Maintenance

Maintenance - This is the list of work performed in the intervals between scheduled and unscheduled equipment repairs, which allows us to ensure the required level of equipment reliability.

Proper maintenance and operation of industrial equipment can significantly reduce equipment repair costs and reduce downtime.

Mechanics often have a question: what list of works should be included in maintenance, who should perform it (working personnel or support services), where to find a standard maintenance manual. I will try to answer these questions further.

Let me start with the fact that the main documents regulating the use of a maintenance system are considered to be two GOSTs: GOST 28.001-83 “System for maintenance and repair of equipment. Basic provisions” and GOST 18322-78 “System for maintenance and repair of equipment. Terms and definitions.” According to these documents, maintenance is divided into types and methods.

A painful issue for chief mechanics is who should perform equipment maintenance. On the one hand, it involves supervision and care of equipment, often without stopping it. On the other hand, it is included in the MRO or PPR system as planned routine work, as an intermediate set of measures between scheduled repairs.

A good solution is to divide the concept of maintenance into routine and planned.

Routine Maintenance(hourly, shift inspection and control, lubrication and other similar work) must be carried out production staff workshop or site. Firstly, it is rational from a personnel point of view (it does not require an increase in the repair service staff). Secondly, this approach is useful for purely methodological purposes - it allows operators working on equipment to become more deeply familiar with the device and principle of operation.

Current or unscheduled maintenance includes:

· strict compliance with the equipment operation requirements specified in the technical operational documentation of the manufacturer;

· monitoring the operating mode of equipment to prevent overloads;

· temperature control;

· control of lubrication frequency at all points;

· instant shutdown and de-energization of equipment that has failed;

· visual control wear of components and mechanisms;

Scheduled Maintenance

Scheduled maintenance and repairs(if necessary) is carried out by maintenance personnel. Planned work traditionally includes work that requires disassembly of any piece of equipment. Of course, such work must be performed by a trained repairman. staff.

Planned or regulated maintenance performed by repair personnel include:

· diagnostics and monitoring of equipment performance characteristics;

· adjustment and adjustment;

· cleaning working parts and other places prone to clogging;

· topping up and changing oil, replacing filters;

· identification of violations in the operation of equipment;

All results of changes in the condition of the equipment being maintained (both during routine and scheduled maintenance) must be recorded. For this purpose they use various methods: keep operational or repair logs, enter them into the computer, use inspection cards.

The method of organizing maintenance and repair using technological maps Maintenance. They allow not only to bring to an accessible form service personnel list and frequency of work during maintenance, but also to monitor the execution of these works. The effect can be enhanced by organizing workaround routes for repair personnel, drawing up specifications for consumables, and drawing up a lubricant map.

Typical maintenance manuals does not exist. The bulk of such documents have a local status and are developed within the framework of a management system. In addition, each type of equipment requires its own list repair work. In order to get rid of unnecessary paperwork, the equipment available at the enterprise is sorted into groups and maintenance methodologies are developed for them.

It is convenient to separate the equipment in two stages.

The first is in accordance with the balance sheet of fixed assets:

· technological equipment;

· electrical engineering;

Most often, mechanics are interested in the “technological equipment” group, as it is the most numerous and requires constant attention.

It, in turn, is usually divided into subgroups according to purpose:

· metal-cutting equipment;

· woodworking equipment;

· foundry equipment;

Within these subgroups, it is much more convenient to select objects for description and implementation of repair functions over them.

Below, you can familiarize yourself with the scope of work that is usually included in maintenance for various groups of equipment:

· List of works during maintenance of metal-cutting machines;

· List of works during maintenance of woodworking machines;

· List of works during maintenance of forging and pressing equipment;

· List of works during maintenance of foundry equipment.

6 Types of planned work

Planned repairs, depending on the volume, complexity and timing of the work, are divided into current, medium and major repairs.

Maintenance provides for the replacement or restoration of individual parts without disassembling the machine, adjustment of mechanisms to ensure or restore the functionality of the unit before the next scheduled repair.

Medium renovation is carried out with partial disassembly of the machine, while replacing or restoring components of a limited range, restoring serviceability and partial service life of the equipment.

At major renovation complete disassembly of the unit, replacement or restoration of all worn parts and assemblies, including basic ones, assembly, adjustment and testing of the unit under load. A major overhaul should not only restore the original characteristics of the unit, but also improve them through modernization.

Modernization eliminates obsolescence of outdated equipment and provides for either an increase in the general technical level of the unit, or its adaptation (specialization) to perform individual work.

Equipment is taken out for major repairs depending on its technical condition, which is determined based on the results of technical diagnostics - assessing the wear of friction surfaces of individual equipment parts and the state of their interfaces during operation without disassembly.

4 PPR system is a set of planned organizational and technical measures for the care, supervision, maintenance and repair of equipment. The measures are preventive in nature, i.e. After each piece of equipment has worked for a certain amount of time, its preventive inspections and scheduled repairs are carried out: small, medium, major.

The alternation and frequency of repairs is determined by the purpose of the equipment, its design and repair features, as well as operating conditions. PPR of equipment provides for the implementation next works:
- overhaul maintenance;
- periodic inspections;
- periodic scheduled repairs: small, medium, major.

