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 general-level documentation and serve to develop guard maps and on 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 of the complexity of operations technological process

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 norm of time 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 Kp=1). Adjusting and fastening operations may have Kp< 1, т.к. после проверки, если adjusting parameter normal or tightening of the fastening connection is not required, they can be skipped. The repeatability coefficient depends on the reliability of the vehicle design and the quality of the previous MOT or TR, varies for various operations, approximately within Kp = (0.2-1), and is determined by processing the relevant statistical data or according to standard MOT and TR technologies.

The complexity of maintenance and repair operations can be set in one of three ways:

• - using ready-made standards from standard technologies and standard norms of time for maintenance and repair of vehicles;
• - processing of data of chronometric observations of their implementation;
• - microelement regulation of operations.

The simplest and most desirable is the first method.

Standard norms of labor intensity are accepted according to

Typical norms of time (labor intensity) are subject to certain operating conditions. With distinction real conditions performance of operations (other equipment, level of mechanization) from the average specified for standard norms, they should be adjusted to the conditions of the designed process. So, for example, with the in-line method of organizing service, the standard labor intensity can be reduced by 15–25% of the typical norm. If the conditions for performing the operation differ sharply from the typical ones (new equipment, new vehicle design), then the labor intensity standard is set in other ways.

Timing observation method

The method of chronometric observations gives the most accurate results, but it is very laborious and requires a long time to establish the complexity of operations due to the large number of observations and the complexity of processing the data obtained. Let us briefly consider the main provisions of the method of time-keeping observations.

For timing, the performers of maintenance and repair work are selected in a special way (work experience, qualifications, age, etc.).

Timing is carried out at certain hours of the working shift (one hour after the start of work, stops one hour before lunch or the end of the working day).

The number of timing observations should be sufficient to reliably determine the average TO. Their minimum number is determined according to table 2, depending on the duration of the operation and the way the work is performed.

Table 2 - Required number of measurements during timing

Timing data are arranged in a variational series (from min to max). The stability and stability of the results of observations is checked by comparing the actual value of the stability coefficient of the chrono-series with its normative (table) value (Table 3).

Table 3 - Normative value of the coefficients of stability of the time series

The stability coefficient of the chronological series is found by the formula:

where t max, t min are the maximum and minimum values ​​from the composition of the time series. A chronological series is considered stable if the actual "stability coefficient is less than or equal to the standard one: K Kn.

If this ratio is not observed, then the observations should be repeated. As an exception, due to the high cost of timing, it is allowed to correct the time series by discarding its extreme values ​​(t max, t min).

The operational time in minutes to perform the operation is found as the average value of the members of the chronological sequence:

where ti is the value of the chronological series members , min; n is the number of members of the chronological series.

Timing and setting the norm can be carried out only after the introduction and debugging of a new technological process, i.e. it is impossible to design the norm of time (labor intensity) of operations at earlier stages of the development of TP.

Microelement method for designing normative complexity of operations

Microelement systems are currently widely used to determine the labor intensity of TP operations.

The essence of this method is that the most complex operations can ultimately be represented as a certain sequence of repeating simple elements, for example: move, install, fix, connect, etc. (Table 4).

If we divide the normalized operation into a number of such microelements and sum up the time available in the database for their execution, then we can find the operational time to complete the entire operation.

The main advantage of this method is the possibility of designing labor intensity norms "at the table" at the stage of TP development, which significantly reduces time and costs in comparison with the method of chronometric observations. Of course, this is possible with great experience and qualifications of process engineers (knowledge of the design of a given brand of car, the operation and capabilities of the technological equipment, fixtures and tools used, etc.).

The time values ​​for the execution of microelements of the operation are “clean”, i.e. with their convenient implementation and free access to the service point. In real conditions, the convenience of performing work (working postures, table 4) and access to a service point (table 5) for each brand of car and operation will be different, therefore, in the operational time for the operation to be corrected by the appropriate coefficients.

Thus, the general equation for normalizing the labor intensity of car maintenance in man-min or man-hours with this method looks like this:

Tn \u003d (t1 + t2 + ... + tn) * K1 * K2 * (1 + (A + B + C) / 100) * P * Kp (5)

where t1 is the time to complete the microelements that make up the operation; n - the number of trace elements in the operation, incl. and taking into account their repetition; K1, K 2 - respectively, the coefficients taking into account the increase in the 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 element self made consists of a combination of two trace elements: 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.

Given this provision, at this stage, based on the collection and synthesis of information on literary sources and regulatory and technical documentation, etc., a base was developed in the amount of 44 microelements (table 4).

With the enlargement of microelements, their versatility decreases, since the probability of repetition in a large number of various operations and processes decreases. But it simplifies the process of designing operations in which they occur. Therefore, in our opinion, the base of microelements for TP TO and TR of cars should consist of two parts. The first part should contain elementary movements encountered in the operations of any labor processes. The second part - larger elements of operations of specialized maintenance and repair works (fastening, welding, etc.).

The base of trace elements presented in Table 4 is not sufficient, it needs to be improved and expanded. With its help, it is possible to design, mainly, the labor intensity standards for control, diagnostic and adjustment operations of maintenance and repair of cars, however, it allows us to demonstrate the possibility of the method under consideration.

Table 4 - Database on microelements of car maintenance operations

	Name of microelement	Time, min
	Step 1
	Going 2 steps.
	Going 3 steps
	Going 4 steps
	Stretch out (remove, bend) a hand
	Take (put) a tool, device, part (take the handle, latch)
	Housing rotation 90°
	Housing rotation 180°
	Body tilt (straighten up)
	Body tilt below the waist
	Deliver (take away) a tool, device, part ","
	Installation (removal) of a tool, device, part is simple
	Installation (removal) of a tool, device, part with docking with the vehicle structure
	Rotate Tool
	Turn the handle, open the latch
	Press the latch
	Place (remove) foot (hand) on the pedal
	Press (release) the pedal with your hand
	Press (release) the pedal with your foot
	Go down into the inspection ditch
	Climb out of the inspection ditch
	Get up on the bumper
	Get off the bumper
	Open (close) the hood (with the latch open)
	Open (close) the cabin door (when the handle is turned)
	Tilt cab
	Install tilt cab
	Blow out the serviced element compressed air from a hose
	Finger movements
	Screw (bait) the nut M8 - M24
	Tighten the nut (bolt) M20 -- Ml 6
	Tighten the nut (bolt) M20 -- M35
	Look (glance) at an object or sign in sight
	Scale reading, cm
	Scale reading, mm
	Look closely at division
	One mind action with single digits
	One mental action with two digit numbers
	Setting the instrument to zero
	Preloading the indicator head
	Unscrew (wrap) the nut, bolt, fitting M8 M16 for a length of up to 20 mm
	Unscrew (wrap) the nut, bolt, fitting M8 -M16 for a length of up to 35 mm
	Unscrew (wrap) the nut, bolt, fitting M20 -M32 for a length of up to 25 mm
	Unscrew (wrap) the nut, bolt, fitting M20 -M32 for a length of up to 35mm

The labor intensity and complexity of the work are largely determined by the characteristics of the object of labor. A car is a complex object of labor in its maintenance.

Process impact points (sometimes called service points) are located on the side, bottom, and top of the vehicle. Therefore, when servicing a car, first of all, it is necessary to provide performers with access to service points. To reduce service time, it is better to provide simultaneous access to several workers from all sides.

In addition, it is necessary to provide the performer with the least fatigue and the greatest safety during work. Studies have 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 where service points are located 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 instruments;
• 19. Mobile overpass for repair;

Specialized post SPP-2 for the replacement of suspension units and running gear

• 1. Locksmith workbench;
• 2. Wrench for wheel nuts;
• 3. Nut driver for spring ladder nuts;
• 4. Cassette for wheels;
• 5. Chest for cleaning materials;
• 6. Ruler for checking wheel alignment;
• 7. Transitional bridge;
• 8. Lift;
• 9. Mobile car mechanic post;
• 10. Universal rack;
• 12. Trolley for removing and installing springs;
• 13. Trolley for removing brake drums with hubs;
• 14. Recoil stop.

Specialized post SPP-3 TR for braking systems of vehicles

• 1. Locksmith workbench;
• 2. Wrench for wheel nuts;
• 3. Cassette for wheels;
• 5. Lift,
• 6. Device for testing the pneumatic drive of the brakes;
• 7. Universal rack;
• 8. Stand for checking the brakes of three-axle vehicles;
• 10. Recoil stop;
• 11. Installation for refueling and pumping brakes;

Specialized post SPP-4 TR of low labor intensity

• 1. Bath for washing parts;
• 2. Locksmith workbench;
• 3. A set of wrenches;
• 4. Chest for cleaning materials;
• 5. Transitional bridge;
• 6. A set of socket keys;
• 7. Suspended pneumatic wrench:
• 8. Footrest;
• 9. Lift;
• 10. The post of a mobile mechanic-auto repairman:
• 11. Rack for components and parts:
• 12. Universal rack:
• 13. Recoil stop.
• 14. Cabinet for tools and instruments:

Specialized post SPP-5 TR electrical systems cars

• 1. Locksmith workbench;
• 3. Motor tester;
• 4. Post of a mobile mechanic-auto electrician;
• 6. Device for checking and adjusting headlights;
• 7. Device for testing breakers-distributors;
• 8. Device for checking electrical equipment;
• 9. Rack for components and parts.
• 10. Universal rack;
• 11. Table for appliances;
• 12. Recoil stop;
• 13. Installation for accelerated charging of batteries;
• 14. Device for suction of exhaust gases;
• 15. Cabinet for tools and instruments;

Specialized post SPP-6 TR for devices of engine power systems

• 1. Bath for washing parts;
• 2. Locksmith workbench;
• 4. Set of wrenches,
• 5. Chest for cleaning materials;
• 6. The post of a mobile mechanic-auto repairman or carburetor;
• 7. Device for checking plunger pairs;
• 8. A device for checking fuel pumps of carburetor engines;
• 9. A device for checking the fuel priming pump and filters;
• 10. Device for checking injectors;
• 11. Universal rack;
• 12. Table for cutlery:
• 13. Recoil stop.
• 14. Device for suction of exhaust gases;
• 15. Cabinet for tools and instruments;

