Maintenance provides for strictly periodic cleaning, washing, refueling, lubrication, control and diagnostic, fixing and adjustment work. According to the nature and place of execution, maintenance works are divided into:

Guards - performed directly on a car installed at a working post;

Precinct - performed outside the post (in auxiliary production areas);

Related works current repair performed during maintenance (at posts or outside them).

Maintenance work on duty is characterized by a well-defined frequency, nomenclature and labor intensity.

Current repair (according to the definition of GOST 18322--73) is a repair carried out during operation to ensure the operability of the vehicle and consists in replacing and restoring its individual parts and adjusting them.

The work of TR, by nature and place of execution, is also divided into guard, workshop and related maintenance work performed at maintenance posts.

During TR, they also perform copper, welding, tinsmith, electrical, tire repair, wallpaper, painting, fastening and adjustment work, the need for which arises between regular maintenance.

TR works are characterized by a large range of eliminated failures and malfunctions and significant fluctuations in the labor intensity of the work performed. The range of works performed during post repairs contains about 500 items, and the labor intensity of one (according to the nomenclature) post repair ranges from 0.10-15.0 man-hours.

Usually, the need for TR work is identified at the request of the driver, in the areas of diagnosis or maintenance.

Development technological process current repair

The current repair is intended to ensure the operational state of the rolling stock with the restoration or replacement of its individual units, assemblies and parts (except for the basic ones) that have reached the maximum permissible state.

Current repairs should ensure the trouble-free operation of the repaired units, assemblies and parts by mileage at least until the next maintenance of TO-2.

Replacement of repaired units and assemblies and fixing and adjustment work are carried out at the sites serving the cars and trailers assigned to them in accordance with the order.

Repair of units and assemblies in the ATP is carried out at the sites. The document, which is the basis for setting the rolling stock for current repairs, is an application for repairs.

A request for repairs is issued when malfunctions are detected, mainly when the rolling stock arrives from the line, and in other cases, with the permission of the deputy head of the workshop for the technical part.

The control mechanic registers the repair request by serial number for each day in the repair request registration log and issues it to the driver. Informs the operation department about faulty vehicles and trailers in convoys.

The driver, having received the application, performs cleaning and washing works of the rolling stock, submits a record sheet to the foreman of the site and, with his consent, puts the car for repair.

The driver participating directly in the repair, having written out an application for repair, presents it to the convoy dispatcher. Based on the application, the dispatcher writes out a registration sheet for the driver's participation in the current repair. After passing a medical examination and a corresponding mark on the record sheet of the driver's participation in repairs, he presents it to the foreman of the section serving the motorcade.

While being under repair, the driver submits to the foreman of the site (performs work on repairing the car assigned to him or, by order of the head of the ATP, goes to the line in a serviceable car in the absence of the driver of this vehicle).

At the end of the shift, the foreman fills out a registration sheet for the driver's participation in the repair, indicates the amount of work performed by the driver and, according to time standards, sets the number of hours worked per shift.

In the absence of spare parts or a small amount of work on a fixed car, the master has the right to transfer the driver to repair another car of the same convoy. In this case, the driver is transferred to a time-paid job.

Remuneration of drivers involved in repairs is made according to the tariff rate of repair workers.

The record sheet for the participation of drivers in repairs is the main document for payment to the driver, which, after registration by the site foreman, is handed over to the dispatcher daily.

After the repair is completed, the foreman of the site (foreman) writes down the name of the work performed in the appropriate section of the application and transfers it to the control mechanics.

Having received a record sheet with a note on the completion of work, the control mechanic checks the technical condition of the vehicles when they are released onto the line, after which he makes a mark on the departure to the waybill, and if faults are found, the car is sent back to the repair sites to eliminate the detected faults.

All applications are daily, at the end of the production of cars, are transferred by the mechanic from the control point to the repair engineer for processing and storage.

The work carried out on the lift in the TO and TR zone includes the following disassembly and assembly operations, repair operations without parts restoration elements, i.e. replacement of faulty units, mechanisms and components of the car with serviceable ones, replacement of faulty parts in them with new or repaired ones.

Routing

As an example, we give guard work on the lift for disassembling the rear axle during maintenance and repair of the KamAZ 5320 car.

Table 4.1

Technological map for dismantling the rear axle of a KamAZ car

The technology of work on the designed lift has been developed and is tied to the general system of maintenance and repair. A technological map has been drawn up for carrying out on-site work on the lift for disassembling the rear axle during maintenance and repair of the KamAZ 5320 car.

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 to develop maps of sentries and 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 most simple and 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 design car), 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 for more early stages TP development.

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, operation and capabilities of the used technological equipment, fixtures and tools, 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

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 replacement 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. Removal trolley 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 appliances:

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. Tester fuel pumps 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

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 units rear suspension 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 appliances;

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 replacement rear axles and gearboxes of GAZ, ZIL cars

• 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 appliances;

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

Special post SP-19 for the replacement of frames of GAZ, ZIL cars

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

Fuel equipment shop (diesels)

Electrical shop

Battery section

Mednitsky workshop

Tire shop

Vulcanization shop

paint shop

wallpaper shop

Forging shop

Welding and tinsmith shop

Page 1

The total labor intensity of the VAZ-2110 is 5.04 man-hours.

Popular materials:

Industrial hazards and measures to reduce them
Working conditions are a set of production factors that affect the health and performance of a person in the process of work. These factors are different in nature, forms of manifestation, effect on a person, etc. Among them, a special gr...

