PART I OPERATION, MAINTENANCE AND REPAIR OF GENERAL INDUSTRIAL

For the uninterrupted and reliable operation of the vehicle, manufacturers have developed a regular maintenance schedule. The main goal of 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, Opel, Chevrolet, Cadillac manufacturers have developed special plans for periodic inspections and maintenance, which must be carried out at a certain time.

Vehicle maintenance check intervals are indicated in the "Vehicle Repair and Maintenance Manual" received by the owner of the car upon purchase. You can find out in advance for any model of Opel, Chevrolet or Cadillac cars using the online TO calculator.

Types of maintenance (technical inspection)

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

Where to get maintenance in Moscow?

There are deadlines set by the automaker for scheduled maintenance: 15 thousand kilometers, but at least once a year.

As practice shows, most cars are operated not in “normal conditions”, for which standard service intervals (TO) are prescribed, but in “severe 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 cross-drawn terrain, on roads with poor coverage, etc.

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

Why get serviced?

What threatens a missed MOT or a “belated” inspection? In addition to the unpleasant opportunity to lose the warranty on the car, the wrong oil in the engine is threatened with slagging of the internal combustion engine and a complete engine overhaul; poor-quality functioning of the spark plugs contributes to the failure of the ignition module; Late replacement of the air filter can lead to costly replacement of the mass air flow sensor and other engine subsystems.

Why is it necessary to undergo MOT at authorized dealers?

Often, professional maintenance masters are faced with the opinion that “TO 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 importer's maintenance schedule is a holistic approach that minimizes any risks resulting in a reduction in safety and an increase in maintenance costs. Neglect a regular full check of the car, according to TO-1, TO-2, TO-3, TO-4, etc. do not do it.

Do not look for "cheap MOT", look for "right MOT"!

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

§ 1. Types and frequency of maintenance

Vehicle maintenance is carried out according to the so-called preventive maintenance system. The peculiarity of this system is that all cars undergo maintenance according to the schedule without fail. The main purpose of maintenance is to prevent failures and malfunctions, prevent premature wear of parts, and timely eliminate damage that prevents the normal operation of the car. Therefore, maintenance is a preventive measure.

A failure is a violation of the vehicle's performance, leading to a temporary cessation of its normal operation (stop on the line, violation of the traffic schedule, etc.).

All other deviations of the technical condition of the rolling stock and its units from the established norms are malfunctions.

Maintenance includes cleaning and washing, control and diagnostic, fastening, lubricating, refueling, adjustment and other work, which is usually performed without disassembling the units and removing individual components from the vehicle.

According to the current regulation, maintenance according to the frequency, volume and labor intensity of the work performed is divided into the following types:

daily maintenance (EO);

first maintenance (TO-1);

second maintenance (TO-2);

seasonal maintenance (SO).

Daily maintenance includes cleaning and washing operations, as well as general monitoring of the condition of the car, aimed at ensuring traffic safety and maintaining a proper appearance.

Carrying out daily maintenance, they perform cleaning and washing work, control inspection, refueling, coolant and oil. EO work is carried out after the end of the car on the line and before leaving the line.

The first maintenance includes all work carried out during daily maintenance. In addition, it includes a number of additional fixing, lubrication and control and adjustment works performed without removing the units and devices from the car and disassembling them.

The second maintenance, in addition to the complex of operations included in TO-1, provides for the performance of control, diagnostic and adjustment work of a larger volume with partial disassembly of the units. Separate devices are removed from the car and checked on special stands and control and measuring installations.

Seasonal maintenance is carried out twice a year and provides for the performance of work related to the transition from one season to another, while trying to combine it with the next TO-2. Typical works for SO are: flushing the cooling system, changing the oil in the engine and lubricating the crankcases of other units, according to the coming season; checking the fuel supply system and flushing the fuel tank. Before the start of autumn-winter operation, the operation of the starting heater and the heating system in the vehicle cabin is checked.

The frequency of maintenance work on the rolling stock is set according to the mileage, depending on the operating conditions.

In table. 1 shows data on the frequency of TO-1 and TO-2 of various rolling stock for three categories of operating conditions in accordance with GOST 21624-76 (since January 1, 1977).

1. Frequency of car maintenance

2. Characteristics of the categories of operating conditions

The maintenance and repair system (MRO) is a set of organizational and technological measures for the maintenance and repair of equipment.

The maintenance and repair system includes planning, preparation, implementation of maintenance and repair with a given sequence and frequency. For these purposes, the MRO System provides standards for the duration of overhaul periods, repair cycles, downtime and labor intensity in the repair (maintenance) of equipment and technological units, the approximate content of repair work for certain types of equipment, and gives instructions on organizing its repair and maintenance.