Between overhauls- this is the daily care and supervision of equipment, making adjustments and repairs during its operation without disrupting the production process. It is performed during breaks in equipment operation (in non-working shifts, at the junction of shifts, etc.) by the staff of the workshop repair service on duty.

Periodic inspections- inspections, washings, accuracy tests and other preventive operations carried out according to plan through a certain amount of hours worked by the equipment.

Periodic scheduled repairs divided into small, medium and major repairs.

Small repairs- detailed inspection, change and replacement of worn parts, identification of parts requiring replacement during the next scheduled repair (medium, major) and drawing up a defective list for it (repair), checking for accuracy, testing equipment.

Medium renovation- detailed inspection, disassembly of individual components, replacement of worn parts, checking for accuracy before disassembly and after repair.

Major renovation- complete disassembly of equipment and components, detailed inspection, washing, wiping, replacement and restoration of parts, checking for technological accuracy of processing, restoration of power, performance according to standards and specifications.

PPR is carried out according to a schedule developed on the basis of PPR standards:
- duration of the repair cycle;
- duration of overhaul and inspection cycles;
- duration of repairs;
- categories of repair complexity (RCC);
- labor and material intensity of repair work.

Repair cycle- this is the period of operation of the equipment from the beginning of its commissioning until the first major overhaul, or the period of operation between two major overhauls. The structure of the repair cycle is the order of alternating repairs and inspections, depending on the type of equipment, the degree of its load, age, design features and operating conditions.

Repair complexity category (RCC) assigned to each piece of equipment. As repair unit 1/11 of the labor intensity of a major overhaul of a 16K20 screw-cutting lathe, which belongs to the eleventh complexity group, was accepted.

Basic repair operations

During the repair process, the following basic operations are performed.

1. The machine or apparatus is disconnected from the communication network, the belts are removed, the engine shaft coupling half is disconnected, and the oil is drained from the reservoirs. If it is an apparatus, then it is freed from the medium that fills it, using drains to drain it by gravity, purged with steam or air, washed with water, etc. After this, the equipment is securely disconnected from the system by installing plugs on the flange connections before or after the shut-off valves. The plugs must have a clearly visible shank with a designated number.

2. Cleaning and washing of equipment.

3. Defects and sorting of parts.

4. Restoration or replacement of worn parts.

5. Balancing rotating parts (if necessary).

6. Assembling a machine or apparatus.

7. Individual testing and commissioning.

Before starting repairs, the equipment is thoroughly washed and cleaned of product residues, grease and other contaminants. Surfaces in contact with products are cleaned with brushes and brushes, washed with hot solutions of soda ash or caustic soda, hot water and treated with steam.

To clean equipment crankcases, they are washed with hot oil, furnace flue gas, kerosene and hot water. The use of kerosene and heating oil, which have a strong odor, in production shops is not allowed in order to avoid defective products produced on machines and devices located close to the equipment being repaired.

Before disassembling the equipment, it is necessary to study the design features of the machine and outline the procedure for its disassembly. In this case, the purpose and interaction of individual components and parts should be established. First of all, remove those parts and Assembly units, which prevent further disassembly. Equipment with a complex design is disassembled in the following order: first into groups of assembly units, groups into individual assembly units, assembly units into parts. The parts must be placed in the order in which they are removed from the machine.

Parts are cleaned of dirt and rust after disassembling the machine using wooden blades, rods and scrapers. In addition, the parts are soaked in kerosene, for which two containers are used: the first for preliminary soaking, the second for final rinsing. The duration of soaking the pre-cleaned parts is 1 – 8 hours, after which they are wiped dry with a rag. The parts are degreased in a hot solution of caustic soda, then washed in hot water and dried.

Lubrication grooves and holes in parts are blown out with compressed air.

Balancing of rotating parts (rotors) can be static or dynamic. Depending on the peripheral speed and the ratio of the width B of the rotating part to its diameter D, the balancing method is chosen according to the data in table. 3.1.

Table 3.1. Data for choosing a balancing method

When repairing gears and sprockets, the possibility of their continued suitability for use is determined.

The parts are assembled in the reverse order of disassembly. In this case, they are guided by the tolerances given in the manufacturer’s instructions and specifications for manufacturing, packaging and delivery. The procedure for conducting individual tests at idle speed and communications is carried out after completion of repair work.

3.4. Mechanization of repair work

When dismantling and assembling machines (units) in order to replace worn components or restore them, various lifting mechanisms are used: standard overhead cranes, truck cranes, loaders, self-erecting gantry cranes, rod lifts, hoists, lever winches, etc.

In mechanical repair shops, standard overhead cranes, trolleys, jib cranes, and roller tables are used to move large parts and assemblies from one metalworking machine to another.

Technical repair operations for boring and grinding compressor cylinder blocks are performed on appropriate machines, drilling holes - on radial drilling and vertical drilling machines, forming keyways - on planing and milling machines, cutting threads - on threading machines, etc. Elimination of cracks and breakages of the bed and frames, surfacing of worn shaft journals, etc. carried out using electric arc welding, for which mechanized welding methods are used.

