The technological process of repair is a part of the production process associated with the implementation of the main work on car repair: disassembling it into units, components, parts; parts repair; assembly, testing and painting; delivery of the car to the customer. These works are performed in a certain sequence in accordance with the technological process.

Elements technological process are the following parts.

Operation - a part of the technological process of repair, performed continuously at one workplace, with a certain type of equipment, by workers of the same profession. The operation usually bears the name of the equipment with which the operation is performed. For example, an assembly operation is performed in an assembly shop using assembly equipment by a fitter, etc.

Installation - part of the operation performed on the product when changing its position relative to the equipment, tool. For example, the assembly operation of a car consists of installing the engine, gearbox, etc.

Transition - part of the operation, installation, performed on one section of the product, with one tool operating in the same mode. For example, the engine installation consists of several transitions: engine slinging; lift, move, put the engine on the frame; fasten the engine to the frame.

A passage is one of several transitions that follow each other. For example, the transition - slinging the engine consists of two passes - linking one sling on the engine on one side and securing the other end on the crane hook; the same, but with the second line and on the other side of the engine.

Working technique - part of the transition or passage, which is a complete cycle of working movements. For example, fastening one end of the sling to the engine on one side is one technique, securing the other end of the sling to the crane hook is another working technique.

The working movement is the smallest moment of the operation. For example, to take a detail is a working movement.

The development of the technological process consists in the fact that for each of its elements a description of the content of the work, the necessary equipment, fixtures and tools, the complexity of the work and labor costs are established. All these data are entered into technological maps. Depending on the volume of work performed, a different depth of development of the technical process is established. For small enterprises with a small amount of work, the technical process is developed at the level of operations and installations using universal equipment and tools. The technological map indicates only the order of operations (route technological map). Works are carried out by highly qualified workers.

For service stations with a sufficiently large amount of work, the development of a technological process is carried out at the level of transitions and passages, indicating the content of work for each operation. Works are performed on special equipment (stands) using special devices and tools according to operational flow charts.

The development of the technical process is carried out separately for the maintenance of TO-1, TO-2 and for repair work for current and major repairs.

The largest volume of work performed takes place during the overhaul of cars, which is carried out at specialized car repair plants.

Cars accepted for repair undergo an external washing and go to the dismantling operation. All units are removed from the car frame, the base part, they are cleaned of dirt, oil, disassembled into components and parts. Removed parts are sorted into fit, unusable and in need of repair. Suitable parts are re-assembled, unusable parts are sent for scrap, parts that require repair are restored and sent to assembly units. The nodes are assembled into units, the units are again installed on the car frame. The assembled car is tested and handed over to the customer.

It is important to note that the development of the technological process for conducting current repair with the peculiarity that in this case the number is smaller and they are performed in a smaller volume.

Scheme of the technological process of repair

The technological process of repairing electrical equipment consists of the following stages of work.

1. External cleaning. It is usually carried out with a dry or lightly moistened wiping cloth in kerosene. Batteries clean well with a warm or hot soda ash solution or hot water.

2. External examination. At this stage, a preliminary assessment of the state of electrical equipment units is given. Inspection of the generator, starter is carried out with the protective tape removed, which allows you to assess the condition of the collector and brushes.

Relay-regulators, signal relays and other relays are inspected with the cover removed.

3. A preliminary check is carried out using control equipment and stands for finding out electrical defects. Generators are checked for speed at rated voltage no load and full load, as well as in electric motor mode. Starters and electric motors are checked in the mode idle move, fixing the consumed current and the frequency of rotation of the armature shaft, distributors and ignition coils for uninterrupted sparking, etc. Taking into account the identified defects, they begin to repair, which can be made about partial or complete disassembly.

4. Disassembly into units and parts. To prevent damage to parts and reduce the time for disassembly, it is necessary to use tools and devices specially designed for these works (pullers, socket wrenches, press screwdrivers, etc.), and in the conditions of specialized production, mechanical disassembly tools (nutrunners, specialized disassembly stands and etc.). Parts are placed on a rack or in a special container.

It should be borne in mind that in the conditions of specialized production (workshops, car repair enterprises), where repairs are carried out by an impersonal method, the work listed in paragraphs 1, 2, 3 is not performed, but immediately proceed to disassemble the electrical equipment units received for repair.

5. Cleaning and drying parts. Washing is carried out with hair brushes in gasoline or kerosene in washing bathtubs placed with exhaust hoods with fuel vapor suction. In the conditions of specialized production, it is advisable to use a machine wash using washing solutions. It is desirable to dry the parts in a stream of hot air at temperatures up to 110°C.

Felt and felt protective seals for bearings and lubricating wicks are washed in clean gasoline, followed by squeezing.

Parts with windings are wiped with a cleaning cloth soaked in gasoline, followed by blowing with compressed air.

6. Control of the condition of components and parts is carried out by an external

inspection or special equipment and tools. Electric

the insulation strength of the windings is checked under voltage 220-

As a result of checks in accordance with the technical specifications, parts and assemblies are sorted into those suitable for further use without repair, requiring repair and unusable.

7. Repair of components and parts, including rewinding of windings and replacement of insulation.

8. Assembly of units and devices is carried out in accordance with the technical specifications, followed by running-in of bearings, brushes and other mates.

9. Control tests make it possible to determine the quality of repair and assembly, as well as to obtain data characterizing the reliable operation of the unit or electrical equipment in the future.

10. Adjustment is made in accordance with the technical specifications for a specific model of the unit or device.

11. Painting the outer surface of electrical units and devices is necessary to update the type of products released from repair.

Repair and maintenance of the engine

Examination technical condition engine on a car

Checking the technical condition of the engine includes checking its power, economy, oil consumption (burnout), compression in the engine cylinders, noise of its operation and toxicity of exhaust gases.

Engine power is checked by changing the dynamic qualities of the car - by reducing top speed, as well as acceleration dynamics. The maximum speed and dynamics of acceleration are determined as a result of road tests with a fully functional running gear. The serviceability of the running gear of the car is determined by the run-out of the car, that is, by the distance that the car travels in neutral gear from a speed of 50 km / h to a complete stop. The maximum speed and acceleration time are determined on a control section of the road 1 km long.

All road tests are conducted with the engine fully warmed up on a level, straight stretch of road with a smooth asphalt or concrete surface, with two people in the car, including the driver, in dry weather and in the absence of strong winds.

The run-out of the car is determined by two races in mutually opposite directions as the average of the two values ​​in compliance with the above conditions. Overrun passenger car usually at least 400 m.

The maximum speed of the car is determined with its preliminary acceleration to the maximum speed in the highest gear to the beginning of the measured section (1 km) based on the results of passing the measured section at maximum speed in two mutually opposite directions. In this case, the time t of the passage of a section of 1 km in seconds is measured, according to which the maximum speed v is determined by the formula v =3600/t. For the actual value of the maximum speed, the arithmetic mean of the speeds obtained from the results of two races in mutually opposite directions is taken.