The maintenance and repair system is designed to provide:

1) maintaining equipment in working condition and preventing its unexpected failure;

2) the correct organization of maintenance and repair of equipment;

3) increase in the coefficient of technical use of equipment by improving the quality of maintenance and repair, and reducing downtime in repairs;

4) the possibility of performing repair work according to a schedule agreed with the production plan;

5) timely preparation of the necessary spare parts and materials.

The MRO System is based on a combination of maintenance and preventive maintenance.

Depending on the importance of the equipment in the technological process, scheduled preventive maintenance can be carried out according to the method of scheduled periodic maintenance and repair according to technical condition (post-inspection method).

The essence of planned-periodic repair is that all types of repairs are planned and carried out within the time limits strictly established by repair standards.

The essence of repair according to technical condition lies in the fact that all types and terms of repair are established depending on the technical condition of the equipment, determined during periodic maintenance.

The maintenance and repair system provides for the following types of maintenance and repairs:

1) maintenance;

2) current repair;

3) overhaul.

Maintenance is a set of works to maintain the performance of equipment between repairs.

Maintenance is carried out by operational (operators, machinists, operators, etc.) and maintenance personnel on duty (assistant foremen, mechanics on duty, electricians, instrumentation and control foremen, etc.) under the guidance of shift supervisors (sections, departments, shift foremen) in accordance with instructions for workplaces and regulations in force at enterprises.

Depending on the nature and volume of work performed, it provides for shift-based (EO) and periodic (TO) maintenance.

Every shift maintenance is the main and decisive preventive measure designed to ensure the reliable operation of the equipment between repairs.

Every shift maintenance includes the following main works: wiping, cleaning, regular external inspection, lubrication, tightening of oil seals, checking the condition of oil and cooling systems of bearings, monitoring the condition of fasteners, connections and tightening them, checking the grounding serviceability, eliminating minor defects, partial adjustment, detection of the general condition of thermal insulation and anti-corrosion protection, checking the condition of enclosing devices in order to ensure safe working conditions, etc.

Every shift maintenance is carried out, without stopping the process.

Identified defects and malfunctions should be eliminated as soon as possible by the forces of the technological and on-duty repair personnel of this shift, and recorded in the shift log.

The shift log for recording the identified defects and the work of shift maintenance is the primary document reflecting the technical condition and performance of the existing equipment, and serves to control the work of the maintenance personnel on duty.

The shift log is maintained by shift supervisors or foremen of the maintenance personnel on duty.

Periodic maintenance- this is maintenance performed at the operating time values ​​or time intervals established in the operational documentation. Planning for periodic maintenance is carried out in an annual schedule.

For chemical production equipment with a continuous technological process, periodic maintenance can be carried out during a scheduled periodic shutdown (SPO) of equipment in accordance with the requirements of technological regulations in order to carry out technological cleaning of tanks, apparatus, units, machines, main pipelines and other equipment from sediments, which does not have a reserve and without which the technological system cannot work. For the rest of the equipment during the period when the equipment is in reserve or during a non-working period.

The main purpose of periodic maintenance is to eliminate defects that cannot be detected or eliminated during the operation of the equipment. The main maintenance method is an inspection, during which the technical condition of the most critical components and parts of the equipment is determined, and the scope of the upcoming repair is specified.

Depending on the nature and scope of the forthcoming work, maintenance personnel of the technological workshop or a centralized repair unit may be involved in periodic maintenance.

The preparation of equipment for periodic maintenance is carried out by shift personnel under the supervision of shift supervisors who are personally responsible.

A typical list of work to be performed by maintenance personnel during periodic maintenance should be compiled as an appendix to the repair log.

Repair is a set of operations to restore the serviceability or operability of equipment and restore equipment resources.

In accordance with the characteristics of damage and wear of the components of the equipment, as well as the laboriousness of repair work, the maintenance and repair system provides for current (TR) and overhaul (CR) repairs.

Maintenance- this is a repair performed to ensure or restore the operability of equipment and consists in the replacement or restoration of individual components and parts of the equipment.

The list of the main works performed during the current repair: carrying out periodic maintenance operations; replacement of wear parts and assemblies; repair of linings and anti-corrosion coatings, painting; replacement of stuffing boxes and gaskets, revision of fittings; checking for accuracy; revision of electrical equipment.

A typical list of works to be performed during the current repair of specific equipment is compiled by the head of the repair unit (deputy head of the equipment shop, shop mechanic or site manager, foreman of the CCR, RMC), approved by the heads of the engineering services of the enterprise and is a mandatory annex to the repair log.

