3.1 Types and frequency of maintenance of machines.
3.2 Technology of maintenance of tractors and agricultural machines.
3.1 Types and frequency of maintenance of machines.
The parameters of the technical condition of the PTS of the machine and its components have different wear rates, so they can reach their limit (Pcr) value for different operating intervals (example-graph).
One parameter D1, for example, the level of engine oil in the engine crankcase, requires monitoring and recovery for 8-10 m.-h. (i.e. every shift), and another parameter D5 (Fig. 1) - for 1000-1200 m.-h. (i.e. Once a year).
In total, during the year of operation of the tractor, it is required to perform 300 ... 400 maintenance operations or, on average, one maintenance operation every 2.5 ... 3.5 m-h.
In order not to stop the tractor often for maintenance and not to tear it away from doing agricultural work. works, all operations are grouped into types of maintenance.
- this is a set of operations for checking and adjusting units and mechanisms performed at a certain interval of time (operating time), called periodicity.
The quality of maintenance is ensured by compliance with GOST 20793-86 “Tractors and agricultural machines. Maintenance”, which defines all types, frequency, cycles, as well as the basic requirements for carrying out maintenance operations.
The frequency of numbered maintenance types can be expressed in the volume of the main work performed, in liters (kg) of fuel consumed, in engine hours, in kilometers of run, in output products.
The complete system of maintenance types by machine groups is shown in Table 1.
Table 1 - Types of maintenance of tractors and agricultural machines
| Type of maintenance | Tractors, myself. chassis | Harvester, complex itself. mash. | Other cars |
| 1. Maintenance. During operational run-in | + | + | + |
| 2. Every Shift Maintenance (ETO) | + | + | + |
| 3. First maintenance (TO-1) | + | + | + |
| 4. Second maintenance (TO-2) | + | + | - |
| 5. Third maintenance (TO-3) | + | - | - |
| 6. Seasonal maintenance (SRT) | + | + | + |
| 7. Maintenance under special operating conditions | + | + | - |
| 8. Storage maintenance | + | + | + |
Frequency of maintenance of tractors and self-propelled chassis set in engine hours, liters or kilograms of fuel used.
Frequency of maintenance self-propelled harvesters installed in physical hectares, liters of fuel consumed, engine hours.
Frequency of maintenance non-self-propelled combines and stationary machines set in hours or tons of processed products.
The frequency of numbered types of maintenance of tractors depends on the year of manufacture.
For tractors, the decision to start production of which was made before January 1, 1982, the frequency is: TO-1 - 60 hours; TO-2 - 240 m.-h.; TO-3 - 960 hours
The scheme of maintenance intervals for these tractors is shown in fig. 2.
Rice. 2. Scheme of the periodicity of maintenance of tractors at: TO-1 - 60; TO-2 - 240; TO-3 - 960 hours
In this scheme TO-1………..72
TO-2……...18
TO-3……...3
TR………...2
KR………..1
The development of the maintenance and repair system takes place in the direction of increasing the frequency of maintenance and repair, reducing the list of maintenance operations, using universal lubricants and working fluids.
Therefore, for tractors, the decision to start production of which was made after January 1, 1982, the frequency of maintenance is: TO-1 - 125 m.-h.; TO-2 - 500 m.-h.; TO-3 - 1000 m.-h.
The scheme of maintenance intervals for these tractors is shown in fig. 3.
Rice. 3. diagram of the periodicity of maintenance of tractors at TO-1 - 125 m.-h.; TO-2 - 500 m.-h.; TO-3 - 1000 hours
In this scheme TO-1………..36
Periodic maintenance of tractors, as mentioned above, includes shift maintenance, first maintenance, second maintenance, third maintenance and seasonal maintenance. The maintenance rules are formulated in such a way that each subsequent maintenance includes most of the operations of the previous one.
Every shift maintenance includes: cleaning and washing of the tractor; external inspection to detect leaks of oil, fuel and coolant; electrolyte level in the battery; deficiencies noted are eliminated; refueling the tractor, if necessary, with fuel, engine and transmission oils; checking by inspection and listening to the operation of the engine, control mechanisms, lighting and signaling; distribution density reduction of power probabilities checking the operation of the engine control mechanisms, lighting and signaling; check the operation of the windshield wiper and brakes.
During the first maintenance (TO-1), in addition to the ETO operations, they check and, if necessary, adjust: the tension of the drive belts; air pressure in tires; control mechanisms (play of the steering wheel, free and full travel of the brake and clutch pedals, etc.). Lubricate tractor mechanisms in accordance with the instruction table. The sludge is drained from the coarse filters and the fuel tank, the filters of the air cleaner and hydraulic systems are washed or replaced. Perform tightening of external fasteners.
The second maintenance (TO-2) after performing the TO-1 operations requires changing the oil in the engine crankcase, checking and adjusting the gas distribution mechanism, element-by-element diagnostics of the main assembly units, ensuring the efficiency and safety of the tractor.
Often, according to the results of a diagnostic report, operational (unscheduled current) repairs of individual assembly units or parts are required.
TO-1 and TO-2 are carried out either at maintenance points of farm units, or directly in the field, using mobile maintenance and diagnostic tools.
The third maintenance (TO-3) is carried out only in closed rooms equipped with the necessary means for disassembling, checking and adjusting the components of the machine (stationary maintenance posts at central repair shops or well-equipped technical service points for farm units).
With this type of maintenance, a general (comprehensive) check of the technical condition of the tractor is carried out in order to establish the possibility of its further operation or the deadline for putting it in for repair.
Complex checks and adjustments of fuel equipment, electrical equipment and hydraulic systems are performed on special stands in the removed state. The TO-3 rules require flushing the fuel tank, oil system and engine cooling system, replacing gear oils with flushing the corresponding crankcases, and changing greases in friction units.
Seasonal maintenance (S), as a rule, is combined with the next maintenance and is performed during the transition to the spring-summer or autumn-winter period of operation, when the average daily air temperature crosses the border of +50C. It provides, in addition to the operations of the corresponding licensed maintenance, the replacement of summer grades of fuel and oils with winter grades (or vice versa), cleaning the radiator of scale and a number of measures to normalize the thermal regime for both the engine and the machine operator (installation or removal of insulation devices, checking and adjusting heater, ventilation, checking engine start systems in cold weather, etc.). The frequency of numbered maintenance of tractors is set in hours of operation and is: TO-1 - 125: TO-2 - 500; TO-3 - 1000 hours.
