installing the glass in place, make sure that there are no fuel leaks. |
Unleaded gasoline, rags |
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High-voltage wires and interference-suppressing tips of spark plugs |
Unleaded gasoline, rags |
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External surfaces of ignition devices, cover and slider of the ignition distributor sensor (4215, ZMZ-4025, 4026) |
Unleaded gasoline, rags |
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Drain the sediment from the fuel tank (in autumn) |
Gasoline container, wrench 24 mm |
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Drain sediment from fuel filter housing |
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Replace: |
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Spark plug |
Candle key |
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Fuel fine filter (for engines ZMZ-402, 406) |
Fuel leakage is not allowed |
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Transmission |
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Check: |
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Condition and tightness of the hydraulic clutch, gearbox and rear axle |
Leakage of liquid and oil is not allowed |
Visually |
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Tightening the rear axle pinion flange nut |
Keys 14, 17, 27 mm, |
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Fastening of a reducer of the back bridge |
Tighten loose nuts |
Key 14 mm |
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Fastening of the main and working cylinders of the clutch, the axis of the pusher of the main cylinder of the clutch |
Tighten loose nuts |
Keys 13, 17 mm |
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Clutch housing to cylinder block |
Tighten loose nuts |
Key 14 mm |
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Mounting the gearbox and its crankcases |
Tighten loose nuts |
Keys 12, 19 mm |
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Clear: |
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Gearbox and rear axle breathers |
- ** Every 500 km.
- ***For filter with paper element
Organizational structure
The organizational structure of the enterprise is linear-functional. The structure of the enterprise, the number of employees is determined by the staffing schedule, internal rules and job descriptions of the enterprise. Workers. appointed to the position, and dismissed from it by order of the head of the enterprise. Structure. The state of the enterprise is a set of linear and functional bodies of the enterprise, as well as a system of their connections, interdependencies and interaction. The structure of the state of the enterprise is influenced by: the number of employees subordinate to one manager, the volume of trade, specialization, the number of subordinate trade units. Organizational structure. LLC "Pizza Treviso" is shown in the figure