When repairing equipment at the site of its installation, manual mechanized tools (electrified and pneumatic) with various devices are widely used: drilling machines, edge cutters, impact wrenches, grinders, electric rolling machines. In this case, devices are used for boring holes in the tube plates of heat exchangers, for deburring and trimming pipes, for crushing the ends of flared pipes to be removed and replaced, for grooving the seats of valve bodies and gate valves, for grinding in pipeline fittings, etc.

AND EQUIPMENT REPAIR

Types of wear

Wear refers to the gradual surface destruction of a material with a change in the geometric shapes and properties of the surface layers of parts. Wear can be normal or emergency. Depending on the causes, wear of parts is divided into chemical and physical and wear by metal seizure (thermal wear).

Normal wear refers to changes in the dimensions and properties of materials of parts that occur under conditions of proper operation of the equipment. The intensity of normal wear is determined mainly by the design features of the components, the wear resistance of the materials used, as well as the correct operation and repair of the equipment.

Normal wear is inevitable, however, the intensity of its occurrence can be influenced by the quality of installation, operation and repair of equipment. Under certain unfavorable conditions, normal wear turns into emergency wear.

Emergency wear is called changes in the dimensions and properties of the materials of parts that occurred in a relatively short term due to improper installation, operation, unsatisfactory maintenance or poor quality repair of equipment.

Chemical wear of the friction surface consists mainly of the formation and subsequent peeling of thin oxide films on them. Oxide films are formed as a result of chemical absorption (chemisorption) of oxygen coming from the air or resulting from the breakdown of lubricant components by the surface layers of the metal. The destruction that occurs as a result of chemical wear is accompanied by the appearance of smallpox-like ulcers, corrosion of the metal or the appearance of rust.

As a result physical wear and tear, the cause of which may be alternating loads, surface friction, abrasive and mechanical effects, microcracks appear on the parts, the surface of the parts becomes rough. The main types of physical wear are fatigue, wear, abrasion and erosion.

Fatigue wear is observed in parts subjected to repeated action of alternating and varying single-valued loads, as a result of which microcracks are formed, and then complete destruction (breakage) of the part occurs.

Small-scale wear occurs during dry and especially liquid rolling friction and is characterized by the formation of cracks on periodically loaded surfaces, followed by peeling of films from 0.005 to 0.2 mm. Parts of rolling bearings and working surfaces of gear teeth are subject to wear-like wear (Fig. 4.1).

Rice. 4.1. Scheme of smallpox wear: a – diagram of tangential stresses that arise when a cylinder or ball is pressed into a flat surface; b – diagram

crack formation

Abrasive wear is the destruction of the surface of parts by tiny particles more than hard materials. In machines, metal particles, lubricant oxidation products, mineral particles (sand, shavings, etc.) coming from outside can be abrasive. The surfaces of all friction units are subject to abrasive wear.

Erosion is the mechanical destruction (erosion, corrosion) of the surface layers of materials of parts moving with high speed, particles of the gaseous, liquid or solid phase - occurs together with intense oxidative processes.

Wear by metal seizure is characterized by the emergence and subsequent destruction of molecular bonds on the friction surface (change in grain structure, decrease in hardness, melting, tempering, etc.).

Conditions for the formation of bonds are caused by both relatively low and high temperatures of the contact areas. This type of wear is observed in various parts of steam boilers, engines, compressors and refrigeration machines.

4.2. The main reasons affecting the wear of equipment parts

The nature and amount of wear is influenced by many design and operational factors. This must be taken into account when manufacturing and restoring repaired parts.

Quality of parts material. The quality of the parts material and its heat treatment have a great influence on their strength and wear resistance. As a rule, for most materials, the harder their working surface is, the greater their wear resistance. But we cannot assume that the degree of hardness of a material is always directly proportional to wear resistance.

Materials that only have great hardness have high wear resistance, however, this increases the possibility of scratches and separation of material particles from the surface. Therefore, these materials must have high viscosity, which prevents particles from detaching.

If parts made of homogeneous materials experience mutual friction, then due to the high friction coefficient they quickly wear out. Consequently, more expensive and difficult to replace parts must be made from a harder, higher quality and wear-resistant material, while simpler and cheaper parts are better made from a relatively soft material with a low friction coefficient.

The correct choice of material for parts is of great importance both from the point of view of saving material and for preventing accidents during operation.

At enterprises Food Industry The most common metals used in equipment repair are ferrous (steel, cast iron) and non-ferrous metals, their alloys and plastics.

Quality of surface treatment of parts. The wear and service life of rubbing surfaces is greatly influenced by the quality of the surface after machining - surface cleanliness. Three wear periods have been established, which are shown on the parts wear curve (Fig. 4.2):

1) the initial period of running-in (section of curve 1–2) is characterized by a rapid increase in the gap in the moving joints;

2) the period of steady wear (section 2–3), after the running-in of the working surfaces, during this period, which is the main period, gradual and slow wear is observed;

3) a period of rapid increase in wear caused by significant changes in the gaps between rubbing surfaces and changes in the geometric shape of parts; from this moment, increased and catastrophically increasing wear begins, which can lead to an accident.