The dynamics of the car's acceleration is determined by the acceleration time to 100 km/h or by the time it takes to travel 1 km from a standstill with intensive acceleration of the car with sequential and fast gear shifting also in two races in mutually opposite directions.

The values ​​obtained as a result of road tests are compared with the passport data of the car. A decrease in maximum speed by 10...15%, as well as an increase in acceleration time by 20...25%, indicate insufficient engine power and the need for a more detailed check of its condition in order to determine the causes that caused the decrease in power and eliminate them.

Removal and installation of the engine

The removal of the engine from the car is carried out, as a rule, if it is necessary to replace or repair parts of the crank mechanism - the cylinder block, its liners, parts piston group (piston rings, pistons, piston pins), when repairing or earthing the crankshaft and its main and connecting rod bearing shells, except for the cylinder head, head cover, oil pan and their gaskets. The need to remove the engine from the car for repair is determined by the results of checking its technical condition.

Due to the fact that the engines of the vehicles under study are structurally integrated with the gearbox and clutch into a single power unit, which is attached to the car body on shock-absorbing supports, if it is necessary to repair the engine, it is usually more convenient to remove the entire power unit from the car (except for the A3LK-2141 car with VAZ-2106 engine, in which the gearbox assembly with the clutch housing is first removed, and then the engine itself is removed).

To remove the power unit, the car is installed on a viewing ditch or lift, and after disconnecting the engine from the body, the power unit is removed from engine compartment up using a hoist or any other lifting device with a load capacity of at least 200 kgf.

On the front wheel drive vehicles removal of the engine from a motor compartment downwards is possible. In this case, one lift is used without a lifting device, and the engine, after disconnecting it from the body, is installed on a special trolley brought under the car standing on the lift.

Depending on the layout and design features power units on the vehicles under study, the sequence and technology for performing individual work on their removal and installation may vary somewhat, however, the general procedure for performing these works is approximately the same for all the vehicles under consideration and is given below.

1. Remove the hood (the hood does not need to be removed if the power unit is pulled down).

2. Drain the oil from the engine (see the section "Repair and maintenance of the lubrication system").

3. Drain the coolant (see section "Repair and maintenance of the cooling system").

4. Disconnect the engine cooling system hoses going to the radiator and heater.

5. Disconnect the electrical wires from the battery, generator, starter, ignition coil, carburetor EPHH, sensors and switches.

6. Disconnect the hose from vacuum booster brakes.

7. Disconnect the fuel supply hoses to fuel pump and a fuel bypass hose from the carburetor.

8. Disconnect the air and throttle valve carburetor.

9. Detach cable drive or clutch slave cylinder.

10. Disconnect the muffler exhaust pipes.

11. Disconnect the front wheel drive (on front-wheel drive vehicles) or cardan transmission (for vehicles with a classic layout) and close the hole in the universal joint yoke in the gearbox with a plug.

12. Disconnect the gearbox from the gear lever and disconnect the flexible speedometer drive shaft from it.

13. Attach the engine to a lifting device.

14. To turn away fastenings of the engine to a body.

15. Remove the engine complete with clutch and gearbox.

Installing the engine on the car is carried out in the reverse order of its removal.

Engine disassembly

Disassembly of the engine is carried out after its external cleaning and washing on a special stand that allows you to turn the engine to ensure the convenience of disassembly and assembly work. In order to ensure high quality subsequent assembly of the engine and not to disturb the balance of its parts, it is necessary to install suitable parts in their previous, run-in places. To do this, during disassembly, parts are marked without damage by punching, paint, tags or inscriptions. These parts include liners, pistons, piston rings, pins and connecting rods with caps, crankshaft and flywheel, flywheel and clutch, cylinder block and main bearing caps and flywheel housing.

Engine disassembly has approximately the same sequence for all engines under study and is performed in the following order. If the power unit was removed from the car, then before disassembling the engine, the starter, gearbox with clutch housing and clutch must be removed.

Remove the ignition system devices (distributor or ignition distribution sensor, its drive, wires high voltage, candles) and a generator.

Disconnect the hoses of the power supply and engine cooling systems, remove the fuel pump, carburetor, fan, liquid pump, thermostat.

Remove the oil level indicator and the tube into which it is inserted, remove the oil filter.

Remove the alternator drive pulley from the crankshaft toe by blocking the flywheel with a locking pin and unscrew the pulley mounting bolt.

Unscrew the front cover and, having disconnected the tensioners, remove the timing belt or timing chain.

Remove the intake and exhaust pipes, head cover and cylinder head with gaskets.

Turn the engine over with the crankcase up and remove the oil sump with gasket, oil pump and oil receiver. Remove the connecting rod covers by unscrewing the nuts of their fastening bolts, and carefully, so as not to damage the mirror (working surface) of the cylinders, remove the connecting rods with pistons through the cylinders and mark the connecting rod covers with connecting rods for their subsequent correct assembly.

For engines with removable liners (UZAM-331, -412), pistons with connecting rods are pushed out of the block along with liners, and then removed from the liners through the lower part of the sleeve, which makes it possible not to drag the connecting rod through the sleeve and avoid possible scratches on its surface. If it is not possible to remove the piston with the connecting rod along with the sleeve, then first the piston with the connecting rod is removed through the sleeve, and then the sleeve is removed using a puller. If it is not necessary to remove the liners, then they are fixed in the block with the help of clamp bushings (Fig. 204), and the pistons with connecting rods are removed, as usual, through the cylinders. If the sleeves are not fixed, then when removing and installing the pistons, they can move out of place and, at the same time, their seal in the block will inevitably be violated.

Rice. 204. Fastening sleeves with sleeves-clamps

Remove the main bearing caps together with the lower shells, remove the crankshaft, and then the upper main bearing shells and thrust washers for axial fixation of the crankshaft.

Press the gearbox input shaft bearing out of the crankshaft using a special screw or impact extractor (Fig. 205).

Rice. 205. Puller for pressing the bearing out of the crankshaft:

1 - capture; 2 - bearing; 3 - hairpin; 4 - striker; 5 - handle

Disassemble the parts of the connecting rod and piston group: remove the piston rings using a special tool (Fig. 206), the antennae of which must be inserted into the gap of the lock of the ring to be removed and, squeezing the puller handles, unclench the ring and remove it from the piston.

Rice. 206. Removing the piston rings from the piston with a puller

Remove the retaining rings from the grooves of the piston bosses and press out the piston pin using a press with a mandrel or a special screw extractor (Fig. 207) or knock out the piston pin with hammer blows through a brass mandrel with preliminary heating of the piston in water to 60 ... 85 ° C (except VAZ engines, on which the pistons are not heated). If the parts of the connecting rod and piston group are slightly worn and can be reused, they must be marked and installed during subsequent assembly in their original places.