GOST 20793-86
Group T51
STATE STANDARD OF THE UNION OF THE SSR
TRACTORS AND MACHINES, AGRICULTURAL
Maintenance
Agricultural tractors and machines.
Maintenance
Valid from 01.01.88
until 01.01.91*
______________________________
* Expiry date removed
according to protocol N 5-94 of the Interstate Council
for standardization, metrology and certification
(IUS N 11-12, 1994). - Note "CODE".
INFORMATION DATA
1. DEVELOPED AND INTRODUCED by the State Agro-Industrial Committee of the USSR
PERFORMERS
S.I. Kostenko, Ph.D. tech. sciences; A.V. Lensky, Ph.D. tech. sciences (topic leader); V.G. Tslaf; V.M.Mikhlin, Doctor of Engineering sciences; G.V.Yaskorsky, Ph.D. tech. sciences; I.A.Skrebitskaya, Ph.D. tech. sciences; L.F. Levina; M.M. Firsov, Ph.D. tech. sciences; M.M. Gulin, Ph.D. tech. sciences; A.L. Mikhailichenko, Ph.D. tech. sciences; A.A. Zudin
2. APPROVED AND INTRODUCED BY Decree of the USSR State Committee for Standards dated 12/17/86 N 3892
3. INSTEAD OF GOST 20793-81 and GOST 22870-84
4. REFERENCE NORMATIVE AND TECHNICAL DOCUMENTS (NTD):
Item number, applications |
|
Annex 1 |
|
The standard applies to all agricultural tractors, self-propelled chassis (hereinafter referred to as tractors) and agricultural machines (hereinafter referred to as machines) in operation.
The standard establishes the types, frequency, as well as the basic requirements for the maintenance of tractors and machines at enterprises and organizations of the agro-industrial complex.
1. GENERAL PROVISIONS
1. GENERAL PROVISIONS
1.1. Types of maintenance of tractors and machines must correspond to those indicated in the table.
Table
Cars |
|||||
Type of maintenance | Tractors and self-propelled chassis, mobile pump stations | Combines, complex self-propelled and trailed machines; sophisticated stationary crop processing machines | Seeding and planting machines; headers, mowers-pickers; tillage machines with active working bodies; | Trailers and carts, conveyors | Tillage machines; simple stationary crop processing machines |
Maintenance during operational run-in (preparation, performance and completion)* | |||||
Every Shift Maintenance (ETO) | |||||
First maintenance (TO-1) | |||||
Second maintenance (TO-2)** | |||||
Third maintenance (TO-3) | |||||
Seasonal maintenance during the transition to the spring-summer period of operation (TO-VL) *** | |||||
Seasonal maintenance during the transition to the autumn-winter period of operation (TO-OZ) *** | |||||
Maintenance before the start of the season (TO-E) for seasonal machines | |||||
Maintenance in special operating conditions (sandy, stony and swampy soils, desert, low temperatures and high mountains) | |||||
Storage maintenance | |||||
____________________
Note. The sign "+" means the presence of a type of maintenance for tractors and machines of this group, the sign "-" - the absence.
* It is allowed to exclude this type of maintenance.
** TO-2 combines, self-propelled, trailed and stationary machines must be performed if their expected operating time per season is more than 300 hours. When the operating time is less than 300 hours, TO-2 should be combined with the preparation of machines for long-term storage.
For self-propelled, trailed and stationary machines, depending on the design (electric drive instead of an engine, etc.), the number of maintenance types can be reduced to ETO, TO-1.
*** Carry out depending on the operating conditions.
1.2. Maintenance during storage (during preparation, in the process and during removal) of tractors and machines should be carried out in accordance with Section 2 of GOST 7751-85.
1.3. The frequency of TO-1 tractors should be 60 hours of operation, TO-2 - 240 hours of operation, TO-3 - 960 hours of operation, the frequency of TO-1 combines and complex self-propelled machines should be 60 hours of operation, TO-2 - 240 hours of operation.
The frequency of TO-1 non-self-propelled machines should be 60 hours of main work under load, TO-2 - 240 hours of main work under load.
STO should be carried out every 10 hours or every shift of operation of the tractor or machine.
1.4. It is allowed to indicate the frequency of maintenance in other units equivalent to the operating time (liters of consumed diesel fuel for tractors, combines and complex self-propelled machines, physical or conditional reference hectares, kilograms or tons of manufactured products, etc.).
1.5. For tractors, the decision to start production of which was made after 01/01/82, the frequency of TO-1 should be 125 hours of operation, TO-2 - 500 hours of operation, TO-3 - 1000 hours of operation.
1.6. It is allowed, in agreement with the customer (consumer), to increase the frequency of TO-1, TO-2 and TO-3 of tractors and machines that are in production after increasing their reliability to the frequency specified in clause 1.5.
1.7. Permissible deviation of the actual periodicity (lead or delay) TO-1 and TO-2 up to 10% and TO-3 - up to 5% of the established one.
1.8. By agreement with the customer (consumer), it is allowed to introduce additional operations to replace engine oil in a diesel engine with maintenance of an oil cleaner, as well as to carry out maintenance of electrical equipment and fuel pump units with a frequency of 2000 hours of operation.
1.9. Seasonal maintenance of tractors should be carried out: TO-VL - at a steady ambient temperature above 5 °C, and TO-OZ - below 5 °C.
1.10. The list of operations for each type of maintenance of tractors and machines of specific brands should contain washing, cleaning, control, diagnostic, adjustment, lubrication, refueling, fastening and assembly and dismantling work (without reference to the previous view), as well as a lubrication table and diagram. Measures to ensure fire safety - in accordance with GOST 12.2.019-86.
1.11. Maintenance of tractors and machines must include maintenance of all their components.
2. REQUIREMENTS FOR THE MAINTENANCE OF TRACTORS AND MACHINES
2.1. Maintenance of tractors and machines should be carried out in accordance with the "Technical description and operating instructions" and technical maintenance documentation.