Rice. 4.2. Part wear curve diagram

To increase the service life of equipment parts, the running-in period should be reduced to the shortest possible time, the period of steady wear should be sharply increased and the period of increasing wear should be prevented. Reducing the running-in period is achieved by precise and clean processing of the surfaces of rubbing parts.

The state of surface cleanliness is measured by special instruments - profilometers and profilographs.

Lubrication. A layer of lubricant introduced between the rubbing surfaces increases the wear resistance of the contacting parts: the lubricant, getting between two rubbing surfaces moving one over the other, fills their unevenness and eliminates their direct contact, reduces friction, wear, the risk of jamming, heating and corrosion (Fig. 4.3).

Rice. 4.3. Diagram of pressure distribution in the oil layer:

O – bearing axis; O1 – shaft axis

The following types of sliding friction are distinguished:

1) dry friction, which occurs in the absence of lubrication on the rubbing surfaces;

2) semi-liquid and semi-dry, observed when the oil film is partially torn or when the lubricant layer is constantly thin, so that the irregularities of the rubbing surfaces partially touch. Semi-fluid and semi-dry friction occurs on insufficiently or improperly lubricated surfaces when a lubricant that does not meet operating conditions is used;

3) fluid friction, which occurs in cases where moving surfaces are completely separated by a layer of lubricant.

The process of creating a stressed oil layer during the operation of a shaft-bearing pair occurs as follows. There is a gap between the shaft and the bearing, starting from the point of contact of the shaft in the liner and diverging in both directions in the form of a wedge-shaped gap. The shaft is located eccentrically relative to the bearing.

When rotating, the shaft carries a layer of lubricant into the wedge-shaped gap. As this gap decreases, the resistance to the flowing lubricant increases more and more, reaching its greatest value in the narrowest part of the wedge-shaped gap. Due to this, the rotating shaft is raised, the bearing and the shaft are completely separated by a layer (film) of lubricant, the thickness of which will be the smallest. The wear of mating surfaces is minimal.

To ensure long-term operation of parts, the correct choice of lubricant and its reliable supply to the rubbing surfaces, as well as the correct lubrication regime for the working surfaces are necessary. If lubrication is improper, parts heat up excessively, rubbing surfaces seize and melt, which leads to equipment failure.

Speed ​​of movement of parts and specific pressure. Any equipment in operation is characterized by performance (performance, speed of moving parts, efficiency, etc.) and durability - the duration of operation of the equipment, during which its performance remains within acceptable limits.

Based on experimental data, it has been established that at normal specific loads and movement speeds from 0.05 to 0.1 m/s, the oil layer does not rupture and lubrication becomes complete. Wear of parts increases with increasing speed of relative movement of rubbing parts, as the temperature of the contacting surfaces increases, which can lead to crushing and melting. For example, for bearings with Babbitt filling, the temperature should not exceed 60 °C from the limit.

Violation of rigidity in fixed joints. In these cases, the tightness in the joints is broken (leaks), dynamic loads arise in the joints, and the tension in the connections sharply increases. To prevent violation of the rigidity of connections, it is necessary to systematically check the rigidity of fastening parts and restore it by tightening, avoiding work with loosening.

Landing violation. This group of faults is characterized by an increase in the gap in movable joints and a decrease in tension in fixed joints. To prevent this, you need to properly adjust the gaps and use special coatings on the surfaces of the moving joints.

Violation of the mutual position of parts in connections. Often there is a violation of components and parts in the kinematic chain, which leads to a deviation in alignment, a change in the distance between parts, and a violation of the perpendicularity of the axes of components and parts. To avoid this type of violation, you should systematically check the relative positions of parts and assemblies, adjust their positions, and, if necessary, restore their correct location.

Flaw detection of parts

To determine the condition of parts, external inspection is used, as well as methods that make it possible to detect hidden defects (magnetic and ultrasonic flaw detection and fluoroscopy). External inspection allows you to identify defects in parts: external cracks, bends, scuffs, wear of the anti-friction layer, thread failure, corrosion, etc.

The inspection ends with measurements using measuring instruments.

Deviations in the geometric shape of cylindrical parts are characterized by non-roundness (ovality, faceting) and deviations in the longitudinal section profile (cone-shaped, barrel-shaped, saddle-shaped).

Small cracks are detected by color flaw detection, the essence of which is as follows. On the surface of the part, cleaned with acetone or gasoline, 3-4 layers of a penetrating solution tinted with aniline dye are applied with a brush or spray. Then the controlled part is washed with a 5% soda ash solution and wiped dry. A thin layer of white adsorbent coating is applied to the cleaned surface with a brush or spray (for example, 0.6 liters of water + 0.4 liters of ethyl alcohol + 300-500 g of chalk).

Liquid from surface defects turns the coating red in the corresponding places.

The method allows you to detect defects up to 0.01 mm in size at a depth of 0.03-0.04 mm; inspection is carried out with the naked eye or using a magnifying glass of 5-7 times magnification.

The luminescent flaw detection method allows you to identify surface defects with a depth of at least 0.02 mm and a width of at least 0.01 mm.