Specialized post for frame replacement SPP-7

2. Oil dispenser; 3. Crane beam; 4. Oil distribution tank; 5. Car repair kit; 6. Lift; 7. Lift; 8. Post mobile locksmith - 9. Rack for aggregates; 10. Rack for frames; 11. Rack for components and parts; 12. Device for suction of exhaust gases 13. Device for draining coolant 14. Device for draining used oils	15. Bath for washing parts; 16. Locksmith workbench; 17. Capture for engines; 18. Capture for cabins; 19. Capture for platforms; 20. Chest for cleaning materials; 21. Transitional bridge; from capsizing; 22. Pneumatic wrench on suspension, 23. Cabin stand; 24. Platform stand; 25. Welding machine; 26. Universal rack; 27. Recoil stop; 28. Device for holding bridges

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 instruments;

Special post SP-4, SP-5 for the replacement of clutches and gearboxes

• 12. Recoil stop.
• 1. Locksmith workbench;
• 2. The track bridge is mobile;
• 3. Chest for cleaning materials;
• 4. Oil dispenser;
• 5. Monorail with a hoist;
• 6. Universal rack;
• 7. Rack for clutches and gearboxes;
• 8. Trolley for transportation of gearboxes and clutches;
• 10. Special device for disconnecting the gearbox;

Special post SP-6 for the replacement of rear axles and gearboxes for GAZ, ZIL vehicles

• 1. Locksmith workbench;
• 2. Nut driver for spring ladder nuts;
• 3. Multi-spindle hanging nut runner for wheel nuts and hub flanges,
• 4. Cassette for wheels;
• 5. Cantilever crane;
• 7. Oil distribution tank;
• 8. Lift;
• 9. Bridge rack;
• 10. Universal rack;
• 11. Trolley for removing and installing wheels;
• 12. Recoil stop.

Special post SP-7 for the replacement of gearboxes of KamAZ vehicles

• 1. Locksmith workbench;
• 2. Multi-spindle nut driver for hub flange nuts
• 3. Crane beam;
• 4. Chest for cleaning materials;
• 5. Oil dispensing tank;
• 6. Pneumatic wrench on suspension,
• 7. Rack for gearboxes;
• 8. Universal rack;
• 9. Recoil stop.
• 10. A device for draining used oils.
• 11. Cabinet for tools and instruments,

Special post SP-8 for the replacement of the rear and middle axles of KamAZ vehicles

• 1. Locksmith workbench;
• 2. Wheel nut wrench multi-spindle suspended;
• 4. Cassette for wheels;
• 5. Track bridge;
• 6. Chest for cleaning materials;
• 7. Oil distribution tank;
• 8. Monorail with a hoist;
• 9. Mobile lift;
• 10. Bridge rack;
• 11. Universal rack;
• 12. Device for draining used oils;
• 13. Device for holding the car in a suspended state
• 14. Cabinet for tools and instruments;

Special post SP-9 for the replacement of front axles and beams

• 1. Locksmith workbench;
• 2. Wheel nut wrench multi-spindle suspended,
• 3. Multi-spindle multi-spindle nut driver;
• 4. Cassette for wheels; a chest for cleaning materials;
• 5. Monorail with a hoist;
• 6. Mobile lift;
• 7. Rack for front axles and beams;
• 8. Universal rack;
• 9. Trolley for removing and installing wheels;
• 10. Recoil stop.
• 11. Installation for pressing the pins
• 12. Cabinet for tools and instruments;

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 instruments;

Special post SP-12 TR for braking systems of KamAZ vehicles

• 1. Locksmith workbench;
• 2. Wrench for wheel nuts;
• 3. Cassette for wheels
• 4. Chest for cleaning materials;
• 5. Lift;
• 6. A device for testing the pneumatic drive of car brakes;
• 7. Universal rack;
• 8. Trolley for removing and installing wheels;
• 9. Recoil stop.
• 10. Device for pumping receivers with compressed air;

Special post SP-13 for the replacement of cabs and platforms of KamAZ vehicles

• 1. Locksmith workbench;
• 2. Capture for cabins;
• 3. Capture for platforms;
• 4. Crane beam;
• 5. Chest for cleaning materials;
• 6. Shelving for cabins and platforms;
• 7. Trolley for moving cabins and platforms;
• 8. Emphasis
• 9. Cabinet for tools and instruments;

Special post for the replacement of CPG engines SP-14

• 1. Recoil stop.
• 2. Bath for washing parts;
• 3. Locksmith workbench;
• 4. Oil dispenser;
• 5. Picking trolley;
• 6. Chest for cleaning materials;
• 7. Mobile post of a car mechanic;
• 8. Pneumatic wrench on suspension;
• 9. Footrest;
• 10. Lift;
• 11. Universal rack;
• 12. Device for suction of exhaust gases;
• 13. Device for draining used oils;
• 14. Cabinet for tools and instruments;
• 15. Mobile overpass for repair;

Special post SP-15 TR and adjustment of ignition system instruments

• 1. Locksmith workbench;
• 2. Chest for cleaning materials;
• 3. Post of a mobile mechanic-auto electrician;
• 4. A device for welding electrical equipment of cars;
• 5. Device for checking and cleaning spark plugs;
• 6. Device for testing breakers-distributors;
• 7. Universal rack;
• 8. Mobile electronic stand;
• 9. Table for instruments;
• 10. Recoil stop;
• 11. Device for suction of exhaust gases;
• 12. Cabinet for tools and instruments;

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 instruments;

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 instruments;

Special post SP-18 for the replacement of frames of KamAZ vehicles

1. Crane beam; 2. Lift; 3. Nut driver for ladder nuts; 4. Post mobile locksmith - 5. Oil dispenser; 6. Oil distribution tank; 7. Device for draining spent shih oils; 8. Device for draining cooling soup liquid; 9. Device for suction flue gases; 10. Rack for components and parts; 11. Rack for aggregates; 12. Rack for frames; 13. Rack for cabins;	14. Bath for washing parts; 15. Locksmith workbench; 16. Capture for engines; 17. Capture for cabins: 18. Capture for platforms; 19. Chest for cleaning materials; 20. Transitional bridge; Suspended pneumatic wrench 21. Welding machine; 22. Platform rack; 23. Universal rack; 24. Recoil stop; 25. Bridge holding device from capsizing; 26. Cabinet for tools and instruments;

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

1. Nut driver for ladder nuts; 2. Nut driver for ladder nuts; 3. Oil dispenser; 4. Oil dispenser; 5. Crane beam; 6. Crane beam; 7. Oil distribution tank; 8. Cabin stand; 9. Lift; 10. Lift; 11. Post mobile locksmith- 12. Post mobile locksmith- 13. Rack for aggregates; 14. Rack for frames; 15. Rack for components and parts; 16. Device for suction flue gases 17. Device for draining cooling soup liquid;

18. Device for draining spent shih oils; 19. Rack for components and parts; 20. Rack for aggregates; 21. Rack for frames; 22. Cabin stand; 23. Platform stand; 24. Locksmith workbench; 25. Cabinet for tools and instruments; 26. Bath for washing parts; 27. Universal rack; 28. Chest for cleaning materials; 29. Device for holding bridges from capsizing; 30. Capture for cabins; 31. Capture for engines; 32. Capture for the platform; 33. Welding machine; 34. Pneumatic wrench on suspension; 35. Recoil stop.

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 necks 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

1. Vertical drilling machine; 2. Hydraulic press (40t); 3. Sharpening machine; 4. Chest for cleaning materials; 5. Chest for waste; 6. Desktop bench press; 7. Fire extinguisher; 8. Overhead crane - beam; 9. Radial drilling desktop machine; 10. Sink; 11. Hand dryer; 12. Locksmith workbench; 13. Machine for boring brake drums and brake linings; 14. Rack for details; 15. Racks, supports for components and assemblies; 16. Stand for testing power steering; 17. Stand for testing pads after gluing;

18. Bench for testing the final drive gearboxes; 19. Stand for riveting brake linings; 20. Stand for gluing overlays; 21. Stand for checking shock absorbers; 22. Stand for testing pneumatic devices of brake systems; 23. Stand for disassembly, assembly and clutch adjustment; 24. Stand for the repair of hydraulic lifts (dump trucks); 25. Stand for the repair of cardan shafts and steering; 26. Gearbox repair stand; 27. Bridge repair stand; 28. Stand for the repair of final drive gearboxes; 29. Stand universal for testing gearboxes; 30. Bedside table for appliances and tools; 31. Urn for scrap metal; 32. Installation for washing aggregates; 33. A box of sand.

Carburetor shop

1. Bath for washing parts; 2. Desktop drilling machine; 3. A device for checking the elasticity of the springs of the diaphragm of fuel pumps; 4. A device for checking the jets and shut-off valves of carburetors; 5. A device for checking the limiters of the maximum speed of the crankshaft; 6. A device for checking fuel pumps and carburetors; 7. A device for checking fuel pumps on cars; 8. Manual rack press; 9. Sectional rack for storing carburetors; 10. Electric grinder;

11. Workbench for disassembly and assembly of carburetors; 12. Chest for cleaning materials; 13. Chest for waste; 14. Fire extinguisher; 15. Pneumatic clamping device; 16. Device for expanding tubes; 17. Sink; 18. Hand dryer. 19. Table for appliances; 20. Swivel chair; 21. Urn for non-ferrous metal; 22. Tool storage cabinet; 23. Cabinet for storage of materials and details; 24. Box with sand;

Shop fuel equipment(diesels)

Electrical shop

1. Locksmith workbench (dielectric worktop); 2. Chest for cleaning materials; 3. Desktop drilling machine; 4. Fire extinguisher; 5. Oscilloscope; 6. Device for cleaning and checking spark plugs; 7. Device for checking instrumentation and sensors; 8. Device for testing anchors; 9. Sink; 10. Rack hand press; 11. Hand dryer; 12. Machine for turning manifolds and milling grooves between plates;

13. Rack for storing electrical equipment; 14. Stand for testing - breaker-distributor; 15. Stand for testing the generator; 16. Stand for checking the starter; 17. Stand for disassembly and assembly of generators and starters with a set of accessories 18. Table for appliances; 19. Office table; 20. Swivel chair; 21. Drying cabinet; 22. Lathe; 23. Bedside table for storing tools; 24. Installation for washing parts; 25. Electric grinder; 26. Box with sand;

Battery section

1. Tank for distilled water; 2. Workbench for battery repair; 3. Capacity for electrolyte preparation; 4. Charger; 5. Loader crane with air drive 6. Chest for garbage; 7. Chest for cleaning materials; 8. Desktop drilling machine; 9. Fire extinguisher; 10. Stand for equipment; 11. Device for pouring electrolyte; 12. A device for draining the electrolyte from the battery and neutralizing it;