Rice. 207. Pressing the piston pin out of the piston with a puller:

1 - piston; 2 - piston pin; 3 - mandrel; 4 - bolt

Conclusion

The purpose of the control work is planning the rational use of resources on the example of service stations. The solution to this problem is feasible under the condition of many factors, the main of which are the economic situation and the competitive environment. A clear understanding of the purpose, location, capacity, as well as its compliance with modern operating requirements road transport will lead to an increase in the efficiency of capital investments.

List of used literature

1. Bashkatova A.V. Formatting a text document: Methodical development. - ATEMK2. MP0703. 001 - St. Petersburg: 2008 - 28s. /Administration of St. Petersburg. Committee on science and higher education. Automotive and Electromechanical College.

2. Epifanov L.I., Epifanova E.A. Maintenance and repair of motor vehicles - M .: Infra-M, 2007.

3. Regulations on the maintenance and repair of the rolling stock of road transport - M .: Transport, 2007.

4. Rumyantsev S.I., Car repair - M .: Transport, 2009.

5. Kramorenko N.A., Vehicle maintenance: A textbook for motor transport technical schools. - M.: Transport, 2007.

When organizing maintenance and repair processes, technological maps are widely used, which determine the rational use of working time and jobs, compliance with quality requirements, ensuring the synchronization of posts, etc.

At the ATP, two types of technological maps are usually used: operational and technological and sentry.

Operational flow charts contain a list of work performed at this post at each workplace. The numbers of operations from the operational-technological cards correspond to the serial number of the operations of the sentry cards. Technological cards developed in the enterprise or adopted based on reference data.

Reducing the scope of maintenance work is unacceptable. It is also unacceptable to perform work on TR that is not included in the list of TR works recommended for execution in conjunction with TO.

The production line TO - 1 is designed to perform the entire scope of maintenance work on TO - 1, as well as to perform related repair work.

The line consists of two posts.

Before putting the car on the first post, the car is driven to the backwater post for heating and drying.

The first post is designed to perform work on the brake mechanism, wheels, suspension, transmission and lubrication work. Two car mechanics of the 3rd and 4th categories work at the post.

The second post is designed to perform work on the engine, clutch, steering mechanism and electrical equipment. At the post work: a car repairman of the 4th category and an electrician of the 4th category.

TO-2 posts are designed to perform lubrication and transmission work, etc., to perform the entire scope of maintenance work on TO-2, as well as to perform related repair work.

Table 2.10 - List of works during engine maintenance

Replaceable assembly	Labor intensity, people - min.
Bolt of fastening of a back support of the engine
Bolt of fastening of a forward support of ICE
Compressor and power steering pump drive belts
Water cooling pump and alternator drive belt
Fan drive belt
Fan countershaft belt
Valve cover gasket
Coolant drain valve
crankcase breather hose
Clamp of fastening of pipes of system of release
Oil filter housing gasket

Table 2.11 - List of works during maintenance of the power system

Table 2.12 - List of works for clutch maintenance

Table 2.13 - List of works during transmission maintenance

Table 2.14 - List of works during maintenance of wheels and hubs

Table 2.15 - List of works during suspension maintenance

Table 2.16 - List of works during maintenance of the body and cab

Table 2.17 - List of works during maintenance of the brake system

Table 2.18 - List of works during maintenance of electrical equipment

Replaceable assembly	Labor intensity, people - min.
Windshield washer pump motor
coolant temperature sensor
Oil pressure sensor
Emergency oil pressure sensor
Fuel level sensor
Optical element
Lens for direction indicator
Diffuser rear light
headlight lamp
Cabin lamp
Spark plug
Night light switch
Spark plug or distributor cap
High voltage wire
Ignition distributor cover
Fuse

Technological process Maintenance car is a certain sequence of work, ensuring their high quality with a minimum expenditure of working time.

Vehicle maintenance is divided into the following main types of work: cleaning and washing and wiping, fixing, control and adjustment, electrical, lubrication and cleaning, tire and refueling, each of which consists of certain technological operations.

The territory intended for the performance of one of the main types of work or individual operations of the technological maintenance process, equipped with the necessary equipment, instruments, fixtures and tools, is called fasting. A post may have one or more work places.

A significant part of the car maintenance work is carried out at the posts, but some operations for the maintenance of electrical equipment, power system devices, tire fitting and others are performed at production and auxiliary sites or in workshops.

Methods for organizing the technological process of car maintenance

There are two methods for organizing the technological process of car maintenance: on universal and specialized posts.

When servicing at universal posts, the entire range of works of this type of maintenance is performed at one post, except for cleaning and washing operations, for which a separate post is allocated for any organization of the maintenance process. At a universal post, work can be carried out by a team of highly skilled general workers or an integrated team consisting of workers of various specialties.

If there are several universal posts in the fleet, car maintenance is organized with the help of specialized teams moving sequentially from one post to another.

With this method of organizing service, mainly dead-end parallel posts are used (Fig. 175). Entry to the post of the car is carried out in front, and the exit - in reverse. Passage direct-flow posts are used for cleaning and washing cars. At each of the parallel universal posts, it is possible to perform a different amount of work, which makes it possible to simultaneously service different types of vehicles. This is the advantage of this service method.

The disadvantage of the dead-end location of the posts is air pollution by exhaust gases in the process of maneuvering the car when it is installed at the post and exit from it, as well as the time spent on maneuvering.

When servicing for specialized posts each of them performs a part of the whole complex of works of this type of maintenance, requiring homogeneous equipment and corresponding specialization of workers.

When organizing services at specialized posts can be applied in-line or operational guard methods.

At in-line method, the entire complex of works of this type of maintenance is performed simultaneously at several specialized posts located in the technological sequence of maintenance. In this case, the posts are located sequentially in the direction of movement of the car (Fig. 175, g) directly or in the transverse direction, and their combination forms maintenance production line. Specialization of posts on the service production line is carried out either by type of work, or by type of work and units, mechanisms and systems.

A feature of the organization of work on the production line is the need to ensure synchronization production, i.e., the simultaneous movement of serviced vehicles from post to post with the same duration of work at each post with the most complete use of each workplace in time. This is achieved by correctly determining the scope of work for posts and workplaces and equipping them specialized equipment and tools, as well as ensuring a uniform and continuous flow of vehicles for maintenance.

Thus, on the production line, a single cycle should be provided for all posts, which is the idle time of the car at this post and is determined from the expression

where t about - the complexity of the work performed at this post, man-min;

p p - the number of workers simultaneously working at this post;

t lane- time for installation and exit of the car from the post, min.

Sequential work stations are dependent, since the violation of the established norms of time or amount of work at least at one post causes unproductive downtime at other posts and disrupts the flow of production. Therefore, the organization of service on the production line requires the same type of vehicles and the same amount of service.

The movement of vehicles on production lines must be mechanized, since other methods of movement (on their own or rolling cars manually on roller trolleys) do not contribute to the synchronization of production. In addition, the movement of vehicles under their own power (with periodic starting and stopping of the engine) leads to smoke in the production room.