The sequence of operations for fluorescent flaw detection is as follows:

1) cleaning the surface from contamination

2) application of a penetrating luminescent composition;

3) applying developing powder;

4) inspection of the part under ultraviolet rays.

The disadvantage of this method is the need to use a stationary flaw detector.

In cases where there are suspicions about the presence of open defects (defects), a magnetic, ultrasonic or x-ray inspection method is recommended.

Magnetic powder flaw detection is based on identifying the magnetic stray field above the defect.

A necessary condition To identify a defect, the location of the defect is perpendicular to the direction of the magnetic field. Therefore, the part must be checked in two mutually perpendicular directions.

X-ray inspection methods require an approach to the part from two sides. An X-ray machine is connected on one side, and a film cassette on the other side. This is not always possible due to the design features of the devices.

The most widely used in repair practice are ultrasonic flaw detectors, which allow:

1. identify defects in welds of any kind;

2. identify internal defects (sinks, delamination);

3. measure the thickness of the walls of apparatus and pipelines with one-way access to them.

Ultrasonic flaw detectors allow you to determine the size and depth of defects. The minimum size of a detectable defect is 1mm². The thickness of the controlled parts is 1-2000 mm.

Ultrasonic flaw detectors are small in size and light in weight, but they are not applicable for testing stainless steel parts. The coarse-grain structure of stainless and alloy steels means that reflected pulses from large grains create interference, which makes it difficult to determine the reflection of a pulse from a defect.

To inspect stainless steel parts, color flaw detection, X-ray and gamma examination are used.

When inspecting pressure apparatus, it is necessary to inspect all welds. Some high-pressure equipment is subjected to inspection that combines 2-3 flaw detection methods.

If access to the weld is possible only from the outside or only from the inside of the apparatus, the density test is carried out by vacuuming the welds.

Weld seam moistened with soapy water. A box with a sponge rubber seal around its entire perimeter is placed on the area under study. The box is connected to a vacuum pump. The presence of soap bubbles observed through the inspection window indicates welding defects.

Thermal or halogen leak detectors can be used to detect gas leaks.

The operation of thermal resistor leak detectors is based on measuring the difference in thermal conductivity of gases. The gas passes near the heat source, which is one of the arms of the bridge. The second arm is a sensor placed in the air.

Thermal resistor leak detector allows you to detect leaks (2-4)∙10ˉ6m³/h.

The halogen leak detector allows you to detect halogen leaks by changing the color of the halogen flame in refrigeration units.

All of the methods discussed above are non-destructive testing methods. However, if we are faced with the phenomenon of intergranular corrosion, then it can be detected using metallographic analysis of the structure of a sample cut from the wall of the apparatus.

Separator repair

High class the accuracy of the separators, the specificity of the materials from which the parts are made, the complexity of manufacturing and restoring these parts in the conditions of the enterprise’s mechanical repair workshops determine the need for periodic inspections of the separators, timely detection of unacceptable wear and replacement of worn parts.

When repairing separators, the greatest specific gravity falls on the drive mechanism parts. Their wear is characterized by extraneous noise, increased vibration, slow acceleration of the drum and a number of other signs.

For inspection, the separator is disassembled, separately the horizontal shaft group and the spindle group. It is not recommended to disassemble the separator unless absolutely necessary, as this can lead to disruption of the fit and running-in of the mating parts. The separator is disassembled carefully, strictly following the procedure outlined in the factory instructions. After disassembly, all critical rotating parts are thoroughly washed, carefully inspected and measured. The most critical parts (spindle, plate holder, plates, especially spacers, bearings, etc.) are examined with a magnifying glass, and if a crack is suspected, X-ray and ultrasonic flaw detection tools are used.

When repairing separators, it is most often necessary to replace worn friction linings on the pads of the centrifugal friction clutch, springs and neck support bearings, thrust bearings, bronze gear (worm wheel), rubber sealing rings, rubber disc of the elastic coupling, etc.

The sequence of disassembling separators of different models has its own characteristics, which are indicated in the manufacturer's instructions.

Maintenance system

Justification of the maintenance system, structure, basic concepts

Maintenance is a set of operations to maintain the operability and serviceability of electronic equipment when used for its intended purpose, waiting, storage, transportation

Repair is a set of operations to restore the functionality of products or components products

Maintaining a given level of readiness of products for their intended use during use with minimal labor, time and money spent on maintenance and repair work is ensured by the maintenance and repair system

The maintenance and repair system is a complex of interconnected tools, documentation and performers necessary to maintain the quality of the products included in it

The purpose of the maintenance and repair system is control technical condition products during their resource or service life, which ensures a given level of readiness for intended use and their performance during use with minimal labor, time and money

The maintenance system is based on a preventive planning system, the essence of which is that a set of maintenance operations is carried out within a certain time frame.

In addition to the strategy, the preventative maintenance system provides different kinds and maintenance methods

The entire complex of maintenance and repair operations can be divided into 2 groups:

1. Planned maintenance work

2. Work to detect and eliminate failures and damage

The main requirement for the process technical operation in general, is that with limited labor costs, to ensure the greatest probability that at the required moment in time, the ERTP means will be operational and will complete the task

Maintenance system composition:

A maintenance object is a REO that has the needs for certain maintenance operations and is adapted to perform these operations.