13. Probe for checking the battery; 14. Sink; 15. Hand dryer; 16. Storage rack for batteries; 17. Trolley for transportation of batteries; 18. Urn for scrap metal; 19. Hood for melting lead and mastic; 20. Cabinet for charging batteries; 21. Cabinet for instruments and fixtures; 22. Stand for acid bottles; 23. Electrodiscillator; 24. Electric crucible for mastic melting; 25. Electric crucible for melting lead 26. Box with sand;

Mednitsky shop

1. Locksmith workbench; 2. Loader crane with air drive 3. Chest for used cleaning materials; 4. Chest for garbage; 5. Chest for clean cleaning materials; 6. Fire extinguisher; 7. Bench stand for soldering irons; 8. Device for expanding and bending tubes; 9. Sink; 10. Hand dryer;	11. Rack for storage of radiators and fuel tanks; 12. Tube storage rack; 13. Stand for repair and testing of radiators; 14. Urn for scrap metal; 15. Installation for steaming and washing fuel tanks; 16. Exhaust cabinet for electric crucibles; 17. Electric muffle furnace for heating soldering irons; 18. Electric crucible for melting metals; 19. Box with sand;

Tire shop

Vulcanization shop

paint shop

1. Workbench for painting; 2. Funnels for paints, primers and solvents; 3. Hydraulic filter with centrifugal pump for air purification 4. Paint sprayer; 5. Red pressure tank 6. Metal mugs; 7. Chest for rags; 8. Oil and moisture separator; 9. Fire extinguisher; 10. Spray booth (for cars); 11. Sink; 12. Hand dryer;	13. Rack for storage of materials; 14. Rack for storage of fixtures and equipment; 15. Chair; 16. Thermoradiation reflectors (in the absence of a drying chamber); 17. Waste bin; 18. Installation for airless spraying; 19. Installation for applying anti-corrosion mastic; 20. Installation for the preparation of paints (drawing up colors); 21. Cabinet for storing paints; 22. A box of sand.

wallpaper shop

Forging shop

Welding and tinsmith shop

Federal Agency for Education of the Russian Federation

SYKTYVKAR FOREST INSTITUTE

State educational institution

Higher professional education

"St. Petersburg State Forest Engineering Academy

them. CM. Kirov"

Faculty of Forest Transport

Department of Automobiles and Automobile Economy

COURSE PROJECT

Discipline: Vehicle maintenance

Topic: Organization of TO-1 car KAMAZ 53212

KP. BLTP. 190601.4 DO.061219. PZ

Made by Skorobogatykh P.A.

Checked by Malashchuk P.A.

Head Department of Chudov V.I. Ph.D.

Syktyvkar 2009

Introduction

Maintenance machines is a set of preventive measures in the overhaul period aimed at preventing failures in units and assemblies and reducing the wear rate of parts. Maintenance includes control and diagnostic, fastening, lubricating, filling, adjusting, electrical and other types of work.

Vehicle maintenance has the following goals: to ensure the constant technical serviceability of units, components in the car as a whole; to maximize overhaul runs; guarantee traffic safety; ensure the minimum consumption of operating materials.

To achieve these goals in our country, a preventive maintenance system has been adopted, which provides for the mandatory implementation of a set of works at a given frequency in the process of using, storing and transporting vehicles. The technological process of car maintenance with a planned preventive system provides for a combination of mandatory work with work performed on demand, the need for which is determined as a result of checking the condition of the car. Maintenance of special equipment installed on the vehicle is carried out, if possible, simultaneously with the maintenance of the chassis.

Depending on the scope of work and the frequency of their implementation, maintenance is divided into the following types: control inspection, daily maintenance, maintenance No. 1 (TO-1), maintenance No. 2 (TO-2), seasonal maintenance (SO). The objective of this course project is to get acquainted with the system of car maintenance, draw up a technological map, determine the number and placement of workers, as well as select technological equipment. Make a drawing of the car in two projections indicating the number and place of the maintenance operation. And a diagram of the technological layout of the post with the arrangement of equipment and workers.

The main technical characteristics of the car KAMAZ 53212

Weight parameters and loads:

Curb weight of the vehicle, kg 8500

Carrying capacity of a / m, kg 11000

Gross weight, kg 19650

Gross trailer weight, kg 14000

Gross train weight, kg 33650

Installed engines:

Model 740.31-240 (Euro-2)

Type: diesel turbocharged, air-to-air aftercooled

Maximum net power, kW (hp) 165 (225)

Rated power, gross, kW (hp) 176 (240)

at the frequency of rotation of the crankshaft, rpm. 2200

Max. useful torque, N m (kgf m) 912 (93)

at crankshaft speed, rpm 1100-1500

Arrangement and number of cylinders V-shaped, 8

Working volume, l. 0.85

Cylinder diameter and piston stroke, mm 120/120

Compression ratio 16.5

Supply system:

Capacity fuel tank, l. 500

Electrical equipment:

Voltage, V 24

Batteries, V/A h 2×12/190

Generator, W/W 28/2000

Clutch:

Type friction, dry, two-disc

Hydraulic drive with pneumatic booster

Transmission:

Type mechanical, ten-speed

Mechanical control, remote

Gear ratios in gears:

7,82 4,03 2,5 1,53 1,000 7,38

6,38 3,29 2,04 1,25 0,815 6,02

Main gear:

Gear ratio 5.43

Pneumatic drive

Dimensions: drum diameter, mm 400

Brake lining width, mm 140

Total area of ​​brake pads, cm2 6300

Wheels and tires:

Wheel type: disc

Rim size 7.5-20 (190-508)

Tire size 10.00 R20 (280 R508)

Over engine type, high roof

Sleeper version

Platform:

The platform is onboard, with metal folding sides, depending on the configuration, it is equipped with a frame and an awning

Internal dimensions, mm * 6100×2320 or 6114×2420 ("euro")

Board height, mm * 500 or 725 ("euro")

Characteristics of a / m gross weight 19650 kg:

Maximum speed, not less than, km/h 90

Climbing angle, not less than, % 25

External overall turning radius, m 9.8

The list of routine maintenance work for the KAMAZ 53212 car

Maintenance TO-1 for the KamAZ 53212 car presented below is carried out in accordance with the "Regulations on the current repair and maintenance of rolling stock". According to this provision, the first maintenance for trucks is carried out every 4000 km. These works include control and diagnostic, inspection, fixing and lubrication and cleaning works.

The list of works includes:

General inspection:

1. Inspect the car, check the condition of the cab, platform, windows, rear-view mirrors, plumage, license plates.

2. Mechanisms of doors, locks of the sides of the platform, towing (support-coupling) device.

3. Check the operation of the windshield wiper and washers, the operation of the heating and glass heating system (in the cold season), and the ventilation system.

Engine, including cooling systems, lubrication:

4. Visually check the tightness of the engine lubrication and cooling systems (including the starting heater).

5. Check the operation of the valve mechanism by ear.

6. Check the fastening of the parts of the exhaust tract (downpipe, muffler, etc.), oil sump.

7. Check motor mounting.

8. Check condition and tension drive belts.

Clutch:

9. Check the free travel of the clutch pedal. Check the tightness of the hydraulic clutch release system.

10. Check the fluid level in the compensation tank of the master cylinder of the clutch release drive.

Transmission:

11. Check the fastening of the gearbox and its external parts.

12. Check the operation of the gearshift mechanism on a stationary vehicle.

Cardan gear:

13. Check the fastening of the cardan shaft flanges. Check the play in the hinged and splined joints of the driveline.

Rear axle:

14. Check the tightness of the connections of the rear (middle) axle.

15. Check the fastening of the gearbox housing, axle shaft flanges.

Steering and front axle:

16. Check the tightness of the power steering system.

17. Check the fastening of the nuts of the levers of the pivot pins of the ball pins of the steering rods.

18. Check the play of the steering wheel and steering rod joints.

Brake system:

19. Check the condition and tightness of pipelines and devices of the brake system.

20. Check the stroke of the brake chamber rods.

21. Change the alcohol in the antifreeze.

Chassis.

22. Check the condition of the frame, components and suspension parts by inspection.

23. Check fastening of ladders and spring pins, fastening of wheels.

24. Check the condition of the tires and the air pressure in them: remove foreign objects stuck in the tread and between the paired wheels.

Cabin, platform (body) and plumage.

25. Check the condition and operation of the locking mechanism, the stop-limiter and the safety device of the tipping cab.

26. Check the fastening of the platform to the vehicle frame,

27. Check the mounting, footpegs, mudguards. Inspect cab and platform surfaces; if necessary, clean corrosion spots and apply a protective coating.

Supply system.

28. Check by inspection the condition of the devices of the power system, their fastening and tightness of the connections.

Electrical equipment.

29. Check the operation of the sound signal, instrument panel lamps, lighting and signaling, headlights, sidelights, rear lights, brake light and light switch.

30. Check the condition and fastening of electrical wires.

31. Check the fastening of the generator and the condition of its contact connections.

32. Clean the battery from dust, dirt and traces of electrolyte; clean the ventilation holes, check the fastening and reliability of contact of the wire lugs with the output pins; check the electrolyte level.

Lubrication and cleaning work:

33. Lubricate the friction units and check the oil level in the crankcases of units with a chemotological map.

34. Clean the transmission and axle breathers.

Vehicle check after service:

35. After servicing, check the operation of the units, components and devices of the car on the go or at the diagnostic station.