The content of the types of maintenance should be developed on the basis of the approximate lists of operations given in the recommended appendices 1 and 2, taking into account the design features of specific types of agricultural machinery, the oils and lubricants used, as well as operating conditions.
2.2. When carrying out maintenance of tractors and machines, one should observe the sanitary rules for organizing technological processes and the hygienic requirements for production equipment approved by the USSR Ministry of Health, as well as the requirements of GOST 12.3.002-75.
2.3. To carry out maintenance of tractors and machines in accordance with the established frequency (clauses 1.3, 1.5), it is necessary to keep records of their operating time. The form of the schedule is given in recommended appendices 3 and 4. The basis for maintaining a maintenance schedule is the daily record of operating time since the start of operation of a new or overhauled machine.
2.4. In the operational documentation (form, service book) of a tractor or machine, in the column for their maintenance, all maintenance, except for maintenance, must be noted, indicating the date, type of maintenance, as well as the operating time since the start of operation of new or overhauled tractors or machines.
2.5. Carrying out seasonal technical maintenance of tractors should be combined with the next maintenance.
2.6. Maintenance during operational run-in, TO-3, TO-VL and TO-O3 of tractors should be carried out in stationary workshops, at stations and maintenance points.
TO-1 and TO-2 of tractors and machines are allowed to be carried out at the place of their work using mobile maintenance units.
2.7. When carrying out maintenance of tractors and machines, equipment should be used that ensures its performance in accordance with the requirements of the list of works in the "Maintenance" section, the document "Technical description and operating instructions".
2.8. When carrying out TO-3, it is necessary to have equipment for resource diagnostics of machines or use a mobile diagnostic unit.
2.9. The parameters of the technical condition of the components of the tractor or machine should be checked using control and diagnostic equipment.
Diagnosis is carried out using the built-in instrumentation of the tractor or machine, or external diagnostic tools.
When diagnosing, the need for carrying out, as well as the list and content of adjustment work (restoration of the parameter) for the maintenance operation, carried out with periodic control, is determined.
2.10. During TO-3, preceding the scheduled current (excluding warranty hours) or overhaul, the tractor must be subjected to resource diagnostics in order to determine the possibility of its further use or putting it in for repair.
If the values of the resource parameters are within the permissible limits, then the planned current or major repairs are carried out after the expiration of the extended operating time, assigned on the basis of determining the technical condition. If further operation is impossible, based on the results of resource diagnostics, the type of repair is established.
2.11. When servicing tractors and machines, oils and lubricants should be used that are indicated in the lubrication table and have a document confirming their brand and quality.
2.12. Carrying out lubrication and refueling operations should exclude the possibility of dirt, dust and moisture getting into the components of tractors and machines, and drained waste oil products into the soil.
APPENDIX 1 (recommended). EXAMPLE LIST OF OPERATIONS BY TYPE OF MAINTENANCE OF THE TRACTOR
1. Maintenance of the tractor during operational run-in
1.1. Maintenance of the tractor in preparation for operational running-in
the tractor is inspected and cleaned of dust and dirt;
remove preservative grease;
inspect and prepare batteries for operation;
check oil levels in components equipped with a checking device and, if necessary, top up with oil;
lubricate the components through the grease fittings;
check and, if necessary, tighten the external threaded and other connections of the tractor;
check and, if necessary, adjust the belt tension (drive, fan, generator, compressor), control mechanisms, track chain tension, tire pressure;
refuel, respectively, with coolant and fuel of the cooling and power supply systems of the diesel engine;
listen to the engine;
visually check the readings of control devices for compliance with established standards.
1.2. Maintenance of the tractor during operational running-in
The following operations must be performed:
check the oil levels in the engine crankcase, coolant in the radiator and, if necessary, add to the specified levels;
check the operability of the diesel engine, steering, lighting and alarm system, wiper and brakes;
after three shifts, they additionally check and, if necessary, adjust the tension of the fan and generator drive belts.
1.3. When servicing the tractor after the end of the operational run-in, the following operations should be carried out:
visually inspect and clean the tractor;
check and, if necessary, adjust: tension of drive belts, air pressure in tires, clearances between valves and rocker arms of the diesel engine, clutch, tractor control mechanisms and brakes;
carry out maintenance of air cleaners;
check and, if necessary, restore the tightness of the air cleaner and, if necessary, tighten the external fastenings of the components (including fastenings of the diesel head);
check the battery and, if necessary, clean the surfaces of the batteries, terminals, wire lugs, ventilation holes in the plugs, add distilled water;
wash the filters of hydraulic systems;
lubricate the terminals of the wire lugs;
replace the oil in the diesel engine and its components, power transmission (in the absence of an oil filter);
inspect and listen to the components of the tractor in operation;
flush the diesel lubrication system when the diesel engine is not running.
Faults found must be corrected.
2. Tractor maintenance when using
2.1. During the ETO, the following operations must be carried out:
clean the tractor from dust and dirt;
check by external inspection that there are no leaks of fuel, oil and electrolyte and, if necessary, eliminate leaks;
check by inspection and listening the performance of the diesel engine, steering, lighting and alarm systems, wipers and brakes.
It is allowed to refuel the diesel tractor with oil during the shift.
2.2. During the first maintenance (TO-1), the following operations should be carried out:
clean the tractor from dust and dirt;
check the oil levels in the diesel crankcase pan, coolant in the radiator and, if necessary, top up to the specified levels;
check the operability of the steering, lighting and alarm systems, wiper, brakes, diesel start blocking mechanism;
check the performance of the diesel engine and the duration of its start-up, the oil pressure in the main oil line;
check the clogging and tightness of the air cleaner connections;
check the duration of rotation of the rotor of the centrifugal oil cleaner after installing the diesel engine;
carry out maintenance of air cleaners according to the operating instructions;
drain the sludge from the coarse fuel filters, oil accumulated in the brake compartments of the rear axle and torque booster, condensate from air cylinders,
check the oil levels in the components of the tractor (according to the table and the lubrication chart and, if necessary, top up to the set level;
lubricate the components of the tractor according to the table and lubrication chart.