Maintenance equipment - consists of control and measuring instruments, technological equipment and structures intended for maintenance

Maintenance is carried out in accordance with operational and technical documentation and maintenance program

The maintenance and repair program is a document containing a set of basic principles and decisions made by application the most effective methods and maintenance and repair modes implemented in the design of objects during their design and manufacture, taking into account the specified requirements and operating conditions. Each aircraft has its own maintenance and repair program.

The governing bodies are the engineering and technical staff that carries out maintenance of electronic equipment and management of the facility and facilities

The maintenance and repair system can be classified as a large cybernetic system, i.e. systems related to information. The specific features of cybernetic systems include:

1. Contact external environment

2. Availability of executive and management bodies

3. Closed chain of influences

Large cybernetic systems are characterized by the use of information to control the state and quality of the system’s functioning. The system carries out circulation, transformation and processing of information

Statistical information about the state of the system in the form of signals is supplied to the maintenance facilities. As a result of processing this information through maintenance tools, data on the type of technical condition of the object is obtained and then decisions are made on operational management this condition

During the maintenance and repair process the following is carried out:

1. Determination and monitoring of technical condition

2. Determination of operability and search for failure points

3. Restoration work

4. Setup and adjustment work

The process of determining the technical condition of a product is called technical diagnostics. Technical diagnostics solves one or more of the following problems:

1. Service check

2. Functionality check

3. Search for the failure point, and the search for the failure point is an integral part of maintenance

The main states of the maintenance and repair system include:

1. Establishing requirements for maintenance and repair parameters for specific types of equipment, including performing maintenance of products with a given quality with minimal labor, time and money.

2. Preparation and implementation technological processes services with a given quality

3. Providing conditions for performing maintenance, including the creation and equipment of units necessary means

4. Optimization of placement production bases And material resources

The effectiveness of the maintenance and repair system is determined by the degree of its adaptability to perform the functions of managing reliability and technical condition during technical operation

Organization of preventive work during maintenance

The main task that arises when developing a maintenance system is the selection and justification of the characteristics of preventive measures systems. In this case, by preventive measures we mean measures aimed at preventing failures of electronic equipment. The choice is determined by:

1. Conditions for the operational use of this type of equipment

2. Requirements for the reliability of its operation

3. Equipment design

4. Availability of backup blocks or channels

After choosing the type of prevention system, it is necessary to determine the main characteristics of this system: frequency and duration of preventive work

The characteristics of any prevention system are determined by the most important requirements for it (achieving the greatest efficiency in the use of electronic equipment, the minimum cost of carrying out preventive work)

Preventive measures carried out during the operation of electronic equipment may differ in frequency, method of implementation and organization of the scope of work, however, all systems of preventive measures must satisfy some basic requirements:

1. The system of preventive measures must ensure the required level of reliability of the equipment in use

2. The time allocated for carrying out preventive maintenance should be optimal from the point of view that increasing the time for carrying out preventive maintenance increases equipment downtime, and reducing the time reduces the quality of its implementation

3. From an organizational and technical point of view, the adopted prevention should ensure the operation of the equipment with a minimum of operating costs

Depending on what principles are used as the basis for determining the frequency of work, all systems of preventive measures can be divided into 2 groups: routine and calendar

Service system used for preventive work, May be:

1. Maintenance system that provides for breaks in the use of electronic equipment

2. REO maintenance system in working order

3. Continuous service system

Maintenance system that provides for breaks in the operation of electronic equipment

Intermittent maintenance is carried out if, for structural and functional reasons, it is necessary to turn off the REO to perform maintenance operations. During operation, the REO can be in one of three states: intended use, prevention, restoration, therefore the quality of the service system can be assessed either by the equipment utilization rate or by the efficiency of the REO operation

Maximum parameter values ​​in this system are achieved with optimal duration and frequency of maintenance work.

This type of maintenance system is used for maintenance of on-board electronic equipment.

What is maintenance, what does it include and what is the frequency of vehicle inspections? The main and first task of vehicle maintenance (maintenance) is to maintain it in good condition and in proper form. The main difference between maintenance and repair is that this activity is preventive and not performed out of necessity.

Repairs are carried out only when a breakdown or malfunction occurs that complicates or eliminates the possibility of normal operation of the car, and maintenance (car maintenance) is planned in advance and regularly. Maintenance usually includes the following types of work:

• Regulating;
• Lubricants;
• Gas stations;
• Control and diagnostic;
• Fastening;
• Electrical.

Car maintenance does not have to include all of the listed work. Much is determined by current needs and requirements, manufacturer’s recommendations, the brand of the machine and its operating conditions. Your repairs will happen less often the more competently you approach the diagnosis of your car. Repair of a generator or starter breakdown will occur less frequently if these components of your car are used correctly. Vehicle maintenance varies depending on the vehicle's mileage and age. There are several types of vehicle maintenance (depending on the frequency of work performed, their labor intensity, complexity, and quantity):

• First;
• Second;
• Seasonal;
• Daily.

