Truck Maintenance Station Calculation

Contents

Contents

Introduction

1 Process Part

1.1 Calculation of the annual program of work and annual mileage of the automobile fleet

1.2 Calculation of annual scope of work

1.3 Distribution of Scope of Work by Posts and Sites

1.4 Calculation of the number of employees

1.5 Calculation of number of posts and flow lines for maintenance and maintenance

1.6 Determination of process equipment requirements

1.7 Calculation of the areas of zones TO, TP, production sites, administration, warehouse and household premises, and also storage areas of cars

1.8 Selection of space-planning solution of buildings and open sites

1.9 Plot Plan Layout

2 Organizational part

2.1 Organizational structure of ATP

2.2 States, Regime and Organization of the Enterprise

2.3 Process Organization

3 Occupational safety, HSE and emergency actions

3.1 General Safety Requirements

3.2 Environmental Engineering Protection

3.3 Emergency Response

4 General conclusions

List of sources used

Process Management

The following jobs will be created in the fuel area:

Fuel system parts washing station;

Fuel tanks inspection station;

Diesel engine nozzle check and adjustment station;

Post of inspection and adjustment of injection advance angle, as well as condition of fuel equipment and electric equipment of diesel engines;

Check, adjustment and repair station of LPT;

Maintenance and maintenance zone, assembly and disassembly of fuel equipment.

A plan view of the fuel section is shown in the A4 format drawing.

The parts of the fuel system will be washed at the washing plant for washing parts of the motor, fuel pumps and tools model D37825 (No. 1, Table 12):

Remove parts from the vehicle;

Drain fuel residues;

Immerse the parts in the unit tank filled with hot water or detergent solution;

Hold the parts in the tank until cleaned of dirt and oils;

When using detergent solutions, rinse the parts with cold or warm water;

Dry parts naturally or using compressed air.

Fuel tanks tightness check procedure:

Empty and remove the fuel tank from the vehicle;

Wash from fuel residues and dry. Flushing is carried out in the unit for flushing and steaming of fuel tanks (No. 3, Table 12) using warm water or steam. Drying is performed by blowing with compressed air till complete drying.

Lower the tank into the water bath (No. 4, Table 12).

Fill the tank with air, creating a pressure of 0.02 MPa using a pump or compressed air supply system. Close the tank neck with sealed plug.

If there are air bubbles, mark the places of tightness disturbance with water-resistant chalk.

Check and adjustment of nozzles will be carried out by means of the tester and adjustment of nozzles of KI15706GOSNITI (No. 6, table 12):

Remove the tested nozzle from the vehicle, clean from contaminants;

Install the nozzle on the device, remove the boot cover until the inlet holes are fully opened, close the "drain" valve;

Set the fan to ON with toggle-switch on the instrument panel;

Create the pressure at which fuel is injected by the pump drive handle, fix it according to the gauge of the device and compare it with the specifications for this type of nozzle. Evaluate quality of fuel spraying, tightness of shutoff cone, hydraulic density along shutoff cone and guide cylindrical part.

The condition of fuel equipment and electrical equipment of diesel engines will be checked directly on the car using the K290 diesel analyzer (No. 5, Table 12). And control and adjustment of the injection advance angle - using an Orion ST03 stroboscope (No. 7, Table 12).

The condition of the HPV will be checked using the test bench for the HPV of diesel engines of the brand SDM120215AT (No. 2, Table 12) and the device for assessing the technical condition of the plunger pairs of the HPV (No. 15, Table 12).

General conclusions

Based on the calculation program, it was established that for ATP, consisting of 100 MAZ6303 cars and 150 ZIL4508 cars, the annual maintenance program will be: EO - 84216 units. (33600 - MAZ, 50616 - ZIL); TO-1 - 3316.5 units (1350 - MAZ, 1966.5 - ZIL); TO-2 - 1052 units. (425 - MAZ, 627 - ZIL). EO will be carried out by the in-line method, and TO-1 and TO-2 by the dead end method by specialized teams.

The annual scope of work for maintenance and maintenance will be (people-parts): EO - 48003.12 (19152 - MAZ, 28851.12 - ZIL); TO-1 - 14738.18 (8937 - MAZ, 5801.18 - ZIL); TO-2 - 19200.96 (12316.5 - MAZ, 6884.46 - ZIL); TR - 67484.02 (43552.74 - MAZ, 23931.28 - ZIL); seasonal maintenance - 1818 (1159.2 - MAZ, 658.8 - ZIL); self-service - 17931.16 (10075 - MAZ, 7856.16 - ZIL); diagnostics - 2907.14 (1823.45 - MAZ, 1083.55 - ZIL).

In order to perform the received scope of work, the enterprise must have 3 posts of the RO flow line (length of the flow line is 38m), 4 dead end posts in the TO-1 zone and 3 dead end posts in the TO-2 zone. The number of TR posts is 10. As well as 2 entry and exit checkpoints.

Based on the occupied area of the equipment, the required distances between the equipment and the walls of the room, it is determined that the area of ​ ​ the fuel area is 50 m2. The areas of the remaining areas are determined by specific areas (Table 13). Areas of maintenance and maintenance zones: EO - 383.7 m2; TO-1 - 511.6 m2; TO-2 - 383.7 m2; TR - 1279 m2. The area of ​ ​ the car storage area is 26077.57 m2. Storage areas are shown in Table 14.

It is necessary to implement a centralized control system on the ATP, since the PS has 250 cars. This will ensure optimal process control and high technological readiness of the PS.

The calculations established that in order to carry out complex maintenance and repair at ATP it is necessary to have: production workers - 101 people, auxiliary workers - 22 people, 2 ITR workers and 13 employees of the operational service.

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