2.3. During the second maintenance (TO-2), the following operations must be performed:
clean the tractor from dust and dirt;
inspect (visually) the tractor;
check by inspection that there are no leaks of fuel, oil and electrolyte and, if necessary, eliminate leaks;
check the oil levels in the diesel crankcase pan, coolant in the radiator and, if necessary, top up to the specified levels;
check and, if necessary, adjust: the tension of the drive belts and the air pressure in the tires;
check the batteries and, if necessary, clean the surfaces of the batteries, terminals, wire lugs, ventilation holes in the plugs, add distilled water;
check the density of the electrolyte and, if necessary, recharge the batteries;
drain: sludge from coarse fuel filters, oil accumulated in the brake compartments of the rear axle and torque booster, condensate from air cylinders;
lubricate the terminals and wire lugs;
lubricate the components of the tractor according to the table and lubrication scheme;
check and, if necessary, adjust the clearances between the valves and rocker arms of the diesel clearance mechanism, the clutch of the torque increaser, the brake of the torque increaser and cardan gear, the clutch of the main diesel engine and the power take-off shaft drive, the steering clutch, the brake system of wheeled tractors, convergence tractor guide wheels, steering wheel mechanism, front axle steering knuckle bearings, axial clearance of guide wheel bearings, track tension and cotter pins, full travel of levers and control pedals, force on the steering wheel rim, on control levers and pedals;
clean the drainage holes of the generators;
change the oil and lubricate the components of the tractor according to the fairy tale table;
clean the centrifugal oil cleaner;
check diesel power.
After completion of the tractor maintenance, the tightness of the air cleaner connectors and diesel intake air ducts should be checked.
If there is a signaling device and a signal is received from it that the air cleaner is clogged, the latter must be cleaned and flushed during the next maintenance.
They check the duration of the diesel engine start, the oil pressure in the main line of the lubrication system, the duration of rotation of the rotor of the centrifugal oil cleaner after stopping the diesel engine, the operation of the engine start blocking mechanism.
2.4. During the third maintenance (TO-3), the following operations must be performed:
clean the tractor from dust and dirt;
check by external inspection that there are no leaks of fuel, oil, electrolyte and, if necessary, eliminate leaks;
change the oil in the diesel crankcase pan, check the coolant level in the radiator and, if necessary, top up to the specified level;
check the operability of the diesel engine, steering, lighting and alarm systems, wiper and brakes;
inspect (visually) the tractor;
check and, if necessary, adjust the tension of the drive belts and the air pressure in the tires;
check the batteries and, if necessary, clean the surfaces of the batteries, terminals, wire lugs, ventilation holes in the plugs, add distilled water;
check the density of the electrolyte in the batteries and, if necessary, recharge or replace them with charged ones;
sludge is drained from the coarse fuel filters, oil accumulated in the brake compartments of the rear axle and torque booster, condensate from air cylinders;
lubricate the terminals and wire lugs;
lubricate the components of the tractor according to the table and lubrication scheme;
check and, if necessary, adjust: gaps between valves and rocker arms of the gas distribution mechanism of a diesel engine;
clutch of the torque increaser, brake of the torque increaser and driveline, clutch of the main diesel engine and power take-off shaft drive, steering clutch, brake system of wheeled tractors, convergence of the tractor guide wheels, steering wheel mechanism, bearings of the front axle steering knuckles, axial idler wheel bearing clearance, track tension and pin cotter pins, engine start blocking mechanism, full travel of levers and control pedals, forces on the steering wheel rim, on control levers and pedals;
clean the drain holes of the generator;
change the oil and lubricate the components of the tractor according to the lubrication table;
clean the centrifugal oil cleaner;
check the external threaded and other connections of the tractor and, if necessary, tighten;
flush the diesel lubrication system;
check and, if necessary, adjust: injectors for injection start pressure and fuel spray quality, fuel injection start angle, fuel pump, gaps between spark plug electrodes and magneto interrupter contacts, diesel starter clutch, bearings of guide wheels and track rollers of a caterpillar tractor, axial movement of the suspension carriages, final drive bearings, worm-sector engagement, sector-nut of the hydraulic booster (if necessary, with tightening of the sector-nut and bipod), hydraulic system units, parking brake, bearings of the intermediate support of the driveline, pneumatic system;
clean and wash the filter-sump of the starting diesel tank, the fuel supply fitting and the carburetor, the cover and the filter of the tank of the main and starting engines, the filters of the turbocharger and the hydraulic systems of the power steering;
clean the holes in the plugs of the tanks of the main and starting engines;
check: wear of tires or caterpillar chain, pitch and profile of the teeth of the drive sprockets, technical condition of the crank mechanism of the starting engine, duration of diesel start-up, oil pressure in the main line of the lubrication system, technical condition of the cylinder-piston group, parts of the crank group, mechanisms gas distribution and diesel distribution gears, cooling capacity of the cooling system radiator, operability of the all-mode regulator (for unevenness, minimum and maximum crankshaft speeds), pressure developed by the booster pump, pressure in front of fine fuel filters, duration of rotation of the rotor of the centrifugal oil cleaner after stopping the diesel engine;
check the relay-regulator and, if necessary, adjust;
check the condition of the insulation of the electrical wiring, isolate the damaged areas;
check the readings of control devices for compliance with their standard and, if necessary, replace;
replace the filter elements of the fine fuel filter;
check air cylinders for leaks;
check (without disassembly) and, if necessary, adjust the clearances in the bearings of the main gears of the main gears;
check and, if necessary, restore the fit of the cardan shaft flanges;
check and, if necessary, rearrange the caterpillars and drive sprockets;
inspect tires and, if necessary, repair damage;
flush the diesel cooling system;
check the power and hourly fuel consumption of a diesel engine;
check the working capacity of the tractor mechanisms in motion.