The first and second maintenance must be performed after a certain mileage of the car, in full accordance with the operating manual. Typically, the mileage before the first technical inspection is about 10–15 thousand km. An important factor The timing of the first and second inspections is also influenced by the operating conditions of the machine: for example, if you have to drive on unpaved surfaces, the air filter must be changed more often than when driving on high-quality asphalt roads.

Seasonal maintenance

Seasonal vehicle maintenance is performed twice a year to prepare the vehicle for use in the warm and cold seasons. Part of the seasonal maintenance is “changing shoes” to winter tires when winter comes, and to summer tires when it ends. In some northern regions of Russia, motor oil is also changed, from winter to summer, and vice versa in the fall. Many drivers also carry out anti-corrosion treatment of the body on the eve of the winter season.

Annual maintenance

The task of daily maintenance is to maintain appearance, tracking the timeliness of refueling with fuel, oil, etc. consumables, control of traffic safety on the road. Checking the presence of everything you need in your trunk is carried out as necessary. I wrote about what is recommended to carry there in the article What you need to have in the trunk. Before each trip the following is checked:

• Completeness of your car;
• State registration numbers and their readability;
• Body condition;
• Rear view mirrors and their adjustment;
• Serviceability of all locks (doors, trunk and hood);
• Serviceability of electrical equipment (windshield wipers, alarm, lighting);
• The tightness of cooling systems, lubrication, the presence of consumable liquids in them;
• Tightness of the braking system drive;
• Operation of instrumentation and control equipment;
• Freedom of movement of the steering wheel.

It must be remembered that if the car gets into an accident, for example, due to a violation of the sealed state of the hydraulic drive of the brake system or another malfunction that was not detected in a timely manner before the trip, the driver of the car will definitely be recognized as the culprit of the road accident, with all the ensuing consequences.

Every 2 years (20–30 thousand kilometers) you need :

• Replace spark plugs (if this was not required before);
• Tighten the fastenings of units, parts and components of the chassis and engine;
• Check the tightness of seals of units and components, etc.;
• Lubricate battery clamps and terminals.

Every 3 years in operation (30–45 thousand km.) :

• Clean the starter commutator, check the fit and wear of the brushes;
• Check the operation of the vacuum brake booster;
• Lubricate and clean the starter drive parts;
• Adjust the direction of the headlights.

Every 4 years (50–60 thousand km.) :

• Replace coolant and brake fluid;
• Clean the generator contact rings and check brush wear.
• Cleaning the drainage holes of thresholds and doors;
• Cleaning carburetor parts.

Every 5 years in operation (60–75 thousand km) must be replaced :

• Gearbox oil;
• Front wheel alignment;
• Flushing the lubrication system;
• Timing belt.

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10.08.2018, 12:24 180187 0 Assembly of Motorists

All drivers are well aware that vehicle maintenance is part of its operation. However, there is still a category of car owners who believe that no one needs a scheduled vehicle inspection with the replacement of spare parts recommended by the manufacturer and that it is simply a waste of money.

Is it really? What is scheduled maintenance? What is it like? What does it include and how often should it be done for different car brands? Is it necessary to do this at all? Experts answer questions, express their opinions and give advice.

So. Why carry out routine maintenance?

First of all, you need to understand that car maintenance itself is preventive measures that are aimed at preventing possible problems with the vehicle. early stages. Those who believe that waiting for a part to fail and then replacing it will be more economical than undergoing scheduled maintenance are deeply mistaken. Any car service center will confirm that car repairs are much more expensive. And even if you have a new car of a global brand, the laws of physics work on its units in the same way as on cars with high mileage, so even a small error in operation or a malfunction identified during diagnostics allows you to avoid serious breakdowns or even accidents.

Moreover, unlike cars of previous generations, a modern car is a complex of complex units controlled by electronics, so without computer diagnostics and other events are indispensable.

Types of scheduled maintenance and what does it include?

Replacement frequency various materials and details of a specific car brand are indicated in the manual for it. Knowing these recommendations from the manufacturer and taking into account the mileage of a particular car, determine the frequency of scheduled maintenance of the car. In this case, the following types of maintenance are carried out for all machines.

EO– daily inspection, which includes mandatory activities before each departure.

At the same time, the driver himself checks the general condition of the car, the position and possible adjustment of the mirrors, the operation of sensors, headlights, other electrical equipment, checking the steering system, brakes, the condition of the body - in a word, inspecting the car and those activities that can be performed independently.

– maintenance, which should be carried out depending on the requirements of the car manufacturer every 10, 15 or 20 thousand km.

Typically TO 1 includes the following types of work:

– replacing the air filter;

- Change of oil;

– checking the battery charge;

– inspection of spark plugs;

– lubrication of hinges;

– checking tires with balancing and inflation if necessary;

– checking the level of technical fluids and topping up if necessary;

– diagnostics of chassis and brake systems, electrical equipment and other car systems with elimination of identified errors and malfunctions.

TO 2– maintenance carried out every 30 thousand km. Its goals and objectives are the same as in TO 1, but with a larger volume of work and its higher complexity.

For example, during maintenance 2, the fuel filter and cabin filter are changed, the brake fluid and coolant are changed. During Maintenance 2, the timing belt and other work can be replaced.