Organization of release and return of rolling stock to the fleet
In modern ATP, the production of cars on the line should be given Special attention. Services, drivers, dispatchers, shift mechanics, etc. participate in the production of cars. A clear organization and timely delivery depend on coordinated work...

Calculation of linear dimensions and determination of the main dimensions of the cart
We take the linear dimensions by analogy (trolley 18 - 578). Picture 1 - Trolley two-axle model 18 - 578 - track width: 1520 mm; - trolley base: 1850 mm; The distance from the level of the rail heads to the level of the bearing surface of the thrust bearing...

TECHNOLOGICAL CHARTS FOR MAINTENANCE AND REPAIR OF KAMAZ VEHICLES (1989)

Introduction
Technological maps for the current repair of units were developed by Tsentravtotekh of the Ministry of Autotransport of the RSFSR at the request of the KamAZavtotsentr manufacturing company of the KamAZ production association.

Technological maps are developed on the basis of the following materials:

1. Regulations on maintenance and repair of rolling stock road transport. Part 1 (guiding).

2. Regulations on the maintenance and repair of rolling stock of road transport. Part 2 (normative). Cars of the KamAZ family. According to-200-RSFSR-12-0115-87.

3. Operation manual for KamAZ vehicles type 6x4 (5320-3902002Р7).

4. Operation manual for KamAZ vehicles type 6x6 (4310-3902002RE).

5. Guidelines for the current repair of cars KAMAZ-5320, KAMAZ-5511, KAMAE-4310 (shop work). RT-200-15-0066-82.

6. Catalogs and drawings of parts and assembly units KamAZ vehicles.

When developing technological maps, equipment, instruments and tools, mass-produced by Rosavtospetsoborudovaniye plants and non-standardized equipment, including those developed at KamAZ, were used.

Technological maps contain standards for the labor intensity of work, agreed with the "Centro-rgtrudavtotrans" of the Minavtotrans of the RSFSR.

Technological maps have been experimentally tested.

Technological maps are typical. In each individual case, it is necessary to link them to the specific conditions of enterprises.

The nomenclature of repaired units, components, mechanisms and devices is selected based on the characteristic and most common works on the current repair of KamAZ vehicles at enterprises.

The list of technological maps includes the repair of: engine, fuel equipment, gas equipment, electrical equipment, pneumatic equipment of the brake system, dump mechanism, transmission.

To facilitate the reading of technological maps, they contain diagrams, drawings.

The technological maps provide a complete list of disassembly, assembly and troubleshooting operations. Under operating conditions, the depth of disassembly and the amount of troubleshooting can be carried out until a defect is detected.

When organizing and performing work on the current repair of units, assemblies, mechanisms and instruments, it is necessary to be guided by the system of labor safety standards and the “Safety Rules for Road Transport Enterprises”.

The current repair of units, assemblies, mechanisms and devices must be carried out in the workshops or sites intended for this.

When disassembling units, assemblies, mechanisms and devices into parts, it is necessary to use pullers and devices that facilitate the work of performers and ensure the safety of work.

Workshops for the current repair of units must be equipped with the necessary lifting and transport mechanisms. It is necessary to transport, remove and install units and assemblies with a significant mass from the stands with the help of lifting and transport mechanisms equipped with devices that protect against a possible fall of units and assemblies.

Devices for fixing units and assemblies on the stands should exclude the possibility of displacement or fall of units and assemblies. Tools and fixtures must be in good condition.

The procedure for carrying out current repairs is set out in technological maps, which reflect the sequence of dismantling and assembly, troubleshooting and testing of units and assemblies, equipment, fixtures and tools, technical conditions and instructions, labor intensity of work and qualifications of performers.

The technological process of the current repair of units should include: cleaning and washing work on the car; identification of faulty units on the car; removal of faulty units from the car; transportation to the workshop; subassembly; external washing (cleaning); disassembly;

washing; cleaning, drying, blowing parts; troubleshooting; picking; assembly; test adjustment; ■ acceptance by quality control department; transportation to the post (warehouse); placing on a car.

Only persons who have been instructed in safety precautions and trained in safe labor practices in special classes organized by the administration of the enterprise are allowed to work on the repair of units, assemblies, mechanisms and devices.

First-aid kits stocked with medicines necessary for first aid should be available in workshops or sites.

For the most rational organization of work on maintenance, repair and diagnostics of vehicles, its units and systems, various technological maps are drawn up.

Based on these technological maps, the scope of work on technical impacts is determined, and the distribution of work (operations) between the performers is also made.

Any flow chart is a guideline for each contractor and, in addition, serves as a document for technical control of maintenance or repair.

The technological map is compiled separately for the type of service (EO, TO-1, TO-2), and within the type of service - by elements.

When developing TP, it is necessary, taking into account the volume of work performed and their repeatability, to strive for the most complete and economically justified mechanization, the all-round reduction of resource, energy and labor costs, and the facilitation of manual labor.

The optimal variant of the technological process of maintenance and repair of cars allows you to get the following benefits:

High labor productivity and quality of work;

Eliminate omissions or repetitions of individual operations and transitions;

Rational use of mechanization;

Perform the required organization and arrangement of workplaces.

2.2 Operating card TO-2 of the KrAZ - 250

The total labor intensity of TO-2 is 16 people ∙ hour (960 people ∙ min)

Map number 1. Control and inspection work.

Labor intensity - 18.65 people ∙ min