Technological map of maintenance of the car KAMAZ 53212

Table 1

Technological map TO-1 of the KamAZ 53212

No. of work performed	Name and content of works	Service Location	Number of service places	Devices, tools, fixtures, model, type	Technical requirements and instructions
General inspection
1	Inspect the vehicle and check the condition of the cabin, platform, windows, rear-view mirrors, plumage, paint, license plates and rear-view mirrors	Top, front, back	-	-	Cabin glass, headlights, sidelights, direction indicators must be intact. Platform boards should not have cracks or breaks. The condition of license plates must meet the requirements of the Rules traffic. Rear view mirrors must be intact and properly adjusted
2	Check the serviceability of the cabin door locks, platform side locks, towing device	Top, back	-		The mechanisms of the doors, locks of the sides of the platform must be in good order. The towing device must be securely fastened to the frame, and its hinged bracket must be cottered
3	Check the operation of the windscreen wipers, the windshield washer and the windshield blower and heater (in winter)	in the cockpit	3	-	The wiper blades must fit snugly along the entire length of the edge to the surface of the windshield and move without jamming or stopping. During operation, the brushes must not touch the seal. The glass washing device must be in good working order and wash evenly the entire glass surface.
Engine, including cooling and lubrication systems
4	Visually check the condition and tightness of the cooling systems, engine lubrication, cabin heating system and starting heater	Up and down	4	-	Oil leakage in the places where the oil filter and crankcase are attached is not allowed. Leakage of coolant in the pipes and radiator is not allowed
5	If necessary, eliminate leakage in the pipelines of the cooling system, engine lubrication, cabin heating system and starting heating	Also	4		Leakage of oil, coolant and fuel is eliminated by tightening nuts, clamps or replacing individual elements of parts
6	Listen to the operation of the valve mechanism	Above	1	-	Let the engine listen to his work, Stukov's valve mechanism properly adjusted, it shouldn't be.
7	If necessary, adjust the clearances between the valves and rocker arms.	Also	16	Device for adjusting valves I801.14.000 (10), set of probes No. 2 (15)	Thermal gaps in the gas distribution mechanism are adjusted on a cold engine no earlier than 30 minutes after stopping. At each position, simultaneously adjust the valve clearances of the two cylinders in the order of operation: 1-5-4-2-6-3-7-8 by turning the crankshaft 90 0 thermal gaps in the following order: install the piston of the first cylinder in c. m.t. compression stroke, turn the crankshaft in the direction of rotation (counterclockwise, as viewed from the flywheel side) through an angle of 60 0 (turning the flywheel by an angular distance between two adjacent holes corresponds to between two adjacent holes corresponds to turning the crankshaft by 30 0 ), At the same time, the valves of the 1st and 5th cylinders are closed (the valve stems can be easily turned by hand), check the tightening torque of the nuts for fastening the rocker arms of the adjustable cylinders and, if necessary, tighten them, to adjust the gap, loosen the nut of the adjusting screw, insert a feeler gauge into the gap and, turning the screw with a screwdriver, set the required clearance. While holding the screw with a screwdriver, tighten the nut and check the clearance. The gap should be 0.25-0.3 mm for inlet valves and 0.35-0.4 mm for exhaust valves.
8	Check the fastening of the oil sump, exhaust pipes, flanges of the exhaust pipes of the muffler to the cylinder block and, if necessary, fix	Up and down	3	Auto mechanic set (large) I-148 (11), chisel (14), hammer (13).	Tighten the oil crankcase fastening nuts with a tightening torque of 1.5-1.7 kgf∙m, exhaust pipes 4.5-5.4 kgf∙m, silencer exhaust pipe flanges 4.5-5.4 kgf∙m
9	Check the mounting and, if necessary, fix the engine to the frame	Above	1	Auto mechanic set (large) I-148 (11)	The nuts of the engine mounting bolts on the frame must be tightened and cottered. Tightening is carried out with a tightening torque of 5.5 - 6 kgf∙m
10	Check the condition and tension of the alternator and water pump drive belts	Above	1	Auto mechanic set (large) I-148 (11)	To ensure the tension of the belt by moving the generator, a correctly tensioned belt when pressing on the middle of the belt with a force of 4 kgf, the deflection should be 15-22 mm.
Clutch
11	Check clutch pedal free play	in the cockpit	1	Ruler (16)	Pedal free play should be 6-12 mm
12	Adjust clutch pedal free play if necessary.	Also	1	Auto mechanic set (large) I-148 (11)	Pedal free play is set by adjusting the clearance between the piston and the master cylinder piston pusher. To adjust the clearance between the piston and the master cylinder piston pusher, pass the eccentric pin that connects the upper eye of the pusher to the pedal lever. Turn the eccentric pin so that the movement of the pedal from the top stop to the moment it touches the piston pusher is 6-12 mm, then tighten and cotter the castle nut.
13	Check the tightness of the hydraulic clutch release system	In cab and below	1	-	Fluid leakage in the main, working cylinder and pipeline is not allowed
14	If necessary, repair the tightness of the pipelines of the clutch release drive	Also	1	Auto mechanic set (large) I-148 (11)	Liquid leakage is eliminated by tightening the nuts and replacing individual elements
15	Check the fluid level in the compensation tank of the master cylinder of the clutch release actuator	Front	1	-
16	If necessary, add fluid to the expansion tank of the master cylinder of the clutch release actuator	Also	1	-	The liquid level in the tank from the top edge should be 15-20mm
Transmission
17	Check the fastening of the gearbox and its external parts	Up and down	-	Auto mechanic set (large) I-148 (11)	Tighten the gearbox mounting bolts with a tightening torque of 5.5-6 kgf∙m
18	Check the operation of the gearshift mechanism on a stationary vehicle	in the cockpit	1	-	Gear shifting should be done without jamming
cardan gear
19	Check the fastening and, if necessary, fix the flanges of the cardan shafts, check the play in the hinged and splined joints of the cardan transmission	Bottom	16	Auto mechanic set (large) I-148 (11)	Backlash in hinged and splined joints is not allowed; tightening of flanges should be done with a tightening torque of 12.5-14 kgf∙m
Rear (middle) axle
20	Check the tightness of the connections of the rear (middle) axle, if necessary, eliminate the leak	Bottom	2	Auto mechanic set (large) I-148 (11)	Oil leakage is not allowed. Leakage should be eliminated by tightening the nuts or by replacing individual elements of the unit; tightening should be performed with a tightening torque of 1.5-1.7 kgf∙m
21	Check and fasten and, if necessary, fix the nuts for fastening the gearbox housing, axle shaft flanges	Bottom and top	-	Auto mechanic set (large) I-148 (11)	Tighten the reducer fastening nuts with a tightening torque of 16-18 kgf∙m
Steering and front axle
22	Check the tightness of the power steering system	Above	-	-	Oil leakage in the oil line and in the pump is not allowed.
23	If necessary, repair the leakage of the power steering system	Also	-	Auto mechanic set (large) I-148 (11)	Oil leakage is eliminated by tightening the nuts and replacing individual elements
24	Check fastening and splitting of the nuts of the pivot pin levers. Troubleshoot if necessary	Bottom	3	Auto mechanic set (large) I-148 (11), pliers (12)	The nuts for fastening the levers of the pivot pins must be tightened and cottered. Tighten the levers with a tightening torque of 36-40 kgf∙m. The levers must not have play in the socket and on the key
25	Check the fastening and cotter pin nuts of the ball pins of the longitudinal and transverse steering rods. Troubleshoot if necessary	Also	3	Auto mechanic set (large) I-148 (11), pliers (12)	The ball stud nuts must be tightened and cottered. Finger play in conical sockets is not allowed. tighten ball pins with a tightening torque of 9-10 kgf∙m
26	Check steering wheel play	in the cockpit	1	Device model NIIAT K-402 (8)	The check is carried out on an equipped car (without load) with the engine running at a speed of 600 - 1200 min -1, with normal tire pressure, set the front wheels straight, The free play of the wheel on a new car should not exceed 15 0. Maximum allowable play 20 0
27	Check play in tie rod joints	Below and in the cab	3	-	The play in the joints of the steering rods must be checked by the relative movement of the ball pins and tips or heads of the rods when the steering wheel is turned sharply in both directions. Play is not allowed in the steering rod joints
Brake system
28	External inspection and according to the readings of standard instruments, check the serviceability of the brake system	Below and in the cab	-	-	The pressure created by the compressor should be 6.2-7.5 kgf / cm 2. When you press the brake pedal, the pressure should drop sharply by no more than 0.5 kgf / cm 2
29	Check the condition and tightness of pipelines and devices of the brake system and, if necessary, eliminate the malfunction	Up and down	-	Auto mechanic set (large) I-148 (11)	Depressurization of the brake system is not allowed. Depressurization is eliminated by tightening the nuts or replacing individual elements of the system
30	Check and, if necessary, adjust the stroke of the brake chamber rods	Bottom	6	Auto mechanic set (large) I-148 (11), pliers (12), ruler (16)	The stroke of the rods should be no more than 40mm. Carry out the check in the following order: install a ruler parallel to the rod with its end resting on the brake chamber housing, mark the location of the extreme point. Press the brake pedal to the stop (pressure in the pneumatic actuator is not less than 6.2 kgf / cm 2, the drums are cold, parking brake system off), mark the location of the same point. The difference between the obtained values ​​is the value of the stroke of the rod. The stroke of the rod is adjusted by turning the axis of the worm of the adjusting lever, having previously unscrewed the lock by two or three turns. By rotating the axis, set the smallest stroke
31	Change the alcohol in the antifreeze	Above	1	Auto mechanic set (large) I-148 (11)	Drain the sediment from the filter housing. To fill in alcohol and control its level, release the draft handle to the lower position and fix it by turning it 90 0, unscrew the plug with a level indicator, pour in alcohol and close the filler hole, turn on the fuse
Chassis
32	Check the condition of the frame, components and suspension parts by inspection	Bottom	-	-	Weakening of riveted joints, cracks and spars and cross members should not be
33	Check the fastening of the spring ladders	Above	-	Auto mechanic set (large) I-148 (11), wrench for spring ladder nuts model I-314 (7)	to tighten the stepladders with the tightening torque of the front ones - 25-30 kgf∙m, the back 95-105 kgf∙m
34	Check wheel alignment	Also	30	Wrench for wheel nuts model I-303M (6) or wheel wrench 535M (9)	Tighten the nuts with a torque of 25 - 30 kgf∙m evenly, in one, two or three steps, starting from the top.
35	Check the condition of the tires and the air pressure in them, remove foreign objects stuck in the tread and between the paired wheels	Also	10	Air dispenser model TsKB S-401 (1) or tip with pressure gauge model 458 (2), pliers (12)	The tire should not have cracks, ruptures, swellings. The tire valve must have a cap. Air pressure 5.3-7.3 kgf / cm 2. Residual depth tread pattern in the center of the treadmill must be at least 1.0 mm
Cabin and platform
36	Check the condition and operation of the locking mechanism, stop-limiter and safety device	Above	-	-	The locking mechanism and safety devices must be in good condition
37	Check the fastening of the platform to the vehicle frame and, if necessary, fix	Also	-	Auto mechanic set (large) I-148 (11)	Tighten the platform fastening nuts with a tightening torque of 18-21 kgf∙m
38	Check the fastening of the footrests, mudguards, fix if necessary	Also	-	Auto mechanic set (large) I-148 (11)	Tighten the footrests with a tightening torque of 1.5-2.5 kgf∙m, mudguards 1-2 kgf∙m
39	Inspect the surface of the cabin and platform, if necessary, clean the corrosion spots and apply a protective coating	Top, front, back	-	Metal brush	Rust, peeling paint, cracks are not allowed
Supply system
40	Visually check the condition and tightness of the power supply system: fuel pump low pressure, filter fine cleaning fuel, fuel tank, fuel sump filter, fuel line connections, high pressure fuel pump and secondary filter	Above	-	-	Leakage of fuel in the instruments and fuel lines of the system is not allowed. Fuel lines must not be bent or cracked.
41	If necessary, eliminate leakage in the devices and connections of the fuel lines of the power supply system	Also	-	Auto mechanic set (large) I-148 (11), pliers (12)	Leakage of fuel from the devices and connections of the fuel lines of the power supply system is eliminated by tightening individual elements of the connections. to tighten with a tightening torque of 4.5-5.4 kgf∙m
electrical equipment
42	Check the operation of the horn, headlights, sidelights, tail light, brake light, instrument panel lamps and direction indicators	In the cockpit and top, front, rear	-	-	All lamps should give light without flashing, and the sound signal should be sharp without rattling or wheezing.
43	If necessary, replace defective headlights, sidelights and taillight bulbs	In the front and in the back	-	Auto mechanic set (large) I-148 (11) sanding paper (19)	When replacing lamps, it is necessary to clean the contacts of the cartridges.
44	Check the condition and fastening of electrical wires	Cabin front, top, rear	-	Auto mechanic set (large) I-148 (11), pliers (12)	Electrical wires must be in good condition and securely fastened.
45	If necessary, insulate damaged electrical wires (up to 200 mm long)	Also	-	Pliers (12), assembly knife, insulating tape	Damaged electrical wires must be carefully insulated.
46	Check and, if necessary, fix the generator	Above	1	Auto mechanic set (large) I-148 (12)	-
47	Clean the surface of the battery from dust, dirt and electrolyte	Above	1	Rubber gloves (17), rags (20), ammonia or soda ash bath, brush (18)	The surface of the battery must be dry and clean. The electrolyte must be wiped with a rag soaked in a solution of ammonia or soda ash.
48	Clean the vent holes in the battery plugs	Also	6	Battery cap wrench (17), wooden stick Æ 1.5mm, rags (20), rubber gloves (17)	-
49	Check the electrolyte level of the electrolyte in the battery and top up with distilled water if necessary.	Also	6	Level tube (17), rubber gloves (17), rubber bulb (17)	The electrolyte level in the cells must be 10-15 mm higher than the upper edge of the safety grid
50	Check the fastening and condition of the wire lugs with the battery terminals	Also	2	Auto mechanic set (large) I-148 (11)	Lug terminals must make good electrical contact.
51	If necessary, clean and lubricate the battery terminals and cable lugs	Also	2	Rags (20), sandpaper (19)	Oxidized battery terminals and wire lugs should be cleaned and their non-contact surfaces should be greased with Litol 24 GOST 21150-87
Lubrication and cleaning work
52	Check the oil level in the crankcase	Above	1	Oil dipstick and rags (20)	Check the oil level with the engine off in the following order: remove and wipe the dipstick, insert it into the socket until it stops and remove it. The oil level must reach the top mark.
53	Top up crankcase oil if necessary	Also	1	Oil dispenser model 367MZ (4), rags (20)	Change oil M-10G 2 k, GOST 8581-78, in winter - M-8G 2 k, GOST 8581-78, all-weather - DV-ASp-10V
54	Check the oil level in the power steering pump reservoir	Also	1	-	The oil level must be between the marks on the dipstick.
55	Top up the oil in the power steering reservoir if necessary.	Also	1	Rags (20)	Add oil to the norm with the engine running at the minimum crankshaft speed. Oil for the hydraulic system of the car brand "P".
56	Check the oil level in the gearbox housing (KP)	Bottom	1	Auto mechanic set (large) I-148 (11), rags (20)	Unscrew and wipe the dipstick, insert into the socket until it stops and remove. The oil level must reach the top mark.
57	If necessary, top up to the norm in the gearbox housing	Also	1	Auto mechanic set (large) I-148 (20), installation for refueling car units transmission oil models 3161 (3)	TSp-15k, GOST 23652 - 79 (at temperatures not lower than minus 30 0 C), TM5-12RK, TU38.101.844 - 80 (at temperatures up to minus 50 0 C).
58	Check the oil level in the crankcase of the rear (middle) axle	Also	2	Auto mechanic set (large) I-148 (11)	Oil in crankcase rear axle should be at the level of the control hole
59	If necessary, top up the oil in the crankcase of the rear (middle) axle	Also	2	Auto mechanic set (large) I-148 (11), installation for refueling car units with transmission oil 3161 (3)	TSp-15k, GOST 23652 - 79 (at temperatures not lower than minus 30 0 C), TN5-12RK, TU38.101.844 - 80 (at temperatures up to minus 50 0 C).
60	Clean the gearbox and rear (middle) axle breathers	Bottom and top	3	Rags (20), wire 1.5 mm in diameter	-
61	Lubricate the king pins steering knuckles front axle	Bottom	4	Solidolon blower model 390 (5)	Grease Litol - 24, GOST 21150 - 87. Substitutes: solid oil Zh, GOST 1033 - 79 or solid oil C, GOST 4366 - 76, Lubricate through grease fittings until fresh grease is squeezed out
62	Lubricate the front spring pins	Front	2	Also	Also
63	Tie rod joints	Bottom	4	Also	Also
64	Lubricate brake adjusters	Also	6	Also	Also
65	Expander shaft bushings	Also	6	Also	Lubricant Litol - 24, GOST 21150 - 87. Substitutes: grease Zh, GOST 1033 - 79 or grease C, GOST 4366 - 76, Lubricate through grease fittings, making no more than five strokes with a syringe
Organizational work. Registration of documents and quality control of maintenance of the car
66	Set the car to the maintenance post.	Fast	-	-	The car must be installed at the working post only after the repair of great labor intensity, cleaning and washing work, in a clean and dry condition.
67	Enter data on the performance of TO1 into the record sheet for maintenance and current repairs of the car.	office desk	-	-	-
68	Provide assistance and monitor the quality of the work of performers.	-	-	The operation is performed by a master or a senior locksmith.