2.5. During seasonal maintenance during the transition to operation in autumn-winter conditions, the following operations must be performed:
fill the cooling system with a liquid that does not freeze at low temperatures;
turn on an individual heater and install insulating covers;
replace summer grade oil with winter grade oil according to the lubrication table;
turn off the radiator of the diesel lubrication system;
set the seasonal adjustment screw of the relay-regulator to position Z (winter);
bring to the winter norm the density of the electrolyte in the batteries;
check the operability of the means of facilitating the start of the insulation diesel;
check the tightness of the cooling system, the duration of the diesel engine start, the integrity of the insulation of the electrical wiring (visually), the charging current of the generator, the voltage and current of the relay-regulator operation, the operability of the cabin heating system (by testing).
Faults found are corrected.
2.6. During seasonal maintenance during the transition to operation in spring-summer conditions, the following operations must be performed:
remove the insulating covers from the tractor;
include a diesel lubrication system radiator;
disconnect the individual heater from the cooling system;
set the seasonal adjustment screw of the relay-regulator to position L (summer);
bring the density of the electrolyte in the batteries to the summer norm;
remove, if necessary, scale from the cooling system;
refuel the diesel fuel system with summer grade fuel;
check: the cooling capacity of the radiator of the cooling system, the cooling capacity of the radiator of the lubrication system, the integrity of the insulation of the electrical wiring (visually), the charging current of the generator, the voltage and current of the operation of the relay-regulator.
When using the tractor in the southern climatic zone, it is allowed to exclude seasonal maintenance operations from the list of works.
3. Maintenance of tractors in special conditions
3.1. When servicing the tractor in desert and sandy conditions, the following conditions must be observed:
diesel is filled with oil and fuel in a closed way;
every three shifts, the oil in the air cleaner sump is changed, the air cleaner center tube is checked and, if necessary, cleaned at each first maintenance;
every three shifts, the electrolyte level is checked and, if necessary, distilled water is added to the batteries;
at TO-1, they check the quality of the oil in the diesel engine and the tension of the tracks and, if necessary, change the oil and adjust the tension;
at TO-2, the fuel tank cap is washed.
3.2. When servicing the tractor at low temperatures, the following conditions are observed:
at ambient temperatures below minus 30 °C, arctic diesel fuel A according to GOST 305-82 and special grades of oils and lubricants recommended by manufacturers are used;
at the end of the shift, the tanks are completely filled with fuel;
condensate from the air cylinders of the pneumatic system is drained;
the diesel cooling system is filled with a liquid that does not freeze at low air temperatures.
3.3. When servicing the tractor on rocky ground, the following conditions must be met:
every shift (visually) check the absence of damage to the chassis and protective devices of the tractor, as well as the fastening of drain plugs of the diesel crankcases, rear and front axles, final drives, drive wheels;
faults found are corrected.
3.4. During maintenance of a tractor operated in high-altitude conditions, the following is changed: the cyclic fuel supply and the performance of the diesel power system pump in accordance with the average height of the tractor above sea level.
3.5. When servicing the tractor on swampy soils, the following conditions must be met:
every shift check and, if necessary, clean the outer surface of the cooling and lubrication systems from dirt;
when working in the forest, the tractor is cleaned of logging residues;
after overcoming water obstacles or wetlands, the presence of water in the power transmission units and the running system is checked, and if found, oil is replaced in the water sludge.
4. List of checks during resource diagnostics:
to determine the need for a major overhaul of the tractor - check the condition of the crank group of the diesel engine;
general condition of the cylinder-piston group of the engine;
general condition of the power transmission;
to determine the tractor's need for scheduled current repairs, check: the general condition of the starting engine;
technical condition of the main clutch and rotation clutches;
technical condition of the main gear, gearbox, power take-off shaft drive;
wear of caterpillar chains or tires;
technical condition of the bearing units of the tractor running gear;
technical condition of oil pumps of hydraulic systems of the linkage mechanism, steering, gearbox, power take-off shaft;
operability of the distributor and power cylinders of the hydraulic system (testing);
performance of electrical equipment.
APPENDIX 2 (recommended). EXAMPLE LIST OF OPERATIONS BY TYPE OF MAINTENANCE OF MACHINES
EXAMPLE LIST OF OPERATIONS BY TYPE OF MAINTENANCE OF MACHINES
1. Maintenance during operational break-in
2. Shift maintenance [ETO]
2.1. They clean the dust of plant residues and dirt from the outer surfaces of the machine of the working bodies.*
________________
* The text corresponds to the original. - Note "CODE".
They wash and clean the internal cavities of machines from residues of pesticides, mineral fertilizers, aggressive liquids.
2.2. They inspect the machine and its components, check by inspection: the completeness of the machine, the technical condition of the components, the fastening of the joints of mechanisms and fences, the absence of leakage in the joints and seals of oil, fuel, cooling, working and process fluids, the correct * condition of the control mechanisms, brake system, lighting and signaling systems, correct adjustment of working bodies and other systems of the machine, correct aggregation of trailed, mounted and semi-mounted machines with a tractor.
________________
*Probably an original error. It should read "correct". - Note "CODE".
2.3. They check the level of working and cooling liquids in crankcases, boxes, containers and bring them up to the standards established in the operational documentation.
2.4. Carry out the necessary adjustment work depending on the condition of the machine.
2.5. Lubricate the components of the machine in accordance with the table and lubrication scheme.
3. First maintenance [TO-1]
3.1. They clean the external surfaces, working bodies and internal cavities of the machine from dust, plant residues and dirt.
3.2. They wash and clean the internal cavities of machines from residues of pesticides, mineral fertilizers, aggressive liquids.
3.3. They clean and wash filters and sumps of oil, fuel, working and process fluids.
3.4. They clean oxidized battery terminals, wire lugs and other electrical equipment.
3.5. They check by inspection: the completeness of the machines, the fastening of the joints of mechanisms and fences, the absence of leaks in the joints and seals of oil, fuel, cooling, working and process fluids, the tension of chains and belts in gears.
3.6. They check by inspection, by testing in operation and using simple diagnostic devices: the technical condition of the working bodies and the main components of the machine; correct aggregation of trailed, mounted and semi-mounted machines with a tractor; good condition of control mechanisms, braking system, lighting and signaling; diesel engines for self-propelled machines and diesel engines for driving working bodies.