Overhaul- this is a repair performed to restore serviceability and complete or close to complete restoration of the resource of equipment with the replacement or restoration of any of its parts, including basic ones.

During the overhaul, partial, and if necessary, complete disassembly of the equipment is carried out.

The scope of the overhaul includes the following main works: activities in the scope of the current repair; replacement or restoration of all worn parts and assemblies; full or partial replacement of insulation, lining, anti-corrosion protection; alignment and alignment of the machine; post-repair tests, etc.

A detailed list of work to be performed during the overhaul of a particular type of equipment is established in the list of defects.

The standards for planning repairs according to the MRO System include the duration of the overhaul period, as well as the norms of time for performing repair work, equipment downtime in repair, labor costs for repairs.

The Maintenance and Repair System provides the optimal values ​​of the standards, however, the following deviations from the standard overhaul life are allowed:

±15% between current repairs;

±10% between overhauls.

The overhaul life (cycle) is the period of operation (time) of the equipment (in hours), during which its specified efficiency is ensured.

There are two types of overhaul resources:

1) resource before the first overhaul;

2) another overhaul resource.

The resource to the first overhaul is the operating time of the equipment from the start of operation to the first overhaul. It is set by the manufacturer and specified in the technical specifications.

The next overhaul life includes the duration of equipment operation between two successive repairs.

The standards determine the structure of the repair cycle.

The volume of current repairs is 10 - 20% of the volume of major repairs. In addition, current repairs of an increased volume are applied (30 - 40% of the overhaul volume).

The downtime of equipment in repair consists of periods of preparatory, repair and final (post-repair) work.

The preparatory work includes stopping the equipment, removing the product, blowing, washing, steaming, etc. The duration of the repair work includes the time for one repair and for testing for strength, density and idle running. The final work is the running-in of the equipment and bringing it to the operating mode.

The complexity of the repair is the cost of labor for one repair and is calculated taking into account the complexity and design features of the equipment.

The MRO system is not free from shortcomings. Continuous improvement of the reliability and maintainability of equipment requires the introduction of appropriate changes to the Maintenance and Repair System.

The main directions for improving the maintenance and repair system.

1. Scientific substantiation of standards for overhaul runs. Currently, the Maintenance and Repair System is built on the basis of experimental and statistical standards, which depend on a number of subjective factors. The development of technically justified standards for overhaul runs will create a scientific foundation for the MRO System.

2. Improving the structure of overhaul cycles. The use of wear-resistant materials and protective coatings, improved maintenance and operation of equipment, and other measures leading to an increase in the reliability of equipment make it possible to increase the turnaround time of equipment. Thus, technological progress requires the improvement of the structure of overhaul cycles in order to ensure minimal repair costs. Improving the structure of the overhaul cycle is possible mainly by reducing scheduled (current) repairs and increasing the duration of overhaul periods.

3. Reducing the downtime of equipment in repair and reducing labor costs for repairs. The nodal repair method reduces the duration of the repair. The development of related professions by repair workers also leads to a decrease in downtime in repairs.

4. Development of PPR system standards for stop repairs.

5. Replacement of average indicators of overhaul runs with differentiated indicators, taking into account the operation of the equipment:

a) equipment operating under normal conditions (neutral environments, low temperatures);

b) equipment operating under severe conditions (corrosive environments, elevated temperatures, significant dust and humidity).

6. Accounting in the standards for the aging process of equipment and the need to increase costs as the equipment is used.

Repair documentation

All stages of repair (planning, preparation, implementation, commissioning of repaired equipment) are documented.

The state of the documentation is controlled by the OGM of the enterprise.

The MRO system establishes the following forms of documents:

1. Annual equipment maintenance schedule. Presented by the management of the shop (head and mechanic), approved by the chief engineer of the enterprise after agreement with the head of the production department and the chief mechanic. This schedule indicates the type of repair (current, capital) and the month during which it must be carried out. The schedule provides for the standards for the time of continuous operation of equipment between repairs and downtime for repairs, the need for labor for the production of repairs, data on the annual downtime in repairs and the annual fund of working time.

2. Equipment repair schedule for the planned month. Compiled by the shop mechanic in accordance with the annual schedule. This schedule is approved by the head of the workshop, it indicates the calendar days and the type of repair, as well as the duration of its implementation.

3. Schedule of shutdown for overhaul of factories, workshops and critical facilities. It is presented by the chief mechanic together with the head of the planning department and is approved by the director of the enterprise after agreement with the management of the higher organization. It indicates the duration of equipment downtime in overhaul in days by months for the entire planned year.