Map-scheme of the arrangement of performers at the maintenance post

Table 2. Map-scheme of the arrangement of performers at the maintenance post

Appointment of the post	The serial number of the performer and his qualifications	Place of execution	Number of works and sequence of their execution	Notes
Control and inspection work, maintenance of the engine, electrical equipment, gearbox, switchgear, clutch, lubrication work.	No. 1, Car mechanic of the 3rd category	Top, front, rear, cab	3, 11, 12, 13, 14, 18, 26, 27, 28, 30, 42, 44, 45, 1-5,10, 22, 23, 6, 7, 36, 38, 39, 8, 9, 17, 21, 33, 34, 35, 40, 41, 43, 46-55, 15, 16	Operation 42 is performed by the 1st and 3rd executor jointly.
Lubrication, cleaning, refueling, running gear, transmission, cardan shafts and RU	No. 2, Car mechanic of the 2nd category	Bottom	13, 14, 27-30, 4, 5, 8, 17, 19, 20, 21, 24, 25, 32, 56-61, 63-65	Operations 27 and 30 Performed by the 1st and 2nd executor jointly
Organizational work, paperwork and quality control of service.	No. 3 Car repairman of the 4th category (foreman)	Above	64, 65, 66	The tasks of the foreman include paperwork, quality control and assistance in difficult situations.

Table of basic and additional equipment

Table 3. Timesheet of the main and additional equipment

No. p / p	equipment identification	Model, type, GOST	Brief technical information	Manufacturer
1	Air dispensing automatic column	TsKB S-401	Stationary, automatic; supply air pressure 5. .8 kgf / cm 2; measurement limits on a scale from 1.5 to 6.5 kgf / cm 2, scale division value 0.1 kg / cm 2	Bezhetsk plant "Autospecial equipment"
2	Handpiece with pressure gauge for air hose	458	Manual, universal; pressure measurement limit 6 kg/cm 2 ; the price of division of the pressure gauge scale is 0.2 kg / cm 2.	Also
3	Transmission oil filling station	3161	Stationary, submersible, with automatic mode of operation; productivity through two sleeves not less than 12 l/min	Cherepovets plant of special equipment "Krasnaya Zvezda"
4	Oil dispenser with pump unit	376M3	Stationary, submersible with automatic mode of operation; productivity 8-12 l/min	Also
5	Mobile brine blower with electric drive and hopper	390	Mobile, with electric drive; maximum developed pressure 400 kg/cm 2 ; productivity 150 g/min; useful capacity of the bunker	Kochubeevsky plant "Autospecial equipment"
6	Wheel nuts for trucks and buses	I-303M	Mobile, electromechanical, inertial-shock action; tightening torque of the nut at the first position of the load 50-60 kgf∙m	Gremyachinsky plant "Autospecial equipment"
7	Nut wrench for spring ladder nuts (ditch)	I-314	Maximum torque 82 kgf∙m	Chita plant "Autospecial equipment"
8	Universal device for checking the steering of cars	NIIAT K-402	Manual, mechanical, universal; measurement range; on the scale of the backlash meter 25 - 0 - 25 o, on the scales of the dynamometer up to 2 kgf
9	balloon wrench	535M	-	Kazan SEZ "Autospecial equipment"
10	Engine valve adjuster	I801.06.000	Tubular wrench combined with a screwdriver	-
11	Auto mechanic set (large)	I-148	Contains 44 items. Key sizes, mm - from 7 to 32	Kazan SEZ "Autospecial equipment"
12	Combined pliers	Pliers 7814.0161 1X9 GOST 17438 - 72	-	-
13	Locksmith steel hammer	Hammer 7850-0053 Ts 12XR GOST 2310-70	Rated weight 500g	-
14	Cold chisel	Chisel 2810-0189 GOST 7211-72		-
15	Probe set #2	Probes No. 2 GOST 882-75	The thickness of the probe plates is 0.02-0.10; 0.15-0.50mm	-
16	Measuring metal ruler	Ruler 1-150	-	-
17	Set of instrument and tool for battery maintenance	E-401	Portable, consists of 15 pieces	Novgorod SEZ "Autospecial equipment"
18	hair brush	GOST 10597-70	-	-
19	sandpaper paper	GOST 6456-75	-	-
20	cleaning rags	GOST 5354-74	-	-
21	locksmith workbench	ORG-1468-01-060A	-	Own production
22	Chest for cleaning materials	OG.03-000	-	Also
23	waste bin	OG.16-000	-	Also

Conclusion

In the course of the work carried out, a scheme for carrying out maintenance at one post for the KamAZ 53212 vehicle was developed. A list of operations performed during the first maintenance was determined, which includes 35 items. During maintenance, fixing, refueling, adjustment, and inspection work is performed. A map-scheme of the arrangement of performers was drawn up. Compiled a timesheet of the main and additional equipment. The graphic part of the course project has been completed. The first part of which is a Drawing of the car in two projections indicating the number and place of the maintenance operation. The second part is a diagram of the technological layout of the post with the arrangement of equipment and workers.