3.7. They check the air pressure in the tires of the wheels of the machines, the level of working and cooling liquids in the crankcases, boxes, electrolyte containers in the batteries and bring them to the standards established in the operational documentation.
3.8. Adjust the working bodies and the main components of the machine using simple control devices.
3.9. Lubricate the components of the machine according to the table and lubrication chart.
4. Second maintenance [TO-2]
4.1. They clean the external surfaces, working bodies and internal cavities of the machine from dust, plant residues and dirt.
4.2. They wash and clean the internal cavities of machines from residues of pesticides, mineral fertilizers, aggressive liquids.
4.3. They clean and wash filters and sumps of oil, fuel and process fluids, air cleaners, replace, if necessary, lubricants in lubrication units.
4.4. They clean oxidized battery terminals, wire lugs and other electrical equipment.
4.5. Check by inspection: completeness of machines; lack of leakage in the joints and seals of oil, fuel, cooling, working and process fluids; tension of chains and belts in gears.
4.6. They check by testing in operation and using diagnostic and control tools: the technical condition of the working bodies and the main components of the machine, the fastening of the joints of mechanisms and fences, the serviceability of the lighting and signaling of the engines of self-propelled machines and engines for drives of the working bodies.
4.7. Check the air pressure in the tires of the wheels of cars; the level of working and cooling liquids in crankcases, tanks, electrolyte in batteries, replace them (if necessary) and bring them up to the standards established in the operational documentation, check the density of the electrolyte and, if necessary, recharge the batteries.
4.8. They regulate the working bodies and complex components of the machine with their partial disassembly and using control installations.
APPENDIX 3 (recommended). MAINTENANCE PLAN FOR TRACTORS
APPROVE:
Ch. engineer | |||
(company) |
SCHEDULE FOR PERFORMING MAINTENANCE OF TRACTORS FOR ____________ MONTH 19
Number | Tractor brand | State registration number | Indicator type | Types of maintenance (in the numerator) and frequency (kg, l, engine hours) of its performance (in the denominator) by the days of the month |
|||||||||||
Planned | |||||||||||||||
Actual | |||||||||||||||
Planned | |||||||||||||||
Actual | |||||||||||||||
Planned | |||||||||||||||
Actual | |||||||||||||||
Planned | |||||||||||||||
Actual | |||||||||||||||
Planned | |||||||||||||||
Total number | Actual | ||||||||||||||
Planned | |||||||||||||||
Actual | |||||||||||||||
Seasonal: | Planned | ||||||||||||||
TO-OZ, TO-VL | Actual | ||||||||||||||
Responsible executor _____________
APPROVE:
Ch. engineer _______________
Maintenance record (date) |
|||||||||||||||||||||||
But- | Tractor brand | Tractor number | Type and date of settlement | Operating time from pos- | Planned operating time (kg, l, engine | ||||||||||||||||||
The text of the document is verified by:
official publication
M.: Publishing house of standards, 1987
Justification of the frequency of maintenance is a complex task related to the field of multicriteria optimization. Several particular criteria have been identified by which the frequency of maintenance can be established: the maximum productivity of the machine, the average time between failures, the minimum unit operating costs, the minimum probability of failure, and a number of others.
Currently, the justification for the frequency of maintenance is not completely algorithmized and does not have a standard methodology. The frequency of maintenance is based on the use of these particular criteria, taking into account the operating experience of the machines and the accumulated statistical data on their performance.
When testing and operating equipment, its failures are analyzed, grouped by frequency and complexity, average indicators are calculated for each complexity group and confidence limits for failure-free operation intervals. Thus, maintenance intervals and lists of technological operations can be obtained, which are refined using the listed technical and economic criteria.
The frequency of numbered maintenance is established by GOST 20793 - 86.
The frequency of maintenance of tractors and combines is set in engine hours developments. Hours may be defined in other units that are equivalent to hours, such as liters (kg) used fuel or conditional reference hectares (cond. et. ha).
This maintenance system was introduced for tractors manufactured in 1982 and later. Prior to this, the maintenance system operated with a frequency of 60; 240 and 960 motor-hours for the corresponding license plates TO-1, TO-2 and TO-3. The new system was introduced in connection with an increase in the technical level of tractors. The introduction of the new system reduces the number of tractors for maintenance by 2 times and reduces the overall labor intensity and consumption of materials by 20 ... 30%.
Allowed actual periodicity deviation(advance or delay) TO-1 and TO-2 up to 10%, TO-3 up to 5% of the set value.
The frequency and conditions of maintenance of tractors are presented in the table.
Periodicity and conditions for maintenance of tractors
|
Periodicity, conditions for maintenance |
|
|
Presale |
In preparation for sale by dealerships (1 time per service life) |
|
During operational run-in |
During the preparation, conduct and completion of the run-in |
|
After 8 ... 10 moto-hours |
|
|
After 125 moto-hours |
|
|
After 500 moto-hours |
|
|
After 1,000 motor hours |
|
|
At a steady average daily ambient temperature above 5 °С |
|
|
At a steady average daily ambient temperature below 5 °С |
|
|
Under special operating conditions |
When operating in desert and sandy soils; at prolonged low and elevated temperatures; on stony soils; on swampy soils |
|
When preparing for long-term storage During long-term storage When removed from long-term storage |
No later than 10 days after the end of use 1 time per month - when stored in open areas and under a canopy; 1 time in 2 months - when stored indoors 15 days before use |
General provisions. The performance of agricultural machines is determined by rational operation, which includes their intended use and a set of maintenance, repair, storage and transportation works.
Regulations are set out in the Comprehensive System for the Maintenance and Repair of Machinery in Agriculture. Repair and maintenance impacts according to this system provide for maintenance (TO) and rrmort "carrying out kotyarakh allows you to get: the necessary technical condition and performance of the machine during the entire period of operation.
Maintenance- a set of operations or an operation to maintain the operability or serviceability of the machine when used for its intended purpose, storage and transportation. It includes cleaning, control and diagnostic, adjustment, lubrication, refueling, fastening and running-in work, conservation, and elimination of minor malfunctions.
Repair- a set of operations to restore the serviceability or operability of the machine and restore its resource or components.