SO– seasonal maintenance. Obviously, this type of maintenance is carried out 2 times a year and includes measures to prepare the car for changing weather conditions, such as changing seasonal oil, tires, checking the interior heater, air conditioning, etc.

Below are examples of scheduled maintenance regulations for some car brands. Each regulation is a document indicating a list of activities and the frequency of their implementation.

Scheduled maintenance of KIA Sportage III

There are similar regulations for scheduled maintenance for Nissan, Mercedes, and Mazda. In a word, there are work schedules for periodic maintenance of absolutely all brands of manufactured machines.

How much does maintenance cost and can you save money on it?

Obviously, a technically trained car owner can carry out some types of work independently. In this case, a maintenance schedule must still be drawn up and if necessary, for example, computer diagnostics of systems or other complex activities, you should contact a car service center.

All this is true for cars with high mileage. But if it is necessary to maintain the warranty of a showroom car, you cannot do without contacting authorized auto centers and undergoing maintenance there with the appropriate marks in the service books. You can save money only if the service allows you to undergo maintenance with its consumables.

In addition, you need to understand that prices for maintenance at authorized car services, even within the same official dealer, can vary greatly. This also applies to the materials they use. Practice shows that if you are not lazy, call different services and compare prices, you can save up to 20% on work and up to 50% on materials.

The conclusion is simple. Scheduled maintenance is necessary, you can try to save money on them, but you absolutely cannot risk your car and ignore them!

For trouble-free and reliable operation vehicle Manufacturers have developed regular maintenance regulations. The main purpose of undergoing scheduled maintenance is the trouble-free operation of all vehicle systems, which in turn is a fundamental factor in ensuring the personal safety of the car owner.

For this purpose, the manufacturers of Opel, Chevrolet, Cadillac have developed special plans for periodic inspections and maintenance, which must be carried out at certain times.

The car's maintenance check intervals are specified in the Car Repair and Maintenance Manual, which the car owner receives upon purchase. You can find out the preliminary maintenance information for any Opel, Chevrolet or Cadillac car model by using the online maintenance calculator.

Types of maintenance (technical inspection)

• Daily maintenance (DM) performed by the car owner before each trip. It is recommended to check the level of engine oil and coolant yourself; condition of the battery, switches, tires, fuel level, exterior lighting, rear view mirrors, brakes; presence/absence of leakage of working fluids, etc.
• The first maintenance (TO-1) includes checks of: open service campaigns, exterior lighting, windshield wipers, level and leakage of working fluids, condition of the engine air filter, brake system, tire pressure, wheel tightening, condition of drive belts of mounted units, engine cooling, transmission elements , parking brake, headlight adjustment; replacing engine oil and engine oil filter
• The second maintenance (TO-2) includes all the work from the TO-1 list plus additionally: inspection of the condition of drive belts of mounted units, engine cooling system, transmission elements, parking brake, headlight adjustment; replacing the cabin ventilation filter, fluid in the vehicle and clutch drive; remote key battery, spark plugs, attachment belt drive, timing belt and rollers * a complete list of maintenance work is available in the maintenance calculator for a specific vehicle model
• Seasonal Maintenance
• Short maintenance (TO-1, TO-3, TO-5, TO-7, TO-9) is the unofficial name of odd maintenance, the work schedule of which is described in paragraph 2
• Long maintenance (TO-2, TO-4, TO-6, TO-8, TO-10) is the generally accepted name for even maintenance with work schedule in accordance with clause 3

Where to get maintenance in Moscow?

There is a deadline established by the automaker for undergoing scheduled maintenance: 15 thousand kilometers, but at least once a year.

As practice shows, most cars are not operated in " normal conditions", for which standard completion deadlines are prescribed service(TO), but in “difficult operating conditions”. That is, the car’s engine often operates in cold start mode, the car moves for a long time in dense traffic (traffic jams), on redrawn terrain, on roads with unsatisfactory surfaces, etc.

This means that the vehicle's main systems are overloaded and therefore require more thorough and more frequent maintenance.

Why undergo maintenance?

What are the consequences of a missed maintenance or a “late” technical inspection? In addition to the unpleasant possibility of losing the car’s warranty, changing engine oil at the wrong time threatens slagging of the internal combustion engine and a complete overhaul of the engine; Poor functioning of spark plugs contributes to failure of the ignition module; Failure to promptly replace the air filter can lead to costly replacement of the mass air flow sensor and other engine subsystems.

Why do you need to have your vehicle undergo maintenance at official dealers?

Often, professional maintenance technicians are faced with the opinion that “MOT is actually just an oil change, and all routine checks are nothing more than a formality.” This approach to scheduled maintenance is fundamentally wrong. The regulations prescribed by the importer for carrying out maintenance are an integrated approach that minimizes any risks that entail a decrease in the level of safety and an increase in maintenance costs. Neglect regular full checks of the car, according to TO-1, TO-2, TO-3, TO-4, etc. do not do it.

Don’t look for “cheap maintenance”, look for “correct maintenance”!

Come to the official dealer of Opel, Chevrolet, Cadillac "Autocenter City" and get a full vehicle inspection at the highest level!