Bibliography

1. Technology for performing routine maintenance of the first and second maintenance of the GAZ 53A car.

2. Central design and technology bureau for the introduction of new technology and research work in road transport (TSENTRAVTOTECH). - M. Transport, 1978. - 136s.

3. Regulations on the maintenance and repair of rolling stock road transport Approved on 20.09.1984 M.: Transport, 1986. 73 p.

4. Practical guide for maintenance and repair of KamAZ P69 type 6X4 / E.A. Mashkov. - M.: Mashinostroenie, 1994. - 243 p.: ill.

5. Report card of garage and technological equipment for motor transport enterprises different power. S.A. Nevsky. - M.: Ed. TSENTRRUDAVTOTRANS, 2000. - 93s.

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Collection technological maps for the maintenance and current repair of the contact network, revised, significantly expanded and prepared for publication by the Regulatory Research Station for Power Supply of the Design and Implementation Center for the Organization of Labor of the Ministry of Railways Russian Federation(NIS E PVC Ministry of Railways of the Russian Federation).

When processing existing and developing new technological maps, materials from the Department of Electrification and Power Supply of the Ministry of Railways of Russia, VNIIZhT, and railways were used; developments of specialists, including and, as well as regulations on the device and operation of the contact network.

The collection is designed for a wide range of engineering and technical workers and electricians for the maintenance and current repair of the contact network, and can also be used in training for the power supply economy.

Technological maps of the collection are developed. B. C. Kravchenko,. took part in the preparation of the issue. The collection is prepared for publication under the general editorship.

Responsible for the release (CE Ministry of Railways of Russia) and (PVC of the Ministry of Railways of Russia).

With the release of this collection, all previously published technological maps for the maintenance and current repair of the contact network are canceled. Please send comments and suggestions on the collection to the address: 107228 Moscow, Novo-Ryazanskaya st., 12, room. 401, NIS E PVC of the Ministry of Railways of Russia.




ISBN -0 © CE MPS RF, 1998

Rented in a set January 15, 1999 Signed v print 03/23/99

Format 60x84/16. Circulation 5000 copies. Publishing house "Transizdat", LR No. 000 dated 01.22.98 Tel.: (0, Printing house IPO "Polygran", Moscow. Order No. 81

Printed from the finished original layout in the printing house of the IPO "Polygran" Moscow, Pakgauznoye sh., 1

MINISTRY OF COMMUNICATIONS OF THE RUSSIAN FEDERATION

Department electrification and electricity supply

APPROVE:

Head of the Department of Electrification and Power Supply

Ministry of Railways of Russia

V. V. MUNKIN

TECHNOLOGICAL CARDS

TO WORK

CONTACT NETWORK DEVICES

ELECTRIFIFIED

RAILWAYS

BOOKII

MAINTENANCE AND REPAIR

CE

№ 000-5/1-2

1999.

A common part......................,......................... ................................................. ...............................6

1. MAINTENANCE

CHAPTER 1.1. DETOURS, DETOURS, INSPECTIONS

Map 1.1.1. Detour by inspection of the catenary .................................................................. ...........eleven

Map 1.1.2. Extraordinary detour with contact suspension inspection .............................................. 13

Map 1.1.3. Extraordinary detour with current collection check .............................................................. ....17

Map 1.1.4. Bypass with inspection to assess the condition and scope of repair of catenary suspension .............................................................. ................................................. ..........................................nineteen

Map 1.1.5. Extraordinary detour with contact suspension inspection .............................................29

Map 1.1.6. Mounted inspection of the catenary .................................................................. ..............34

Map 1.1.7. Inspection of the transition of the power line through the contact network ... ... ... ... 38

Map 1.1.8. Inspection of a vertical safety shield on an artificial structure .............................................................. ................................................. .................................40

Map 1.1.9. Inspection of a horizontal protective shield on an artificial structure .............................................................. .............,.....,...................... .................................42

Map 1.1L0. Inspection of the electric traction track circuit .......................................................... ...........44

Map 1.1.11. Inspection of the grouping point of the docking station..............................................45

CHAPTER 1.2. DIAGNOSTIC TESTS AND MEASUREMENTS

Map 1.2.1. Diagnosis of control parameters of the contact suspension by a laboratory car with a scoring assessment of its condition ............................................................... ................................48

Map 1.2.2. Measurements of zigzags, offsets and height of the contact wire suspension from a removable insulating tower .................................................................. ................................................. .........50

Map 1.2.3. Measurements of zigzags, offsets and the height of the contact wire suspension from the railcar ............................................................................._... .......:~........................................ ...................................54




Map 1.2.4. Diagnosis of porcelain plate-type insulators located on the supports of the contact network direct current from the side

way................................................. ................................................. .........................................57

Map 1.2.5. Diagnosis of plate-type porcelain insulators located on the supports of the AC contact network from the side

way..........g...................... .........................,......................... .........................................61

Map 1.2.6. Diagnosis of plate-type porcelain insulators of amplifying and supplying DC and AC wires located on independent supports or on the field side of the contact supports

networks ................................................. ................................................. .........................................65

Map 1.2.7. Diagnosis of plate-type porcelain insulators on

insulated flexible crossbar .............................................................. .........................................70

Map.1.2.8. Diagnostics of catenary insulators of alternating current with the electron-optical device "Filin-3" and ultrasonic flaw detector UD-8............................................................... ................................................. ................................................. ................75

Map 1.2.9. Diagnostics for heating of current-carrying clamps and contacts

disconnectors with devices of the IKD or IKT type .............................................. ...................77

Map 1.2.10. Measuring the dimensions of the supports.................................................... .................................80

Map 1.2.11. Measuring the wear of a contact wire with a hand measuring tool .............................................................. ................-................................ ...............................81

Map 1.2.12. Static performance measurement and condition check

current collectors of electric rolling stock .............................................................. .......................84

Map 1.2.13. Testing the contact suspension of the main tracks with a current collector having an increased static pressure .............................................................. ................................................. 89

Map 1.2.14, Preventive testing and measurements of transformers

current TFN-35 grouping point .............................................. .............................................91

Map 1.2.15. Preventive tests, measurements and adjustment of the protection equipment of the docking station (ZSS) ............................................................... ................................................. ..............98

Map 1.2.16. Preventive tests and measurements of 3.3/27.5 kV switchgear busbars

grouping point .......................................................... ...............................................109

Map 1.2.17. Switch preventive testing and measurements

Central Research Institute of the Ministry of Railways of the point of grouping .............................................. ...............................................

Map 1.2.18. Preventive testing and measurement of the MPS switch

3.3/27.5 kV grouping point .......................................... ................................................. ...117

Map 1.2.19. Preventive testing and measurement of circuit equipment

control, protection and own needs of the grouping point ..............................................

Map 1.2.20. Preventive testing, measurement and performance verification

equipment signal pointer"Lower pantograph" ........................................................122

Map 1.2.21. Measurements with a spark gap check

(IP) ........................: ..................... ..............................:..........."....... ...............................................127

Map 1.2.22. Measurements with a function check of the protective device in

group grounding circuits ...............: .............................. ................................................. ....129

Map 1.2.23. Measuring the resistance of the ground circuit of a support with individual grounding .............................................................. ................................................. ....................................133

Map 1.2.24. Group ground input resistance measurement

support ............................; .............. ................................................. .........................................141

Map 1.2.25. Measuring the individual resistance of the earth circuit

support united by a group grounding cable .............................................................. ...........

Map 1.2.26. Measurement of leakage currents from reinforcement of foundations and reinforced concrete supports .............................................................. ...............................:..................... ..:........ ………………………..148

Map 1.2.27. Measuring rail-to-ground potentials and compiling (adjusting) a potential diagram .............................................................. ......:...................................... .............

Map 1.2.28: Measurements to determine the degree of corrosivity of the soil in relation to steel reinforcement of reinforced concrete supports (foundations)............................................... ................................................. ................................................. ..............155

Map 1.2.29. Measurements with checking the insulation of the anchor from the guys of the support .............................................. ... .................... .....................:................................,..................158

Map 1.2.30. Measurements with verification of additional insulation in the grounding nodes of a support with a sectional disconnector or a horn arrester and

details of suspension fastening in an artificial structure ..............................................

Map 1.2.31. Measurements with checking the insulation of the suction line in DC sections .............................................................. ................................................. ...............................166

Map 1.2.32. Diagnosis of the state of the underground part of a centrifuged reinforced concrete support using the ADO device ....................................

