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

Introduction
Technological maps current repairs units were developed by "Tsentravtotech" of the Ministry of Autotrans of the RSFSR at the request of the manufacturing company "KAMAZAutocentre" production association KamAZ.

Technological maps are developed based on the following materials:

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

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

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

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

5. Manual for routine repairs of KamAZ-5320, KamAZ-5511, KamAE-4310 vehicles (shop work). RT-200-15-0066-82.

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

During development technological maps Equipment, instruments and tools were used that were mass-produced by the Rosavtospetsoborudovanie plants and non-standardized equipment, including those developed at KamAZ.

Technological maps contain standards for labor intensity of work, agreed upon with the “Tsentro-rgtrudavtotrans” of the Ministry of Autotrans of the RSFSR.

Technological maps have undergone experimental testing.

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

The range of repaired units, assemblies, mechanisms and devices was selected based on the typical and most frequently encountered work on routine repairs of KamAZ vehicles at enterprises.

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

To make it easier to read technological maps, they contain diagrams and drawings.

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

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

Current repairs of units, components, mechanisms and devices must be carried out in workshops or areas designated for this purpose.

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

Maintenance workshops for units must be equipped with the necessary lifting and transport mechanisms. Units and assemblies that have a significant mass should be transported, removed and installed from stands using lifting and transport mechanisms equipped with devices that protect against possible falling of assemblies and assemblies.

Devices for securing units and assemblies on stands must prevent the possibility of units and assemblies moving or falling. Tools and accessories must be in good condition.

The procedure for carrying out routine repair work is set out in technological maps, which reflect the sequence of disassembly and assembly, troubleshooting and testing of units and components, equipment, devices and tools, technical conditions and instructions, labor intensity of work and qualifications of performers.

The technological process for routine repair of units should include: cleaning and washing work on the car; identifying faulty components on the car; removal of faulty units from the vehicle; transportation to the workshop; sub-disassembly; external washing (cleaning); disassembly;

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

Only persons who have undergone safety training and have been trained in safe labor techniques in special classes organized by the enterprise administration are allowed to work on the repair of units, components, mechanisms and devices.

Shops or areas must have first aid kits stocked with medications necessary to provide first aid.

Modern development of production places increased demands on the maintenance of the infrastructure of industrial enterprises. These include ensuring a continuous production process, introducing design and technological improvements to finished products, reducing the time required for manufacturing products and carrying out repair work, increasing the efficiency of spending fixed and working capital of the enterprise. A systematic analysis of manufacturing companies reveals two opposing trends: enterprises are introducing more and more new types of work, and at the same time, the qualifications of personnel are increasingly decreasing.

As a result, the capacity of the tasks being performed often exceeds the capacity of the workers. This directly leads to a decrease in productivity, deterioration in the quality of work and the occurrence of emergency situations, which can lead not only to equipment failure, but also to industrial accidents. And if a drop in productivity and quality is fraught with material losses, then a deterioration in the level of safety jeopardizes the activity of the enterprise as a whole.

To ensure compliance with increased requirements for infrastructure maintenance, enterprises create specialized units within their boundaries, and also attract specialized organizations to perform certain types of work. But, as practice shows, simply changing the staffing structure or attracting contractors is not enough to improve productivity and safety during work. Solving these problems requires the use of a number of special effective tools, one of which is technological maps, which determine the order of performing standardized operations of the technological process.

What does the technological map contain?

A technological map is a unified document intended for enterprise employees engaged in the repair or maintenance of production equipment. The map contains a list of necessary equipment, tools and sets of personal protective equipment, a list of labor protection instructions. It specifies the sequence, frequency and rules for performing operations, types and quantities consumables, time standards, material costs, as well as regulatory documents used in assessing the quality of work.

Technological maps are developed with the aim of systematizing and increasing the safety of the production process by streamlining the actions of personnel in repair processes or technological services equipment. Their implementation also contributes to solving problems of determining and optimizing material and technical costs per unit of product or service.