Storage- a set of organizational and technological measures that provide protection against corrosion, aging and dismantling.
Transportation- time of movement without use for its intended purpose.
Types and frequency of maintenance of machines. When using machines, the following types of maintenance are provided: every shift (EJU), scheduled (TO-1, TO-2, TO-3), seasonal (Table 1).
Every shift maintenance is carried out after 8.10 hours of operation of the tractor or machine.
Seasonal maintenance of tractors and vehicles is carried out 2 times a year: before the beginning of the spring-summer and autumn-winter periods of operation.
Table number 1. Frequency of scheduled maintenance
* Figures in parentheses are for tractors, the decision to start production of which was made after January 1, 1982.
** The frequency is given for the third category of road conditions.
The frequency of maintenance of tractors is allowed to be determined by the amount of fuel consumed or in conditional reference hectares (c.s. ha), combines and agricultural machines - in physical hectares (physical ha). The coefficients for the conversion of units of operating time are given in appendices 1 and 2.
The frequency of vehicle maintenance in table 1 is given for the third category of road operating conditions. The characteristics of other road conditions are given in Appendix 3. The frequency standards for them are corrected using correction factors (Appendix 4).
Maintenance of tractors in use. It consists of the following processes. Daily maintenance. NTO consists of external inspection, cleaning and checking of fuel and oil leaks, oil level in the engine crankcase and coolant in the radiator; operation of control devices; lighting devices; alarms; brakes, as well as testing the tractor on the go.
First maintenance. TO-1 includes STO operations and additionally: air cleaner and battery control; draining sludge from fuel and oil coarse filters; checking the oil level in all tanks and lubricating points in accordance with the lubrication chart.
Second maintenance. TO-2 contains the operations of TO-1 and additionally: inspection and verification of the valve mechanism of the engine, clutch, steering control mechanism, brake system and running gear; oil change in tanks according to the frequency; flushing the engine lubrication system; checking the fastening of the components of the tractor and the engine.
Third maintenance. TO-3 includes resource diagnostics, which makes it possible to determine the need for repair or maintenance of tractor components. At TO-3, TO-2 operations are carried out and additionally check and adjust the main engine systems (power supply, lubrication, ignition, etc.), transmission and chassis units, hydraulic system, pneumatic system, electrical equipment https://a-contract.ru. Check the operation of all tractor mechanisms in motion.
Seasonal maintenance. It contains the following operations: replacing the coolant, oil grades, connecting (or disconnecting) the heater and radiator of the lubrication system, bringing the electrolyte density to the seasonal norm, installing (or removing) insulating covers.
Maintenance of tractors in special operating conditions. This service is designed to prepare the tractor for operation in desert and sandy soils, low and high temperatures, stony and swampy soils, and high mountains.
Maintenance of combines and self-propelled machines when using. It is divided into the following types. Daily maintenance. ETO consists of an external inspection, cleaning the air cleaner and checking for oil and water leaks; refueling the car with fuel, oil and water, testing on the go.
First maintenance. TO-1 includes ETO operations and additionally: maintenance of the fuel and engine oil cleaning system, valve mechanism, machine working parts (cutting and threshing devices, transport devices, etc.); checking and adjusting chain and belt drives, safety clutches, clutches, steering and brakes.
Second maintenance. TO-2 contains the operations of TO-1 and additionally: checking the engine performance by diagnosing; maintenance of power supply systems, lubrication, brake, electrical equipment and hydraulic systems.
Car maintenance. This type of service includes processes similar to those of the same name for tractors.
Daily maintenance. The STO contains operations similar to those carried out during the STO of tractors.
First maintenance. TO-1 includes ETO operations and additionally: maintenance of power supply and ignition systems; engine oil change; checking the oil level in all tanks and topping up if necessary; maintenance of the battery, fuel and oil filters; lubrication of points in accordance with the lubrication map.
Second maintenance. TO-2 contains the operations of TO-1 and additionally: checking the performance of the engine and other components of the car using diagnostics; control and maintenance of electrical equipment, lighting and signaling devices; check steering, brakes and running gear.
Seasonal maintenance. This includes operations similar to those for tractors.
Maintenance of tractors and agricultural machines during storage. In the system of maintenance and repair of machines, the following types are provided. Service in preparation for long-term storage. It is carried out no later than 10 days after the end of the use of the machine.
In preparation for storage, the machine is cleaned, delivered to the storage site, and the components to be stored in warehouses are removed. Then the cavities and openings are sealed from the penetration of moisture, dust, the surfaces of the working bodies are preserved, the damaged paintwork is restored, the machine is installed on supports (linings).
Service during long-term storage. It is carried out once a month when stored outdoors and under a canopy, and once every two months when stored indoors.
During storage, the correct installation of the machine on stands, completeness, reliability of sealing, and the condition of anti-corrosion coatings are checked.
Service when removed from long-term storage. It is carried out 15 days before the start of use.
When removing the machine from long-term storage, the machine is removed from the stands, the previously removed components are cleaned, reactivated and installed on the machine, anti-corrosion coatings are washed off the working bodies. If corrosion is detected, it is removed and the damaged areas are touched up. Check the operation of the machine on the go and make the necessary adjustments.
Types and frequency of car repairs. The performance of machines is restored in the process of current or major repairs. Current repair (TR). Typically, maintenance is performed while the machine is in operation to restore its performance. It consists in the replacement or restoration of individual faulty components. At the same time, faulty components can be replaced with repaired or new ones, if other main parts still retain a significant residual resource.
The current repair of tractors can be scheduled, which is carried out after 1700 ... 2100 moto-hours of operation according to the results of preliminary resource diagnostics, and unscheduled in order to eliminate the consequences of failures or preventive work, the need for which is established when using the tractor.
The current repair of combines is carried out after the end of the harvesting season based on the results of technical diagnostics; unscheduled repairs are performed to eliminate the consequences of failures or preventive work.
The current repair of agricultural machinery consists of scheduled and unscheduled repairs, which are carried out after the field work season.
The current repair of cars is not regulated by frequency, and it is carried out to ensure and restore performance (as needed or for preventive purposes).