Map 1.2.33. Diagnosis of the state of the underground part of a centrifuged reinforced concrete support using the DIACOR device ...................................174

Map 1.2.34. Ultrasonic diagnostics of a centrifuged reinforced concrete support with an assessment of its bearing capacity ........178

Map 1.2.35. Tests and measurements with verification of a special choke-transformer (DT) .............................................................. ................................................. ................................................. ..184

Map 1.2.36. Tests and measurements with checking the insulation of the motor drive, the control panel and the remote control circuits of the disconnector.................................................................................. .........................187

Map 1.2.37. Testing the scheme for melting ice or preventive heating of the catenary .................................................................................. ................................................. ...................192

2. CURRENT REPAIRS

CHAPTER 2.1. COMPLETE INSPECTION AND REPAIR

"Map 2.1.1. Comprehensive check condition and repair of the contact sub-

weights ................................................. ...............................................".......... ...................................197

Map 2.1.2. Comprehensive inspection of the condition and repair of non-insulating interface of anchor sections.................................................................................. .........„....................................... .........................213

Map 2.1.3. Comprehensive inspection of the condition and repair of the supply (suction line) or reinforcing wire .................................. , .........._.........................................................................220

Map 2.1.4. Comprehensive inspection, assessment of the condition and scope of repairs

underground part of the support (foundation) with excavation of soil .................................................................. ............224

Map 2.1.5. Comprehensive survey, assessment of the condition and volume of repair of the above-ground part of the reinforced concrete support .............................................................. ................................................. ...........228

Map 2.1.6. Comprehensive examination, assessment of the condition and scope of repairs,

forecasting the service life of a metal supporting structure .............................................. 231

Map 2.1.7. Comprehensive inspection of the condition and repair of rigid anchoring of the wire and its fasteners, attachment points of anchoring branches

wires to the compensating device............................................................... ...............................236

Map 2.1.8. Comprehensive check of the condition and repair of the support guy…………………239

Map 2.1.9. Comprehensive check. condition, and repair of the console.......................................241

Map 2.1.10. Comprehensive inspection of the condition and repair of brackets, racks and extensions for hanging reinforcing, supplying and other wires

contact suspension .............................................................. ................................................. ..............247

Map 2.1.11. Comprehensive inspection and repair of flexible crossbar

with stress relief .............................................................. ................................................. ...........251

Map 2.1.12. Comprehensive inspection and repair of the insulated flexible cross member without stress relief .............................................................................. ...................................................257

CHAPTER 2.2. CONDITION CHECK, ADJUSTMENT AND REPAIR

Map 2.2.1. Checking the condition, adjusting and repairing the insulating interface of the anchor sections and the neutral insert .................................................................. ...............................................263

Map 2.2.2. Checking the condition, adjusting and repairing the air arrow.... ……….270 Map 2.2.3. Checking the condition, adjustment and repair of the sectional insulator .............................................................. ................................................. ................................................. 277

Map 2.2.4. Checking the condition, adjustment and repair of contact suspension in artificial structures .............................................................. ................................................. ...........283

Map 2.2.5. Checking the condition, adjusting and repairing the compensating device .......................................................... ................................................. ............................................... 288 Map 2.2.6. Checking the condition, adjusting and repairing the sectional disconnector without de-energizing .............................................................. ................................................. ......................295

Map 2.2.7. Checking the condition, adjusting and repairing the sectional disconnector with stress relief .............................................................. ................................................. .........................305

Map 2.2.8. Checking the condition, adjusting and repairing the manual or motor drive and the control panel of the sectional disconnector.................................................................. .................................307

Map 2.2.9. Checking the condition, adjusting and repairing the horn gap without removing the voltage .............................................. ................................................. .......................................312

Map 2.2.10. Checking the condition, adjusting and repairing the horn arrester with voltage relief .............................................................. ................................................. .................317

Map 2.2.11. Checking the condition, adjustment and repair of the tubular arrester .............................................................. ....................,.,..............,........... ...................................................321

Map 2.2.12. Checking the condition and repair of individual grounding of a contact network support, grouping point, artificial and other metal structures …………………………………………………………………………………………….. 324

U Kart 2.2.13. Checking the condition and repair of individual grounding of a reinforced concrete support .............,………………….......................

Map 2.2.14. Checking the condition and repair of group grounding supports ……………...331

Map 2.2.15. Checking the condition and repairing the point of connection of the suction line to the traction rail circuit .............................................................. ................................................. ...................336

Map 2.2.16. Checking the condition, adjustment and repair of transformers

currentTFN-35 grouping point .............................................. ..............,..............,........,......339

Map 2.2.17. Checking the condition, adjustment and repair of protection equipment

docking stations (ZSS).................................................. ................................................. ..

Map 2.2.18. Checking the condition, adjustment and repair of tires and disconnectors RU-3.3 / 27.5 kV of the grouping point .............................................. ................................................. .............344

Karga 2.2.19. Checking the condition, adjusting and repairing the switch of the Central Research Institute

IPU of the grouping point ..... „„ .......................................... .................... „...........,. „...........,.., 348

Map 2.2.20. Check of a condition, adjustment and repair of the MPS-switch

3.3/27.5 kV grouping point .......................................... ........ "………………... ...................355

Map 2.2.21. Checking the condition, adjusting and repairing interlocks, equipment and circuits for auxiliary needs of the grouping point………………………………………..................................361

CHAPTER 2.3. PARTS REPLACEMENT AND CLEANING

Map 2.3.1. Replacing the retaining clip....,……………….............,.,.................. ......364

Map 2.3.2. Replacing the contact wire butt clamp...............................................................367

Map 2.3.3. Replacing the supply, connection or adapter terminal ...............................

Map 2.3.4. Replacing the string clamp……………………………………………………378

Map, 2.3.5. Replacing the wedge clamp under tension .............................................., .............................. ....381

Map 2.3.6. Replacing the wedge clamp when de-energized.,............................,.,....,.185

Map 2.3.7. Replacement of the movable block of the compensator...............................................389

Map 2.3.8. Replacing the fixed block of the compensator.................................................... ......392

Map 2.3.9. Clamp replacement .................................................................. ...............395

Map 2.3.10. Replacing the eyelet .................................................................. ................................................398

Map 2.3.11. Installing a shunt on a contact wire with local wear .... …………401

Map 2.3.12. Replacing a bolted butt joint of copper or aluminum (steel-aluminum) wires with an oval tubular connector……………………. 405

Map 2.3.13. Decontamination of the mortise insulator in the lower fixing cable, fixing guy or in the longitudinal wire .................................................................. ......................409

Map 2.3.14. Cleaning from contamination of insulators of the contact network located on supports and crossbars .............................................................. ......,..,........................................ ...............................412

Map 2.3.15. Cleaning From contamination of anchor insulators with insulated

flexible cross member without stress relief .............................................................. ...............„.„.415

Map 2.3.16. Decontamination of the suspension insulators and the second insulators from the support of the neutral insert of the lower fixing cable of the insulated flexible crossbar under tension............................................................... ................................................. ...............417

Map 2.3.17. Washing of catenary insulators with a mobile unit UPO.................................................................................. ................................................. ...............................421

Map 2.3.18. Decontamination of the lower above-ground part of supports and foundations, sealing of cracks and painting .............................................................. ................................................. .................424

GENERAL PART

This collection contains typical schemes technological processes for maintenance (TO) and current repairs, (TR) of the contact network of direct and alternating current and points of grouping of docking stations. The list of technological maps of the collection corresponds to the scope of work of Appendix 5 to the "Rules for the design and technical operation of the contact network of electrified railways"" (PUTEKSCE-197).

The collection is intended to guide the organization and performance of work. Technological maps provide for the performance of work by personnel of contact network areas (ECC) and specialized teams of repair and inspection sites (RRU) of power supply distances (EC) equipped with vehicles, mechanisms, devices and main mounting devices, provided for in Appendix 4 to PUTEKS TsE-197. The maps reflect the current level of engineering and technology, organization of production and labor in the performance of work on the contact network, the components and structures of which correspond to standard projects and PUTEX.

The development of technological maps is based on:

Typical time limits for maintenance and Maintenance contact network of electrified railways (Moscow, Transizdat, 1995).

Technological maps for work on the overhaul and current repair of the contact network (Moscow, Transport, 1973).

Rules for the design and technical operation of the contact network of electrified railways, TsE-197 (Moscow, Transport 1994).

Collection of technical instructions and information materials on the economy of power supply (Moscow, Transizdat, 1996).

Preventive testing of power equipment of traction substations. Collection of guidelines (Moscow, Transport, 1967).

Instructions for the protection of railway underground structures from corrosion by stray currents, TsE-3551 (Moscow, Transport, 1979).

Guidelines for the maintenance and repair of contact network support structures, K-146-96 (Moscow, Transizdat, 1996).

Instructions for grounding power supply devices on electrified railways TsE-191, (Moscow, 1993 p).

Faults and deviations from the established norms revealed during the maintenance or repair work, which can cause interruptions in the movement of trains, power outages or violating safety requirements, must be eliminated immediately, about which the work manager must report to the power dispatcher and then be guided by his instructions. Their implementation is carried out according to the relevant Technological maps and is additionally standardized, and in the absence of time standards - according to actual costs.

The technological maps define the categories of work in relation to safety measures, set out the basic requirements to ensure the safety of personnel when performing work in accordance with the "Safety Rules for the Operation of the Contact Network of Electrified Railways and Automatic Blocking Power Supply Devices", TsE / 4504 (Moscow, Transport 1988 .) and "Safety instructions for electricians of the contact network", TsE / 4816 (Moscow, Transport, 1992).

The cards indicate the sequence of operations that ensures the safety of personnel. The sequence must be strictly observed when performing work. The composition of the performers and the norms of time correspond to the "Typical norms of time for maintenance and current repairs of the contact network of electrified railways", approved by the Ministry of Railways of the Russian Federation on 06/07/95.

The composition of the performers does not include signalmen for fencing the place of work. Their number is determined by the "Instruction for ensuring the safety of train traffic during work on the contact network from insulating removable towers", TsE / 4373 (Moscow, Transport, 1987), taking into account local conditions and is specified in the work order. The number of signal accessories and portable radio stations required for them is not provided for in section 3 of the technological maps and is determined additionally.

In * a number of technological maps (for work not included in the collection of Standard Time Standards) the time standards are indicated, adopted on the basis of statistical and calculated data. In the future, it is planned to develop technically justified time standards for these works.

The time standards given in the technological maps take into account only operational time and must be adjusted in accordance with the instructions of the general part of the "Typical time standards for maintenance and current repairs of the contact network of electrified railways" (Moscow, 1995!). The performance of additional operations during the TS, not provided for by the technological map, is normalized according to the actual costs.

It is allowed to combine several works, if the composition of the performers, their qualifications and the category of work in relation to security measures are the same in the technological maps for these works. In these cases, the time limit for performing combined work must be reduced by multiplying by K \u003d 0.925 - when performing work from an isolating removable tower and by K \u003d 0.936 - for work without an isolating tower.

PART 1. MAINTENANCE

CHAPTER 1.1. DETOURS , BYPASSES , INSPECTIONS Technological map № 1.1.1.