Mechanized movement using conveyors of various designs can be discontinuous or continuous. In this regard, production lines are divided into lines intermittent and continuous action. The speed of movement during continuous movement is taken much lower (2 - 3 m/min) than with discontinuous (10 - 12 m/min). Lines of continuous action are used only for harvesting and washing operations with EO.

At operational post method, the complex of works of this type of maintenance is also distributed among several specialized posts, but located in parallel. At each of the posts, a group of operations is performed to service certain units or systems. Cars are serviced at dead-end posts independent of each other, where they usually arrive on their own.

With this method of maintenance, it is possible to specialize equipment at each post and mechanize the production process, perform maintenance work, and also carry out TO-2 in several races between shifts, thereby excluding long-term downtime of vehicles.

The main advantages of the in-line service method are: reducing the labor intensity of work and increasing labor productivity due to the specialization of posts, jobs and performers; widespread use of technological equipment and equipment, since at each post the same operations are performed continuously; reducing costs and improving the quality of service; better use of production space; improving labor and production discipline due to the continuity and rhythm of production; improvement of working conditions.

According to NIIAT, the productivity of the production line is 45 - 50% higher than the productivity of universal posts and 20 - 25% higher than specialized parallel posts.

Service Method Selection

The organization of the technological process of maintenance depends on the number and type of vehicles, the time allotted for maintenance and its labor intensity, as well as on the mode of operation of vehicles on the line.

The organization of maintenance according to the in-line method is advisable with a large number of the same type of vehicles and a relatively short period of time for the maintenance process, as well as with a constant volume and labor intensity of these works.

The in-line service method can be used for a diverse fleet of vehicles if the production program for each type of vehicle justifies the application of this method for this type of service. In this case, it is possible to use the same production line, provided that vehicles of each type are serviced at different times. The same line can be used for various types of vehicle maintenance, provided that they are performed at different times and the line is suitably adapted.

The choice of service method also depends on overall dimensions cars. With significant vehicle sizes, a large area of ​​​​the production facility is required for their maneuvering. In this case, even if you have a small car park, you should stop at the in-line service method.

At low production program for this type of maintenance, a diverse fleet of vehicles and various modes of operation of vehicles that do not ensure their concentrated arrival, which is necessary for the smooth operation of the production line, the method of maintenance at universal dead-end posts is expedient.

The initial data for choosing a maintenance method are the daily program for each type of maintenance and the number of posts required for maintenance.

The in-line method of maintenance, as the most progressive, has found application in fleets in the organization of mainly EO and TO-1 and, to a lesser extent, TO-2. Moreover, continuous production lines are used only for cleaning, washing and wiping works included in the scope of the EU, and intermittent production lines are used for TO-1 and TO-2, since these types of maintenance require a number of operations to be performed on a stationary vehicle and, in addition, the volume of work at individual posts may deviate from the average norms.

When organizing TO-1 on a stream in car fleets, a large number of different options for production lines are used, differing in the number of posts (from 2 to 7) and jobs (from 1 to 5), technological equipment, etc. A significant difficulty in organizing in-line production is the fluctuation of the actual the laboriousness of servicing cars that arrived at the production line, due to their different technical condition, different operating conditions, etc.

Based on the condition of stability (in terms of labor intensity) of the shift program of the line, NIIAT found that it is advisable to organize TO-1 on the stream with a minimum shift program of 11 - 12 services of the same type of cars or road trains and developed standard maintenance documentation trucks GAZ and ZIL.

The type of production lines TO-1 includes two types of lines (for 2 - 3 posts) and 18 options for the arrangement of performers on the lines (from 5 to 14 people), which allows the introduction of a line method of car maintenance in various fleets with an annual fleet mileage of 6 up to 22 million km(at average annual mileage car 34 thousand km). Lines for two posts with a capacity of 11 - 14 services per shift are intended for fleets with 180 - 220 listed cars. Lines for three posts with a capacity of 15 - 21 services per shift are designed for fleets with 240 - 300 vehicles. The scheme of the technological layout of the production line is shown in fig. 176. Operational flow charts, consisting of a set of technologically indivisible operations, technical conditions and time standards for their implementation, recommended tools and equipment, as well as a scheme for placing performers at work posts, are developed taking into account the requirements of the scientific organization of labor.

NIIAT research has established that the rhythmic and efficient operation of the TO-2 maintenance production line can be ensured if the associated maintenance operations are of low labor intensity (up to 20 man-min) and are technologically connected with TO-2. Based on this, the average labor intensity of current repairs per TO-2 of GAZ and ZIL trucks should be no more than 15% of the total amount of work.

TO-2 on the stream is advisable for a daily program of three or more cars. NIIAT has developed a classification of works for TO-2 trucks GAZ and ZIL with a breakdown of operations into four groups to be performed at specialized posts: 1 - group - control operations to determine the technical condition and service life of the main units and components of the vehicle; Group 2 - operations for the maintenance of electrical equipment and the power system (associated with starting the engine); Group 3 - maintenance operations for other units, components and systems of the vehicle; Group 4 - lubrication and cleaning and filling operations.

TO-2 direct-flow lines, linked to the above type of TO-1 lines in terms of the total number of posts and basic technological equipment, are designed for a program from 3 to 12 maintenance per shift (for fleets with a number of vehicles from 180 to 700). At the same time, it is advisable to carry out the operations of the 1st group 1–2 days before putting the car in TO-2 at the diagnostic station (post) and send the car for maintenance after preliminary performance of maintenance operations of great labor intensity, the need for which was identified during the diagnostic process car.

Organization of car diagnostics

Diagnostic stations. The organization of car diagnostics allows you to identify hidden faults and predict the reliability of the units and systems of cars, as well as eliminate the subjective approach to assessing their technical condition.

The introduction of diagnostics into the technological process of car maintenance and repair, in addition to reducing labor costs, helps to extend the service life of units and assemblies by reducing the cases of their disassembly.

Diagnostic stations are organized universal dead-end posts or specialized posts of production lines equipped with stands with running drums, equipped with brake installations to simulate speed and load modes of operation of vehicles in operational conditions. Diagnostic posts are also equipped with equipment and instruments for recording parameters that determine the technical condition of the units, systems and mechanisms of the vehicle.

Stations and posts for comprehensive diagnostics of vehicle components have been created in a number of cities: Yelgava, Kharkov, Kiev, Chelyabinsk, etc. service stations.

The bench drive system allows two test modes: cold and dynamic running. During a cold break-in, all vehicle units are scrolled idle with the help of generators direct current balancing type (MPB-28/26, power 43 kW), operating in engine mode. At the same time, the technical condition of the power transmission is determined by its impedance, as well as the condition of individual units using vibroacoustic methods.