Capital repairs (CR). This type of repair is designed to restore serviceability and full or close to full life of the machine by replacing or restoring any components, including basic ones. A distinction is made between the overhaul of a machine and the overhaul of components.
Overhaul includes cleaning, disassembly, flaw detection, replacement, repair or restoration of parts, assembly, adjustment, running-in, painting and testing. The level of resource recovery should be at least 80% of the performance of new machines.
The frequency of overhaul of tractors, combines and trucks is given in appendices 5, 6 and 7.
The need for major repairs is determined on the basis of resource diagnostics.
The structure of the repair cycle for machines used in agriculture is shown in Figure 1.
Organization of work and means of maintenance of the machine and tractor fleet depend on the type and location of maintenance. Organization of maintenance of machines. Maintenance operations are performed by specialized personnel.
The tractor driver (machine operator) carries out daily maintenance of the machine and eliminates simple malfunctions.
The foreman and machine operator perform TO-1, TO-2 and seasonal maintenance.
The foreman and locksmith carry out daily maintenance of combine harvesters and complex machines, especially when they are used in groups.
A foreman and a master diagnostician with a machine operator carry out TO-3 tractors.
Malfunctions found during numbered technical services are eliminated by the master adjuster if the duration of the repair work is no more than 2 hours. Complicated defects are eliminated by repairmen with the participation of a machine operator.
The workers of machine yards, with the involvement of machine operators, perform maintenance during the storage of machines.
Depending on the complexity of maintenance, it is carried out at one of the following levels:
- the first level - the place of work of the machine (more often field conditions);
- the second level - brigades, departments of farms or mechanized detachments;
- third level - central repair shops (CRM) of farms;
- fourth level - repair and technical enterprises (RTP) of district or inter-farm associations.
At the first level, ETO or TO-1 is carried out, at the second - TO-1, TO-2 and seasonal maintenance, at the third - TO-3, at the fourth - TO-2 (partially - 30 ... 50%) and TO-3 energy-saturated tractors such as "Kirovets", T-150 and M'GZ-80.
Maintenance at the first level is carried out using mobile facilities * on the rest - stationary facilities, which are equipped with maintenance points and stations.
Mobile maintenance facilities. These include maintenance units, mobile diagnostic units and mobile repair shops.
Maintenance units (ATO) are designed for carrying out in the field: external cleaning of machines; refueling with lubricants and coolant; wheel tire inflation and air purge of radiator cores; lubrication of bearings with grease; checking and adjusting individual mechanisms of machines and eliminating minor faults.
For agriculture, ATO-9966G units are produced on the chassis of the GAZ-66-01 car, ATO-9966E on the GAE-53-12-01 chassis, ATO-4822 on the G'AZ-52-01 chassis, ATO-9993 on the self-propelled chassis T -16M and ATO-1500G on the chassis of the trailer 2PTS-4M.
The mobile diagnostic unit based on the chassis of the UAZ-422D vehicle is equipped with the KI-13905M kit, which is designed to diagnose tractors during TO-3 and combine harvesters after the working season. The number of serviced tractors is 180, grain harvesters - 40, attendants - 2 people. A similar set of KI-13925 is placed in the van of the Moskvich IZH-2142.
Mobile workshops are designed to troubleshoot tractors and agricultural machines in the field. They are equipped with diagnostic equipment for monitoring some units of power systems, lubrication and electrical equipment and technical equipment for drilling, grinding, tinsmithing, soldering and electric gas welding.
The industry produces mobile repair shops MPR-3901, MPR-9924 and MPR-817M. Two service technicians service up to 100 tractors.
Stationary maintenance facilities. They are produced in special kits designed to work in conditions of various levels.
Sets of equipment: KSTO-1 is designed for maintenance under conditions of the second level, KSTO-2 - the third level and KSTO-3 - the fourth level (Table 2).
Diagnostic electronic units KI-13940 and KI-13950 are designed for diagnosing tractors of all brands at service stations. The settings allow you to determine the technical condition of the tractor units, automatically process the measurement results, register them, compare them with the permissible values and print the results or display them. Full diagnostics of Kirovets tractors
Table number 2. Composition of sets of stationary maintenance facilities (KSTO)
| Name | Equipment brand | Number included | ||
| KSTO-1 | KCTO-2 | KCTO-3 | ||
| Fuel filling station novka or column |
03-9936 KER-40-1.0 |
1 | 1 | 1 |
| Washing machine | 03-1769 OM-ZZbO OM-5285 OM-5359 |
1 | 1 | 1 |
| Lubrication unit and gas stations |
0З-9902 03-4967 |
1 | 1 | 1* |
| Sm washing machine face system |
OM-2871 | 1 | 1 | 1 |
| Set of equipment of the master - serviceman |
ORG-4999 ORG-4999L | 1 | 1 | 1* |
| Compressor | M-155M-2 | - | 1 | - |
| Set of diagnostic funds |
KI-13919A KI-13910 | - | 1 | - |
| Set of control and change measuring instruments |
KI-13920 | - | 1 | - |
| Stand for diagnosing wheeled tractors |
KI-8948 | - | - | - |
| diagnostic kit | KI-13920 | - | - | - |
| Stand for diagnosing cars |
KI-8930 KI-8960 KI-8935 |
- | - | - |
* Quantity depends on the number of machines served.
Equipment for maintenance of machines during storage. Basically, these are installations for applying all kinds of anti-corrosion materials (lubricants).
Installation 03-9995 is designed for cleaning surfaces and applying anti-corrosion coatings. Its units are mounted on a four-wheeled trolley and include tanks for washing liquid, paintwork and conservation materials, an electric compressor, an electrical cabinet and a control panel.
Installation 03-4899 is designed for applying plastic anti-corrosion coatings on the surface of machine parts.
Apparatus-pulverizer 03-9905 is also used for applying anti-corrosion and paint coatings.
The KI-2911 unit is designed to store batteries removed from combines, tractors and cars. It automatically keeps the batteries fully charged. To do this, periodically in automatic mode, the voltage at the battery terminals is monitored and recharging is performed. The installation is used in a specially equipped room. It serves up to 200 type 6 CT batteries, which are placed on special racks.