4. Title list of overhaul. It is compiled by the chief mechanic and head of the planning department and approved by the director of the enterprise. It shows the distribution of funds allocated for major repairs to all facilities that are to be subjected to major repairs, and the quarterly expenditure of the total amount.

5. Statement of labor costs (general, including machine) for PPR equipment. Represented by the management of the shop in OGM. This statement provides a differentiated calculation of planned labor costs for all types of repairs. On the basis of such statements received from the shops, the OGM plans the total labor costs for the enterprise, as well as the work of the central (sometimes shop) repair bases.

6. Repair journal for accounting for scheduled preventive repairs and inspections. Compiled for each individual equipment, which has its own inventory number. It records the date of the repair (beginning and end) and its type, a summary of the repair, the names of the performers, as well as the actual time of work after the previous current and major repairs.

7. List of defects (list of repair work) to be eliminated during each repair. It is submitted by the workshop management after agreement with the head of the PPR bureau and the technical supervision service. It is approved by the chief mechanic of the plant and contains a list and scope of work to be carried out during repairs, a list of necessary materials and spare parts, qualifications of performers, etc.

8. List of works to be performed during the overhaul. The statement is submitted by the shop management after agreement with the chief mechanic and approved by the chief engineer of the enterprise. It indicates the names and scope of work, the list and quantity of materials needed for the repair. According to this statement, an estimate is made of the cost of each type of work, and all work is distributed among the performers.

9. The act of handing over the equipment for repair by the management of the technological shop and acceptance for repair by the management of the repair shop, which confirms the fact that the facility is prepared for repair work.

10. The act of delivery of equipment from repair by the management of the repair shop to the management of the technological shop, which indicates the quality of the work performed, their compliance with technical specifications, as well as the date the repair was completed.

Repair financing

Each industrial enterprise makes depreciation deductions for major repairs and for the full restoration of fixed assets. Depreciation deductions for overhaul are the target fund of the enterprise and are spent only on overhaul and modernization of fixed assets.

The cost of current repairs and work performed in the process of overhaul maintenance are included in the components that determine the cost of manufactured products. Reducing the volume of current repairs is one of the direct ways to reduce the cost of products, i.e. improvement of one of the most important indicators of production. Costs for current repairs are planned before the beginning of each reporting year on the basis of accumulated experience by recalculating the expected scope of work, taking into account the implementation of new organizational and technical measures.

Repair planning

The main documents for planning repairs are:

Established repair standards;

Standards for the frequency of examination and testing of vessels and apparatus;

Title list of capital repairs of fixed assets of the enterprise;

Estimate and technical documentation;

Annual schedule of planned and periodic repairs of equipment;

Monthly plan-schedule-report of equipment repair;

Act on the establishment (change) of the calendar period for the repair of the previous year;

Draft schedule for shutdown repairs of chemical production facilities.

When planning repairs, it is necessary to take into account the interconnection of technological systems (workshops) at the enterprise, as well as the actual state of the equipment and corrosion protection.

Repair cycle- this is the smallest recurring period of operation during which the established types of maintenance and repair are carried out in a certain sequence, provided for by the MRO System.

overhaul period is the operating time of the equipment between two successive repairs.

The structure of the repair cycle- this is the alternation of repairs in a certain sequence and at certain intervals.

Based on the established standards, the head of the repair unit, together with the head of the workshop, draws up a draft annual schedule for planned and periodic repairs of the workshop equipment, which is submitted for approval by the OGM, OGE, PTO and the chief instrument operator (metrologist).

After agreement with the heads of the engineering services of the enterprise, the schedule is approved by the head of the enterprise (chief engineer) before November 15 of the year preceding the planned one, and is the main document for repairs.

Based on the approved annual repair schedules, taking into account the actual use of the equipment over the past period, a monthly plan-schedule-report for the repair of workshop equipment is compiled. Monthly schedules are approved by the chief mechanic (power engineer) of the enterprise and the head of the production and technical department no later than the 25th day of the month preceding the planned one.

To control compliance with repair standards, the head of the repair unit assigned to a given production workshop must keep a final record of the operating time and condition of the equipment by months and years with an entry in the repair log for this equipment.

2.1. Maintenance (TO) - a set of operations to maintain the operability of equipment during its operation, while waiting (if the equipment is in reserve), storage and transportation.

The TO includes the following work package:

• maintenance of equipment in good (or only operable) condition;
• cleaning, lubricating, adjusting and tightening detachable connections, replacing individual components (wear parts) in order to prevent damage and progressive wear, as well as repairing minor damage.