The measurement of torque, power supplied to the drive wheels, fuel consumption and other parameters is carried out in the dynamic running mode. In this case, the balancing generators are driven by the wheels of the car and operate in the generator mode, giving current to the load resistances. The stand allows you to simulate the speed of up to 75 km / h and create a load of up to 102,970 watts (140 hp).

The number of revolutions of the running drums is measured by electric tachometers, the pointer scales of which are graduated in rpm and km/h. The total number of revolutions of the run-out of the drums is recorded by electric pulse counters. The control panel contains the starting equipment of the electric drive system, signaling devices and instrumentation.

To carry out complex diagnostics of vehicles, a number of devices have been developed that allow assessing the technical condition of the engine at various loads and speeds according to the maximum power developed by it, determining the fuel efficiency of the engine, checking and adjusting the carburetor, checking the technical condition of electrical equipment using the electronic stand HADI-2, assessing the condition of the cylinder -piston group by gas breakthrough into the engine crankcase and by rarefaction in the suction pipeline, check the gas distribution mechanism in terms of vibration parameters using special equipment, assess the condition of the power transmission units in terms of total angular clearances and vibration parameters, check the effectiveness of the brakes according to the limiting values ​​of the angular deceleration of the wheels and stopping distance. When testing the brakes, the driving drums of the stand, connected by an electromagnetic clutch, are disconnected.

Such stands and devices are used in a number of car fleets in Kiev, Kharkov and other cities.

There are also stands in which the load on the running drums is created using hydraulic brakes.

At the diagnostic station, developed by the Chelyabinsk Polytechnic Institute and implemented in the bus depot No. 1 of Chelyabinsk, the general technical condition of the buses is determined on the inertial stand 1 (Fig. 177), installed on the inspection ditch. Inertial flywheels 11 of the stand, consisting of a set of disks, are selected from the condition of equality of the reduced moments of inertia of the masses of the bus and the masses of the stand. The driving drums 17 are driven by electric motors 6 through gearboxes 7.

The general technical condition of the bus is evaluated by fuel efficiency (fuel consumption at idle, constant driving modes and during acceleration), dynamic qualities (acceleration intensity) and roll-over indicators (path and time).

Measurement of fuel consumption and acceleration and coasting parameters is carried out as indicated above (see Chapter V).

The bus is placed on the stand so that the driving wheels are between the drums 17 and 19. During the entrance of the bus to the stand, the drums are blocked by brakes rear axle 9, driven by a hydropneumatic cylinder 8. Then the bus is fixed with braces.

To measure the vacuum in the engine intake manifold, a differential vacuum gauge is connected to the tube going from the carburetor to the vacuum regulator using a tee. Wear in the gearbox, in the cardan and main gears is determined by the total play, and the runout cardan shaft- an indicator device mounted in the inspection ditch.

On the stand ΙΙ, the simultaneous action of the brakes of the left and right wheels and the braking force are determined, and the correct installation of the front wheels is checked on the stand ΙΙΙ (see Chapter IX).

The state of the steering is determined by the backlash dynamometer by backlash and friction forces. The radial and axial clearances in the pivot joints are measured using an indicator device. The air pressure in the tires is checked using the principle of measuring the stiffness of the side tires, using a device with a recording device.

Electrical and ignition devices are checked using an electronic oscilloscope and special equipment (see Chapter VI).

Two laboratory assistants work at the station at the same time, communication between the operator in the cabin and the traffic controller is maintained using an intercom. The total time for bus diagnostics before TO-2 is 30 - 40 minutes. The cost of equipping the diagnostic station (6300 rubles) pays off in 0.6 years.

At the diagnostic stations, a test log is kept, in which the data obtained during the tests are entered. The conclusion on the condition of the units and systems and the identified malfunctions are recorded in the checklist of the car to adjust the scope of work TO-2.

Diagnostic stations and posts have been set up in a number of republics (the RSFSR, the Ukrainian SSR, the Latvian SSR, and others). The introduction of diagnostics in the 1st taxi fleet of Glavlenavtotrans, where the assessment of the technical condition of the car is carried out according to 14 parameters, gave the following results: with a total capital cost of 9610 rubles. thanks to the reduction in the volume of TO-2 and repairs, savings in the amount of 1868 rubles were obtained; the cost of spare parts and materials was reduced by 18%, and the savings in the amount of 15,572 rubles were obtained on wages (with accruals), which is 19% of actual expenses for the year.

The introduction of diagnostics, in addition to the economic effect, made it possible to improve the culture of production and lay the foundations for the scientific organization of labor.

Express diagnostic lines. Inspection and inspection work on units and mechanisms that ensure traffic safety is recommended to be performed at intervals of 300 - 500 km(which corresponds to the probability of 0.95 - 0.97 failure-free operation of vehicles with an average time between failures of 10,000 km).

These works in large car fleets and at car service stations should be carried out on special lines of express diagnostics, which can consist of three posts.

The 1st post is equipped on a flat area and is designed to check: the condition of the tires and the air pressure; installation and strength of the luminous flux of headlights, sidelights, taillight and brake light; alarm devices; windshield wipers; cabin door locks, side locks and fifth wheel couplings; rear view mirror installation. This post must be equipped with a device for checking the installation and strength of the luminous flux of headlights (model NIIAT E-6), a tip with a pressure gauge for tire inflation (model 458), and a device for checking the sound signal.

The 2nd post is equipped on the inspection ditch and serves to check: the state of the steering; fastenings of rotary levers and steering bipod; installation angles of the front wheels; cardan shaft fastenings; tightness of pipelines and components of the brake system.

The performance of these works is ensured by the presence of the following equipment: a backlash dynamometer (model 523), instruments for measuring the angles of the front wheels (models 2142 and 2183), a ruler for checking the convergence of the front wheels (model 2182). In the future, high-speed stands should be installed at this post to check the steering controls and the angles of the front wheels.

3rd post - a stand with running drums to check the operation of the brakes.

The introduction of express diagnostics helps to improve the technical condition of the vehicle fleet and reduce the number of traffic accidents.

Maintenance planning

Planning TO-1 and TO-2 is carried out according to the calendar schedule. At the same time, to establish the planned day for putting the car for maintenance, they proceed from the average daily mileage for the past month or the planned mileage for the next month. Taking into account the frequency of service established for this fleet, a maintenance schedule, according to which cars are sent to the service area. The number of cars arriving daily for service must correspond to the daily production program.

Such scheduling of maintenance according to calendar time is reasonable only if the average daily mileage of vehicles is stable and the fleet utilization rate is not less than the calculated value. Otherwise actual runs individual cars will differ significantly from the average mileage for the fleet, which are accepted during planning. This is due to fluctuations in the daily mileage of individual cars, as well as the different duration of their downtime for various reasons.