Advantages of implementing technological maps

The development of technological maps allows the company to obtain the full amount of information necessary for the high-quality and safe organization of the production process, replenishing the lack of knowledge about innovations in the field of equipment, technology for its repair and maintenance.

As practice shows, the use of technological maps helps reduce the rate of equipment wear by 15-20%, while repair costs are reduced by 13-14%, and the labor intensity of work is reduced by 16%. Compliance with the instructions contained in the documents ensures trouble-free operation of the equipment throughout the entire period between scheduled repairs and significantly reduces the risks of emergency situations and unscheduled shutdowns of the production process.

In addition, the surveys carried out during preparation make it possible to further plan the timing and costs of periodic repair and maintenance work, increase production efficiency and reduce the time required for planned repairs.

The presence of a technological map greatly simplifies the preparation of production schedules, preparation of planning and economic documentation, personnel training and systematization of the work of the supply service.

The introduction of technological maps contributes to a systematic reduction in the costs of repair and maintenance of equipment, providing significantly lower costs of funds and resources in comparison with the costs of technical re-equipment and reorganization of the production structure.

A challenge for professionals

When starting to develop technological maps, you must first familiarize yourself in detail with the objectives of the enterprise and its capabilities in terms of equipment, tools, personnel and logistics. Often, enterprises, trying to minimize costs, prefer to entrust this work to full-time technical employees. At the same time, they forget about the importance of a professional approach and familiarity with innovations in the field of industry quality and safety standards, which only a specialized organization can guarantee.

It is often beneficial to entrust the development of technological maps to external organizations. having high level competence in this area. In particular, it can provide services for the development of technological maps for enterprises in any industry. The preparation and transfer of documentation to the customer can be done either in standard paper form or using specialized software.

Involving our specialists has a number of advantages compared to independent development:

• objective and impartial assessment of opportunities and prospects by independent experts;
• access to regularly updated professional databases of regulatory documentation, equipment, tools and materials;
• regular retraining and training of personnel in connection with the emergence of new technologies and solutions;
• interest of company specialists in achieving results.

An additional advantage of cooperation with our company is our rich practical experience in the field of maintenance of infrastructure of industrial enterprises, implementation innovative technologies and modernization of technological processes.

Over the course of several years, we have been developing our competencies in cooperation with the largest enterprises in the engineering, chemical, petrochemical and metallurgical industries. The company's experience allows us to talk about a real reduction in labor costs when using technological maps.

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

List of works during maintenance:

Power unit: calibrated tightening of the nuts securing the head, pan, journal supports, eliminating knocks in the engine, adjusting and restoring valve tightness, checking the tension of the generator-fan belt, checking the tightness and filling level of the cooling system, technical condition of the pump, flushing and adjusting the carburetor, checking fuel pump operation, checking the fuel level in the carburetor, checking the ignition system - condition high voltage wires, condition of the distributor, condition of the spark plugs, clutch operation - reliability of operation, condition of the clutch parts, oil change is carried out at a certain mileage.

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

Gearbox: check the oil level and quality, change the oil at a certain mileage, check for extraneous noise, smoothness of speed switching, reliability of speed fixation, condition of bearings, condition of differential - condition of gears, satellites, bearings, condition of cardan transmission: determination of technical condition by play in the connection, external condition of the unit.

Support system: checking the operation of shock absorbers, springs, rods, the condition of ball joints and dampers, checking wheel camber and toe, checking wheel wear, condition of wheel bearings, wheel balancing.

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

Power supply system: checking the condition of the generator, the condition of the commutator, brushes, rectifier, the condition of the contacts, the output voltage and current, replace the bearing lubrication, the condition of the starter, the condition of the brushes and commutator, the developed torque, the condition of the contacts, checking the condition of the battery, the level and density of the electrolyte, the condition terminals, checking and correct readings of instrumentation, checking lighting and alarm systems.