In the scope of maintenance, work can be performed to assess the technical condition of the equipment to clarify the timing and scope of subsequent maintenance and repairs.

The TOR system is a system of maintenance and repair (planned and according to the actual technical condition of the equipment).

The system of maintenance (TO) and repair according to technical condition includes maintenance, diagnostic monitoring of the technical condition, performance of work during routine shutdowns* and restoration of a working state in case of deviation of the values ​​of the diagnosed parameters from those established by the regulatory and technical documentation.

* Scheduled stop - stopping the operation of equipment for the production of work regulated by the current regulatory and technical documents (passports, TU, RD, etc.)

2.2. The specific content of work for each type of maintenance of the equipment of the enterprise is determined by the job descriptions and regulations set forth in this document, by type of equipment.

2.3. Repair - a set of operations to restore serviceability or operability and complete or partial restoration of the resource of equipment and its components, ensuring operation with a given reliability and efficiency in the periods between repairs and diagnostic controls.

2.4. Current repair (T) - repair carried out during operation to ensure the guaranteed operability of the equipment, consisting in the replacement and restoration of its individual parts and their adjustment.

2.5. Maintenance is assigned to prevent failures and restore the operability of enterprise equipment.

2.6. Medium repair (C) - repair performed to restore the operability and partial restoration of the equipment resource based on the results of diagnostics and the amount of its operating time with the replacement or restoration of components of a limited range and control of the technical condition of the components, performed in the prescribed amount.

2.7. Overhaul (C) - a repair performed to restore serviceability and complete or close to complete restoration of the resource of equipment with the replacement or restoration of any of its parts, including basic ones, and their adjustment.

2.9. Operational diagnostic control - control of the technical condition of the equipment, carried out in accordance with the schedule, as well as the operational parameters of the equipment at a given time and in dynamics.

2.10. Scheduled diagnostic control - control of the actual technical condition of the enterprise equipment by parameters that allow assessing the technical condition of the equipment, making a forecast of its performance, operating time before repair or until the next diagnostic control, and determining the amount and type of repair.

2.11. Unscheduled diagnostic control - control of the technical condition of the enterprise's equipment, carried out in the event of a sharp change in the values ​​of constantly monitored parameters or in the case when, based on the results of operational control, a decision is made about the alleged development of the defect.

2.12. Operational state (operability) - the state of the equipment, in which the values ​​of all parameters characterizing the ability to perform the specified functions comply with the requirements of regulatory and technical and (or) design (project) documentation.

2.13. Inoperable state (inoperability) - the state of an object in which the value of at least one parameter characterizing the ability to perform the specified functions does not meet the requirements of regulatory and technical and (or) design (project) documentation.

2.14. The frequency of maintenance (repair, diagnostic control) is the time interval or operating time between a given type of maintenance (repair, diagnostic control) and the subsequent one of the same type or another of greater complexity.

The type of maintenance (repair, diagnostic control) is understood as maintenance (repair, diagnostic control) allocated (selected) according to one of the signs:

stage of existence, periodicity, scope of work, operating conditions, regulation.

2.15. Repair cycle - the smallest repeating time interval or equipment operating time, during which all established types of repairs are performed in a certain sequence in accordance with the requirements of regulatory and technical documentation.

2.16. Repair according to technical condition - a repair in which the technical condition is monitored at intervals and to the extent established in the regulatory and technical documentation, and the scope and start time of the repair is determined by the current technical condition, information about which is obtained from the results of diagnostic control or reliability data product or its components.

2.17. According to the degree of equipment failure, repairs can be carried out according to the typical scope of work for current, medium or major repairs.

2.18. A scheduled shutdown is a shutdown of the operation of equipment for the production of maintenance, diagnostic and repair work, regulated by the current regulatory and technical documents (passports, TU, GOST, RD, etc.).

2.19. Operating time - the total duration or volume of equipment operation.

2.20. The operating time before a scheduled shutdown is considered to be the operating time until the work regulated by other applicable documents.

2.21. Labor intensity of maintenance (repair, diagnostic control) - labor costs for carrying out one maintenance (repair, control) of this type.

2.22. Spare part (spare part) - a component of the equipment intended to replace the same part that was in operation in order to maintain or restore the operability of the equipment.

2.23. The exchange fund is a stock of the most important spare parts located at specially designated storage bases for restoring the number of spare parts and promptly carrying out repair work to restore the operability of the enterprise's equipment.

2.24 TDiNO service - technical diagnostics and equipment reliability service