Notes: 1.In the case of the operation of the fleet during a discontinuous week, the maintenance of vehicles on Sundays is not carried out, and the schedule is shifted. 2. The implementation of TO-1 is indicated by one square, and TO-2 - by two squares

Therefore, it makes more sense to plan by mileage taking into account the actual mileage of cars and their operating conditions (road conditions, work with trailers, etc.), since in this case the cars are sent for maintenance according to the established frequency. However, with this method of planning, uneven loading of the service area is possible.

Compliance with the maintenance schedule is one of the main factors ensuring the good technical condition of the car park.

The procedure for sending vehicles for maintenance and paperwork

When returning the car from the line, the duty mechanic of the control point checks its appearance, completeness and technical condition, after which the cars are sent to the storage area, to the maintenance or repair area. In fleets equipped with posts (lines) of express diagnostics, cars after the set mileage are sent to check the condition of systems and mechanisms that ensure traffic safety.

If the car is in good condition, then the mechanic on duty removes the token with the number of this car from the scoreboard, located in the section "Cars on the line" and passes it to the control room of the operation department along with a signed waybill. Before leaving the line, the driver receives a waybill and a token in the control room, which he presents to the mechanic on duty at the checkpoint, and after checking appearance vehicle receives permission to leave.

Tokens of vehicles requiring maintenance or repair are placed by the mechanic on duty in the appropriate sections of the scoreboard.

The primary accounting document is the Vehicle Maintenance and Repair Record Sheet, which is issued by the mechanic on duty and transferred to the production dispatcher. If the car needs maintenance, then the sheet is stamped "TO-1" or "TO-2", and if current repairs are necessary, the "Application for Repair" section lists all the work the need for which was identified during the inspection of the car. In the event of an accident or damage to the vehicle associated with its improper operation on the line, the specified section of the sheet is stamped "Accident" or "Breakdown".

Cars are sent for maintenance by the duty mechanic of the control point according to the list of car numbers, which is presented to him daily by a technician for accounting for maintenance and repair of cars, and direction for current repairs is carried out as a result of inspecting the car or at the request of the driver.

Mechanic Semushkin

Request for repair: 1. Replace the left rear spring.

Dispatcher Petrov

Note. The form of the vehicle maintenance and repair record sheet is used in the following cases: premature return of the vehicle from the line, late entry to the line, downtime on the line, as well as during current repairs between shifts, during routine repairs with the replacement of the unit.

In these cases, the required amount of repair is indicated on the accounting sheet.

The reverse side of the sheet is filled in in accordance with the application.

Cars are placed at the posts of maintenance and repair by order of the production manager. Having received accounting sheets from the mechanic of the control point, the dispatcher, depending on the workload of work posts, the volume of current repairs and the schedule for the release of cars on the line, decides the issue in such a way as to ensure the timely preparation of cars for release on the line. A car requiring routine repairs is usually first sent to the repair area for troubleshooting, and then for maintenance.

The production manager instructs the driver-driver subordinate to him about the time of sending the cars to the post of the corresponding type of service or repair and gives him the accounting sheets for these cars.

After the cleaning and washing work is completed, the driver-driver puts the car at the maintenance post and submits a record sheet there.

If in the process of performing maintenance the need for repairs is established, then the foreman of the corresponding group of workers decides whether it is possible to carry it out on his own. If it is inappropriate or impossible to perform super-volume work in the maintenance area, the foreman writes down their content in the "Application for repair" section of the record sheet. After the service of such a car is completed, the driver-dispatcher passes the record sheet to the production manager, who instructs the head of the corresponding production site to eliminate the malfunction.

At the end of the maintenance at the production sites, the accounting sheet is filled out. The performance of the current repair is noted on the reverse side of the accounting sheet indicating the date and month. When replacing units, the stamp "Replacement" is put and the numbers of the removed and delivered units are indicated. Then the driver-driver puts the car in the parking lot and passes the record sheet to the production manager, who signs it and puts it in the closet in the "TO done" box. As the sheets are accumulated, they are sent to the mechanic on duty at the checkpoint to draw up a waybill for the production of cars and transfer their tokens to the control room. If the units that ensure traffic safety were subject to repair, and the token of this car was on the scoreboard in the section "Current repairs with inspection", then the mechanic transfers the token to the control room only after inspecting the car.

In the event of a vehicle failure on the line, the mechanic on duty at the control point writes out an accounting sheet for the repair of this vehicle and hands it over to the driver of the technical assistance vehicle. After the malfunction is eliminated and the registration sheet is filled out, the latter is returned to the mechanic on duty.

Every day at the end of the release of cars, all sheets of accounting are transferred from the control point to the accounting technician for processing and storage.

Timely analysis of accounting data for the implementation of maintenance and current repairs in fleets is one of the conditions for improving production in order to improve the technical condition of the vehicle fleet. Of particular importance is the analysis of the production of current repairs, since the volume of it and the duration of vehicle downtime due to technical malfunctions largely depend on the quality of maintenance, the state of the material base of the vehicle fleet, logistics, qualifications of workers, etc. The influence of these and other factors on the level of the current repairs can be established by a systematic analysis of the frequency of repair cases and downtime of individual vehicles, the frequency and causes of malfunctions of individual units and mechanisms.

The main document for obtaining data used in the analysis is the Vehicle Maintenance and Repair Record Sheet. The information contained in the accounting sheets makes it possible to obtain any data necessary for the operational management of production, as well as for the development and implementation of measures to improve the technological process of maintenance and current repairs. This information allows you to:

Control the quality and timeliness of maintenance and current repairs in the fleet, as well as the quality of work of car repair enterprises;

Assess the general state of production by changing the number of cases and the frequency of current repairs, as well as vehicle downtime due to technical malfunctions, etc.;

Assess the qualifications of drivers and their attitude to the car during operation;

Take into account the faults that occur most often under certain operating conditions in order to adjust the maintenance regimes;

Control the labor intensity of work to adjust the required number of workers at production sites;

Put forward requirements for improving the design of cars, etc.

Record sheets provide an opportunity to track the change in the technical condition of individual vehicles. Therefore, the information contained in the accounting sheets should be processed, systematized and analyzed using the following documents: "Vehicle face card" and "Accounting for current repairs and downtime of vehicles by units, production sites and causes of its occurrence."

In the front card of the car are entered: daily mileage - based on waybills or speedometer readings; all maintenance and repair operations, downtime associated with them - on the basis of accounting sheets and data from the production manager; downtime for other reasons - according to the duty mechanic of the checkpoint according to the scoreboard about the location of the cars.

The analysis of the data of the front card, in addition to assessing the quality of the performed maintenance or repair and driver qualifications, makes it possible to quickly plan maintenance based on the actual mileage of the vehicle and monitor the performance of maintenance.

Analysis of the data of the second document gives an idea of ​​the work of production in general and each production site in particular.

These documents are maintained by the accounting technician and are with him. Personal cards after they are filled in and replaced with new ones are stored for a year, and data on accounting for current repairs and vehicle downtime are stored for at least two years to compare them over a long period.