Body: lubricate the hinge components, reliability of operation and locking of the locks, condition of the body, re-preserve the body.

Lubricate in accordance with the components lubrication chart.

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

daily, TO-1, TO-2. Maintenance allows you to maintain the functionality of your vehicle's mechanisms between repairs. Current repairs are integral part maintenance. It is intended to restore the functionality of the unit.

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

When a car arrives at a car repair shop for maintenance or routine repairs, it is necessary to complete the following list of mandatory works:

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

The reliability and durability of components and assemblies depends on the quality of lubricants and compliance with the terms of their replacement, determined by the manufacturer of the vehicle and component units.

Let's look at the types of work performed and their frequency using the example of a Gazelle car.

Table 4. Periodic maintenance of Gazelle cars (TO-1, TO-2, CO)

	Periodicity	Technical requirements	Tools and materials
Engine
Check:
Condition and tightness of cooling, power, and lubrication systems				Leakage of coolant, fuel, oil is not allowed	Visually
Ignition timing angle ZMZ-4025, -4026, UMZ-4215.				Adjust if necessary	Straboscope
Check fastening:
Cylinder heads (4215, ZMZ-4025, 4026)
Oil sump				Tighten loose nuts	Key 13 mm
Settler filter (UMZ-4215), filter fine cleaning fuel (UMZ-4215)				Tighten loose nuts	Key 13 mm
Radiator and water pump, thermostat housing, water pump pulley and tension pulley**				Tighten loose nuts	Key 13 mm
Generator and starter				Tighten loose nuts	Key 17 mm, 19 mm
Carburetor air and throttle valve drives				Tighten loose fastenings	10 mm wrench, screwdriver
Adjust:
Belt tension (belts** 4215, ZMZ-4025, 4026) of the drive units				Ruler with dynamometer, wrenches 12, 13 mm
Minimum crankshaft speed at idling and carbon monoxide (CO) and hydrocarbon (CH) content				Tachometer, screwdriver, gas analyzer
Gap between spark plug electrodes				The gap should be 0.8-0.95 mm (ZMZ-4025, 4026); 0.7-0.85 mm (ZMZ-4061, 4063, UMZ-4215)	Dipstick, spark plug wrench
Gap between valves and rocker arms (4215, ZMZ-4025, 4026)				13 mm wrench, screwdriver, feeler gauge
Clear:
Frame air filter carburetor and blow out the filter element				Blow out the corrugations from the inside and then from the outside	Compressed air source
Carburetor air filter housing and replace filter element
Fuel filter-sump housing and its filter element (autumn)				After installing the housing in place, make sure there are no fuel leaks	Keys 10, 12 mm, pliers,
Settling cup of the fine fuel filter (for UMZ-4215 engines) and rinse the mesh filter element. Replace the paper filter element***				After installing the glass in place, make sure there are no fuel leaks	Unleaded gasoline, rags
High Voltage Wires and Spark Plug Interference Suppressor Tips				Unleaded gasoline, rags
External surfaces of ignition devices, cover and slider of the ignition sensor-distributor (4215, ZMZ-4025, 4026)				Unleaded gasoline, rags
Drain the sediment from fuel tank(autumn)				Gasoline container, 24 mm wrench
Drain sediment from the fuel filter-sump housing
Replace:
Spark plugs				Spark plug key
Fine fuel filter (for engines ZMZ-402, 406)				Fuel leakage is not allowed
Transmission
Check:
Condition and tightness of the hydraulic clutch, gearbox and rear axle				Liquid and oil leaks are not allowed	Visually
Tightening the rear axle drive gear flange nut				Keys 14, 17, 27 mm,
Rear axle gearbox mount				Tighten loose nuts	Key 14 mm
Fastening the clutch master and slave cylinders, the clutch master cylinder pusher axis				Tighten loose nuts	Keys 13, 17 mm
Clutch housing to cylinder block				Tighten loose nuts	Key 14 mm
Fastening the gearbox and its housings				Tighten loose nuts	Keys 12, 19 mm
Clear:
Transmission and rear axle breathers