DETOUR WITH INSPECTION OF THE CONTACT SUSPENSION 1. Composition of performers

Head of the district, electrician or electrician of the 6th category Conditions for the performance of work

The inspection tour is carried out:

2.1. From the front cab of an electric locomotive or electric train.

2 2. By order and notification of the energy dispatcher, indicating the time of the detour, the name of the section to be bypassed, and the number of the train from which the detour will be made..

3. Mechanisms, devices, assembly; fixtures, tools, protective equipment and signal accessories

Notepad for writing with writing utensils, butt

4. The norm of time for 1 km of the way is 0.05 people. h.

5. Preparatory work

5.1. Receive an order to perform work and instructions from the person who issued it.

5.2. Notify the energy dispatcher of the upcoming detour, indicating the track number, the name of the haul, station (or section), the start time of the detour and the number of the train from which the detour will be made.

5.3. Arrive at the station (stop) from which the detour will begin.

6. Diagram of a sequential technological process

	Name of operations
	Performing an Inspection	6.1.1. When driving around, carefully observe the condition of the contact suspension, identify visible damage to its individual elements, violations of their adjustment or position, as well as deviations from technical requirements and the norms set forth in PUTEX (TsE-197). When driving, pay special attention to: The position of the supports (tilt and deflection are not allowed), the reliability of their fixing in the ground (there should be no subsidence, landslides or soil erosion near the supports), serviceability of the grounding; Compliance of the position of the clamps with the air temperature or technical standards, the distance between the contact wire and its main rod, the lower fixing cable or fixing guy (it is unacceptable to reduce this distance - preload), the serviceability of inclined strings or rigid struts, as well as lift limiters; The magnitude of the sag of the longitudinal wires and their relative position, the preload of the wires to the grounded structures, the presence of dangling wires, the sagging of the wires of the middle anchorings or the anchoring branches of the mates of the anchor sections; The condition of the insulators, the presence of damaged insulating parts or the presence of bending of the connecting fittings, as well as the preload of the suspension insulators of the garlands to grounded structures; The condition of the compensatory devices (breaks in the cores of the cables are not allowed, the distances between the blocks, as well as from the bottom of the compensator weights to the ground and from the top of the cargo bar to the fixed compensator block must correspond to the air temperature); The condition of the cable and strings (breaks of strings and cores on the cable are not allowed, the slope of the strings along the path should not exceed 30 ° to the vertical); Condition and adjustment of arresters, sectional insulators, air arrows; Condition of disconnectors, loops and drives; The presence of mechanical vibrations ("dancing") of the wires of the contact network; Interaction of pantographs of oncoming trains and contact suspension along the adjacent track; The voltage level on the instruments in the driver's cab. Sharp fluctuations of the kilovoltmeter needle during movement indicate a violation of the current collection. 6.1.2. Inspection results l all identified deviations from technical standards record in a notebook indicating their location (name of

		rut or station, track number, support, span, etc.). 6.1.3. If deviations are detected that can cause disruptions in the movement of trains, take measures through the energy dispatcher to eliminate them, organize the passage of trains at this place with the pantographs lowered or with a speed limit.

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

	Name and content of the work	Place of work	Number of seats or service points	Labor intensity	Devices, tool, fixtures, model, type	Technical requirements and instructions
General car inspection (0.43 Person hour)
	Inspect the car, check the condition of the body, windows, plumage, license plates, paint, door mechanisms.	Top, saloon			Visually	License plates must be legible, doors must close tightly, glass must not be cracked.
	Check the operation of the windscreen wipers, the windshield washer and the windshield blower and heater (in winter)				Visually	The wiper blades must fit snugly along the entire length of the edge to the surface of the windshield and move without jamming or stopping. During operation, the brushes must not touch the seal. The glass washing device must be in good working order and wash evenly the entire glass surface.
	Check the condition and operation of the interior lighting devices				Visually	Interior lighting should respond to the opening of doors and turn on mechanically
	Check the condition and operation of the door and hood opening mechanisms; if necessary, remove them to check the condition of the parts				Visually	Doors, hood, trunk lid should open without jamming and excessive noise
Engine (1.3 Person hour)
	Visually check the tightness of the engine cooling system and the heating system.	Motor-ny, from below, salon			Visually	Leakage of coolant in the pipes and radiator is not allowed. Coolant leakage is eliminated by tightening nuts, clamps or replacing individual elements of parts
	Check the fastening of the radiator and its lining	Motor			Key 10 to 12	Fasteners must not be loosened
	Check the fastening of the fan, water pump	Motor			Key 10 to 12	Do not loosen fasteners
	Check the condition and tension of the drive belt.	Motor			Keys 17 and 13	Tighten loose belts, pressure force 100 N, deflection value 10-15mm
	Visually check the tightness of the lubrication system.	Motor			Visually	Oil leakage at the attachment points of the oil filter and crankcase is not allowed.
	Check cover fastening camshaft and toothed belt tension				See Attachment	See Attachment.
	Check muffler piping.				Visually	Exhaust system tightness
	Check the fastening of the engine oil pan				Visually	No smudges
	Check the condition and fastening of the engine mounts.	Top, bottom			Visually	Supports should not be deformed and transmit vibration to the body
		motorized, bottom			Visually, oil dispenser	Change of oil
Coupling (0.15 person hour)
	Check the action of the return spring, free and full travel, pedals, operation clutch.	Bottom and interior			Ruler, keys 12, 13	Liquid leakage is not allowed. The full travel of the pedal is 120-130 mm., adjustable with a nut on the clutch fork.
Gearbox(0.14person hour)
	Visually check the condition and tightness of the gearbox				Visually	Oil leakage is not allowed
	Check the operation and fastening of the gearshift mechanism; if necessary, fix the gearbox and its components	Motor				there should be no extraneous sounds, spontaneous disengagement of gears is not allowed
Steering(0.45 person hour)
	Check and, if necessary, adjust the angles of the front wheels; if necessary, carry out static and dynamic wheel balancing				Stand SKO-1	See Attachment
	Check the fastening of the crankcase of the steering gear, steering column				Keys, 12,13,14	Tighten loose bolts
	Check the play of the steering and steering rod joints	Bottom and interior			Visually, the torque wrench is 22 mm.	The play of the steering wheel should not exceed 5o (18-20mm). There should be no outside noise. The movement and rotation must be smooth. Steering wheel nut tightening torque 31-50 N
	Check ball stud nuts				visually	Cotter pinning is unacceptable, tightening torque 66-82 N
	Front wheel drives, condition of the ball joint and upper support				See Attachment	Replacement of defective elements
	Check the mounting of the anti-roll bar				visually	Tightening if necessary or replacing defective parts
Brake system (0.43 person hour)
	Check the condition and tightness of the connections of pipelines of the brake system				Visually	Leakage brake fluid not allowed. Check the tightness of the brake chamber and pipe connections by pressing the brake pedal 2-3 times. Work to be performed by two performers
	Check fastening brake valve and details of its drive	Motor			visual
	Check the condition of the brake drums and discs, pads, linings, springs	Up and down			visual	Pad wear should not exceed 1.5-2 mm
	Check the fastening of the brake support plates of the rear wheels				visual	Lift
	Check the operation of the brake booster, the amount of free and working travel of the brake pedal; if necessary, add fluid to the main brake cylinders; when air enters hydraulic system drive to remove air from the system	Engine, bottom and interior			See Attachment	See Attachment
	Check the operation of the drive and the operation of the parking brake	Bottom and interior			Key for 13	The number of handbrake clicks from 4-5
Suspension, wheels (0.44 per hour)
	Check the tightness of the shock absorbers, the condition and fastening of their bushings				Visually	Check condition, tighten if necessary
	Check the condition of the rims and the fastening of the wheels, the condition of the tires and the air pressure in them; remove foreign objects stuck in the tread				Visually	There should be no visible damage and extraneous noise and knocks
Body(0.24 person hour)
	Check the condition of ventilation and heating systems, as well as door seals.				visually	Replace seals if damaged.
	Check the condition of the special anti-corrosion coating and painting of the body. If necessary, clean corrosion spots and apply a protective coating.				Visually	Repair damage
Power system (0.16 person hour)
	Check the fastening and tightness of the fuel tanks, the connection of pipelines	motorized, bottom			Visually	Fuel leakage is not allowed, tighten loose fasteners
	Check the operation of the drive, completeness of opening and closing of the throttle and air dampers	Motor			Key 10 and screwdriver	The damper should move without jamming, fully open and close.
Rechargeable battery (0.3 person hour)
	Check the condition of the battery by the density of the electrolyte and the voltage of the cells under load	Motor			Hydrometer, load fork	Under load, the charge is from 13.5 to 14.4V, the density of the cell is 1.27-1.29
	Check the condition and fastening of the electrical wires connecting the battery to the ground and the external circuit, as well as the fastening of the battery in the socket	Motor			Rags, 10% solution of ammonia or soda ash	Leads and wire lugs must be free of oxides and lubricated. Tighten loose bolts
Generator, starter (0.24 per hour)
	Inspect and, if necessary, clean the outer surface of the generator and starter from dust, dirt and oil	Motor			Degreaser, rags, compressed air source	Replace worn brushes
	Check alternator and starter	Motor			Keys. 17 and 13	Lift
	Check alternator pulley mounting	Motor			Head for 17	Lift
Ignition devices (0.23 per hour)
	Check the condition and, if necessary, clean the surface of the ignition coil, low and low wires high voltage from dust, dirt oil.	Motor			Gasoline, rags	Replace damaged wires
	Remove spark plugs and replace	Motor			Candle wrench 21 mm	New candles
Lighting and signaling devices (0.28 per hour)
	Check the fastening and operation of the rear lights and brake light, direction indicators, instrument panel lamps and horn	Top and salon			Visually	Checking connectors, replacing light bulbs
	Check the installation, fastening and operation of the headlights; adjust headlight beam direction	Top and salon			Device K310, visually	Luminous flux adjustment
Lubrication and cleaning works (0.48 per hour)
	Lubricate door hinges, door keyholes, rubbing areas of the door opening limiter	motorized and top	Friction nodes		Oil dispenser, syringe	Lubricate components and assemblies
	Change the oil in the engine crankcase and at the same time replace the filter element of the fine oil filter	Motor				The oil level is set between min and max
	Clean the breathers and top up the oil in the crankcases of the vehicle units	Motor-ny and from below			Rags, funnel with extension tube	The level is set to the max mark for lubrication of 5th gear
	Replace filter element air filter engine	Motor			crosshead screwdriver	Replace filter

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