Technological processes are understood as a sequence of technological operations necessary to perform a certain type of technical impact. The procedure for the implementation of the technological process depends on the type and volume of technical impact, while taking into account the right of the car owner to carry out selective work from the scope of maintenance and current repairs (TP) in any combination.

The technological process should provide flexibility in the performance of the ordered maintenance and TP services, which involves the use of universal and specialized posts, and, therefore, the possibility of carrying out various combinations of production operations of all works of this type without moving the car (with the exception of specialized posts).

The basis of the organization of the technological process at service stations and car repair is the following functional diagram. Cars arriving for MOT and TP are washed and delivered to the acceptance point to determine the technical condition, the required scope of work and their cost. Last e acceptance, the car is sent to the appropriate production site, depending on the staffing of the production and technical base and its condition. The main elements of the production and technical base include production posts (washing, acceptance, in-depth diagnostics, maintenance and TP) and specialized areas (repair of individual vehicle systems, tire fitting, etc.). In the case of occupancy of work posts at which work must be performed according to the work order, the car arrives on a waiting car, from where, as the posts are vacated, it is sent to one or another production site. After completion of the work, the car goes to the post of issue of cars.

There are various options for the sequence of work, depending on the ordered service:

1) P-UMR-D b -PR-K-UMR-S-V;

2) P-D b -Dz-S-UMR-PR-UR-PR-K-UMR-S-V;

3) P-Dz-PR-K-UMR-V;

4) P-D 3 -S-UMR-PR-UR-PU Kts-PR-UMR-S-V;

5) P-UMR-PR-UR-PU SC-PR-K-UMR-V;

6) P - Dz - UMR - PR-S-PR - MU - PR - UUK - K - U MP - C - B;

7) P - Dz - UMR - PR-UR-PR - UUK - K - UMR - C - B;

8) P - PR-V.

The symbol means:

P - acceptance;

D b - diagnostics of systems that determine traffic safety (carried out at the acceptance point equipped with a diagnostic complex, and as an independent type of service is included in the maintenance performed according to service books);

Dz - diagnostics at the request of customers (in-depth diagnostics);

UMR - cleaning and washing works;

C - parking (in the event of a queue);

PU STs - production site No. 1 (locksmith shop);

PU Kts - production site No. 2 (body shop);

PR - guard work (including the installation of the car on a lift);

UR - local work (include work in specialized areas: tire fitting, balancing, slipway, nozzle cleaning installations, radiator washing, etc.);

UUK - stand for monitoring and adjusting the angles of installation of the stake eu(descent-collapse);

MU - painting area (includes: painting booth and preparatory area);

K - control (performed at posts with filling out an inspection sheet, including: a test drive, control of security systems and adjustment work);

B - delivery of the car to the client.

Option 1- a typical variant of maintenance according to the service book, when the client arrives at a certain mileage or time interval. In this case, the car is being diagnosed at the acceptance point, the inspector inspects it, checking the absence (presence) of leaks, the integrity of the protective rubber products (anthers, brake hoses), the thickness brake discs and pads, the serviceability of signaling and lighting devices, the level of liquids. After UMR, work is carried out on maintenance and elimination of faults noticed during the inspection. Further, the control of the work performed is carried out, and then the washing and cleaning of the interior. The car is issued to the client.

Option 2 when a client combines TO and TP in one visit. For this, in addition to D b, in-depth diagnostics D 3 is performed to identify problems. In this option, the client leaves the car for a rather long time (several days or more), so the car passes through the parking lot to wait and pick up.

Option 3 is implemented with limited free time at the client and on the condition that the car drives into the workshop in its pure form (warm season, dry roads), therefore, UMR is not performed before work.

Option 4 is implemented when the car enters a small or medium body repair in the absence of the need for a locksmith repair (replacement or repair of a door, fender, bumper, hood, etc.). The car is installed at a post in the body shop for mounting / dismantling of body elements.

Option 5 eliminates system diagnostics and is implemented when the client needs to perform a specific service that requires special equipment and / or installation of the car on a lift (for example, tire fitting, wheel balancing, air conditioning refueling, nozzle cleaning, etc.).

Option 6 typical for major repairs - replacement or repair of elements of both the body and mechanical systems that ensure the operation of the engine, transmission and suspension. An example would be emergency vehicles repaired under insurance.

Option 7 implemented when repairing or replacing suspension elements, after which it is necessary to check and adjust the angle of the wheels.

Option 8 is implemented when it is necessary to fix a car problem that does not require diagnostics, if the client is in a hurry (this explains the exclusion of WMR and C), or to fix a problem after repair, when the cause is obvious.

Ticket number 21

21. System of maintenance and repair of the rolling stock of motor transport of the Republic of Belarus. The purpose, purpose and essence of maintenance and repair of vehicles.

The organization of work on the maintenance of cars is carried out in accordance with the technological maps for a car. Technological maps are developed by the manufacturer, which include a list of mandatory work. The organization of work on current repairs can be carried out by two methods, individual and aggregate. With the aggregate method, faulty units, devices, units are replaced with new ones or pre-repaired ones taken from the revolving fund. In this auto repair shop, repairs are carried out by an individual method, in which faulty components, assemblies are removed from the car, repaired and put on the same car. In the case of claims on the quality of the work performed by the customer, if they incur material costs, then they are carried out by the mechanic himself, who committed this inaccuracy, if his fault is obvious.

Technological processes involve two types of work, restoration and maintenance of the vehicle.

The technological process of restoring working capacity provides for a set of works in order to eliminate a specific failure, the speedometer, the stove motor, brakes, etc. have failed. The driver arrives and himself says a malfunction that arose during the operation of the car.

The technological process of maintaining operability provides for a set of works that ensure the normal functioning of the technical serviceable systems within the specified aisles, restoration of engine idle, ignition adjustment, tire pressure equalization, wheel alignment, etc. The driver usually says that something is wrong with the car, increased consumption fuel, car moving away from rectilinear movement, whistling from the motor side, the mechanic, as a rule, already represents what list of work needs to be carried out to clarify and eliminate this malfunction. When it is detected, the mechanic tells the driver the type of malfunction and sends it to the store for a new part, if it is required.

When the car arrives at the car repair shop, the driver of the car must approach the chief mechanic or any free mechanic to describe the list of work that he wanted to carry out, the malfunctions, what their nature is, and in what time it is necessary to complete the repair. The driver must leave a contact phone number in due time, since, during the repair process, parts can be identified, components to be replaced in the absence of the driver in the auto repair shop, he is informed by phone about the need to replace this part.

The laboriousness of car maintenance is usually small and 2 mechanics are assigned to it at two inspection pits in the room, but car repairs can also be carried out in the adjacent territory up to two cars. The auto repair shop has it all. necessary tools for independent work of all four mechanics: a set of tools for a car mechanic, a compressor hose 10 meters long and can be used both indoors and outdoors, a pneumatic wrench for loosening wheel nuts, an electric battery wrench for loosening nuts on the engine and others.