• ** Every 500 km.
• ***For filter with paper filter element

Organizational structure

The organizational structure of the enterprise is linear-functional. The structure of the enterprise, the number of employees is determined by the staffing table, internal rules and job descriptions enterprises. Workers. are appointed to a position and dismissed from it by order of the head of the enterprise. Structure. The staff of an enterprise is a set of linear and functional bodies of the enterprise, as well as a system of their connections, interdependencies and interactions. The staff structure of an enterprise is influenced by: the number of employees subordinate to one manager, the volume of turnover, specialization, and the number of subordinate trading units. Organizational structure. Pizza Treviso LLC is shown in the picture

Basic information, elements of the technological map (TC):

1. List of works

2. Technical requirements

3. Tools, equipment

4. Operating materials (brand, volume)

5. Standard time (person-min.)

6. Diagram, drawing or photograph

7. Control points

Technological map (Table 1).

Type of examination:

Daily maintenance of a sedan car: NISSAN brands PRIMERA

Performer: car owner.

Table 1. Flow chart for daily vehicle maintenance

	Name of the procedure (operation)	Technical requirements, instructions, notes (diagnostic signs)	Tool, equipment, device	Operating materials (brand, volume)	Standard time (person/min.)	Diagram, drawing or photograph	Control points
	Daily external inspection of the car body	Checking for chips and scratches
	Checking the proper condition of all doors	Make sure the door latches are working properly	by opening/closing
	Checking the reliability of opening and closing the engine compartment hood	Make sure all latches lock securely. Make sure the second latch prevents the hood from closing when the primary latch is lowered.	by opening/closing
	Visual inspection of the engine compartment	Checking for traces of oil, brake and coolant leaks	visually
	Checking the windshield washer fluid	Check if there is enough fluid in the washer reservoir	visually
	Checking the engine coolant level	On a cold engine, check the coolant level.	visually				The coolant level should be at the max mark
	Checking the engine oil level	Remove the dipstick from the engine, wipe it with a dry cloth and reinsert it completely into the same place. Now take it out and check the oil level.	Oil level dipstick, rag				The level should be between the max and min marks.
	Checking the fluid level in the power steering reservoir	Unscrew the reservoir cap and check the fluid level	visually				The level should be between the max and min marks
	Check the condition of the pipelines	Pay attention to the tightness of the fitting nuts, signs of leakage and the presence of cracks	visually
	Checking the brake fluid level and working fluid hydraulic clutch	Make sure that the brake fluid level is between the min and max marks, which are marked on the wall of the master cylinder barrel and the clutch hydraulic reservoir.	visually				The brake fluid level should be at the max mark
	Checking the battery	Check the electrolyte level in each battery section	visually				The electrolyte level should be between the min and max marks
	Daily external inspection luggage compartment car
	Checking the proper condition of all doors, including the trunk lid	Make sure that the trunk lid latches are working properly	by opening/closing
	Checking the presence of a spare wheel, jack, wheel wrench, pump		visually
	Checking the driver's bag		visually
	Daily inspection of car tires		visually
	Check for cuts, damage, or excessive wear	Carefully check for damage or signs of heavy wear.	visually
	Checking tire pressure		Visually or using a pressure gauge	pressure gauge MD-214 GOST 9921			2.0-2.3 kg/cm2
	Daily inspection of lighting devices
	Checking headlights, brake lights, side lights, turn signals	Check the reliability of fastening and serviceability of all lighting devices	visually
	Daily inspection of windshield wiper blades
	Checking the wiper blades	Check the quality of glass cleaning, inspect the brushes, pay attention to the presence of cracks and signs of wear on the rubber elements	visually

Total daily service- 20 person-min.