The maintenance worksheet includes:

• 1. Full car wash.
• 2. Determination of the technical condition of the vehicle systems, which includes:
  • - technical condition of the power unit: checking the components - the crank mechanism, gas distribution, cooling system, power supply and clutch systems.
  • - power supply systems.
  • - ignition systems.
  • - the condition of the gearbox, cardan drive and differential.
  • - steering.
  • - carrier system.
  • - power supply and alarm and control devices.
• 3. Elimination of identified defects and adjustment work.
• 4. Vehicle assembly.
• 5. Surrender finished car to the customer.

List of works during maintenance:

Power unit: calibrated tightening of the nuts for fastening the head, pan, neck supports, eliminating knocks in the engine, adjusting and restoring the tightness of the valves, checking the tension of the alternator-fan belt, checking the tightness and filling level of the cooling system, the technical condition of the pump, flushing and adjusting the carburetor, checking fuel pump operation. Checking the fuel level in the carburetor, checking the ignition system - condition high voltage wires, the condition of the distributor, the condition of the candles, the operation of the clutch - the reliability of operation, the condition of the clutch parts, the oil is changed at a certain mileage.

Braking system: tightness of the system, production of pads and discs, brake fluid level.

Gearbox: check the level and quality of the oil, the oil is changed at a certain mileage, check for extraneous noise, smooth gear shifting, reliability of fixing speeds, condition of the bearings, condition of the differential - condition of gears, satellites, bearings, condition of the driveline: determination of the technical condition according to backlash in the connection, the external state of the node.

Carrying system: checking the operation of shock absorbers, springs, rods, the condition of ball bearings and dampers, checking the camber and toe-in, checking the wear of the wheels, the condition of the wheel bearings, balancing the wheels.

Control system: checking the steering wheel play, wheel play, changing the oil in the gearbox.

Power supply system: check the condition of the generator, the condition of the collector, brushes, rectifier, the condition of the contacts, the output voltage and current, replace the bearing grease, the condition of the starter, the condition of the brushes and the collector. Developed moment, condition of contacts, checking the condition of the battery, electrolyte level and density, condition of the terminals, checking and correct readings of instrumentation, checking lighting and alarm systems.

Body: to lubricate the hinge points, the reliability of operation and fixing of locks, the condition of the body, to re-preserve the body.

Lubricate in accordance with the lubrication chart of the units.

Periodic maintenance and ongoing repairs ensure the maintenance of trouble-free and reliable operation cars. Maintenance is divided into three periods:

daily, TO-1, TO-2. Maintenance allows you to keep the mechanisms of the car working between repairs. Maintenance is an integral part of maintenance. It is designed to restore the performance of the unit.

To perform maintenance and current repairs, a set of devices and instrumentation is used. This kit is in stock.

When a car arrives at a car repair shop for maintenance or current repairs, it is necessary to perform a list of mandatory works:

• 1. Wash the car from operational contamination.
• 2. Check the technical condition of the vehicle components and assemblies.
• 3. Draw up a technical condition map indicating defective components and assemblies.

The reliability and durability of the operation of components and assemblies depends on the quality lubricants and maintaining the terms of their replacement, determined by the manufacturer of the car and components.

Maintenance (TO-1) TO-1 is performed after 15,000 km or after a year of vehicle operation. For each vehicle, this parameter is determined by the vehicle manufacturer.

At TO-1, they check the reliability of fastening of units and assemblies, the absence of fluid leakage.

They clean electrical wiring and units from operational pollution. Check the reliability of the electrical contact, check the integrity of the insulation. Accumulator battery cleaned of operational pollution, clean the ventilation holes, clean the terminals from oxides, check the level and density of the electrolyte. The fan belt deflection is checked. The free movement of the throttle control rods and air damper, the efficiency of the brakes, measure the play of the steering wheel. The oil is changed in the engine, gearbox, axle. Check the operation of the alarm system, locks, lighting.

Lubricate the units in accordance with the lubrication chart.

Faulty units and units are subject to repair.

Maintenance (TO-2) TO-2 is performed after 30,000 km or after two years of vehicle operation.

TO-2 consists of work performed during TO-1 and a set of specific works.

Serviceability of mechanisms for opening and closing doors;

Tightness of the engine cooling system;

• - checking the fastening and condition of the radiator;
• - fastening of the cover of distribution gears, fan pulley, water pump, radial clearance in bearings;
• - tightness of the engine lubrication system;
• - stretch the nuts of the inlet and outlet pipelines and exhaust pipes of the muffler;
• - check the condition of the engine mounts;
• - check the condition of the power system devices;
• - remove and wash the filter element and glass fine cleaning fuel;
• - check the operation of the drive and the free travel of the clutch pedal;
• - backlash in the hinges and spline connection of the driveline;
• - check the condition and tightness of the rear axle;
• - play of the steering mechanism;
• - check the fastening and cotter pin nuts of the hinge pins and steering knuckle levers;
• - condition of the front axle beam;
• - remove the brake drums and clean the brake mechanisms from dirt;
• - check the condition of the main brake cylinder, amplifiers, pipelines;
• - checking the serviceability of the drive and the operation of the parking brake system;
• - checking the fastening: step-ladders of the front and rear springs, shock absorbers, brackets for their fastening;
• - checking the fastening of the wheels, the condition of the rims and disks, the condition and wear of the tires;
• - clean the battery from dirt and dust, check the electrolyte level in all battery banks;
• - check the condition of the spark plugs;
• - after maintenance, check the operation of units, mechanisms and devices with a control run;
• - check and, if necessary, adjust the clearances between the valves and rocker arms;
• - remove the hubs, wash the hub bearings and seals in kerosene, check the condition of the bearings, put fresh grease in the wheel hubs, adjust the hub bearings.

Diagnostics D-1 and D-2. One of the elements of the technological process of maintenance and repair is diagnostics, which serves to determine the technical condition of vehicles, their units and assemblies without disassembly. The specific property that distinguishes diagnostics from the usual definition of a technical condition is not an increase in the accuracy of its assessment, but the identification of hidden faults without disassembling the car. Currently, there are two options for performing diagnostic work: together with maintenance and repair, or at specialized posts and diagnostic lines.

Diagnostics D-1 is used to check the units and mechanisms that ensure traffic safety. This type of diagnosis is performed before TO-1. It is justified to carry out control and diagnostic work before TO-2 in the zone or at the diagnostic post in order to regulate the technological process and select from the mass of cars entering TO-2 those that have a significant amount of high-labor TR. This type of diagnostics is called in-depth diagnostics D-2, performed at the post using a stand for checking the traction qualities of cars. Such diagnostics are not carried out in the workshop due to the lack of equipment. Most often, according to the customer, a list of technical impact on the car is immediately revealed, or during the inspection, problematic components and assemblies of the car are identified.

industrial technological auto repair shop