7/26/2017

AT 6702
VEHICLE
MAINTENANCE

UNIT I MAINTENANCE, WORKSHOP PRACTICES, SAFETY AND TOOLS

Maintenance – Need, importance, primary and secondary functions,
policies
Classification of maintenance work
Vehicle insurance
Basic problem diagnosis
Automotive service procedures
Workshop operations
Workshop manual
Vehicle identification
Safety – Personnel, machines and equipment, vehicles, fire safety
First aid
Basic tools – special service tools – measuring instruments
Condition checking of seals, gaskets and sealants
Scheduled maintenance services
Service intervals
Towing and recovering

1
 7/26/2017

Introduction

Maintenance means keeping all the systems and

features functioning as possible to the manufacturer’s
original design intentions
Maintenance helps the vehicle to start run and stop as
the manufacturer intended, so that maximum amount
of performance, reliability and service life are
achieved

Need of Vehicle Maintenance

To keep the vehicle in good running condition

To keep the operation cost less

To provide safety on vehicle operation

To give feed back to manufactures for development and

rectification
To adhere to the legal requirements of vehicle
operation.

2
 7/26/2017

Importance of Vehicle
Maintenance
To extend the life of the vehicle
To boost the performance of the vehicle
To improve fuel economy
To improve safety
To have higher resale value
To maintain the vehicle in good condition
To reduce the wear and tear of components
To reduce the risk of serious problems in future
To improve the driving quality of your vehicle

Most Important Faults Found In

Vehicles Delivered
 Incorrect valve stem clearances
 Wrong ignition timing
 Water leakage around windscreens
 Wrong setting of carburetors
 Wheels out of balance
 Faulty door and boot locks
 Incorrect front wheel alignment
 Improperly adjusted brakes
 Non aligned head lamps

3
 7/26/2017

Cont…
 Incorrect spark plug gaps
 Incorrect levels of lubricants and
 Insufficiently tightened nuts, bolts and
fasteners

Points to be taken care in establishing an

automobile Service station/workshop

1.Service enhance
2. Reception/Diagnosis (Service adviser)
3. Filling Repair order and Estimates (Service adviser)
 Accurate preparation of Repair orders

 Clear Explanation of work and cost estimate

agreement obtained.
4. Work allocation/Instructions (Fore man / Technician)

4
 7/26/2017

Cont…
5. Repairs (Technicians)
6. Final Inspection [Foreman / Chief Technician]
7. Delivery preparation (Service Advisor)
8. Delivery (Service adviser)
9. Post service follow-up (service Adviser)

Site Organization for the Vehicle Operations and

Vehicle Maintenance Complex

5
 7/26/2017

Vehicle Operations
Facilities
 Administrative
 Heated parking
 Vehicle washing/cleaning

Vehicle Operations Facilities

 Administrative
 Heated parking
 Vehicle
washing/cleaning

6
 7/26/2017

Vehicle Maintenance Facilities

 Multipurpose vehicle
maintenance

 Special purpose vehicle

maintenance

 Dynamometer (Facility for

verifying and certifying vehicle
emissions.)

 Refueling maintenance (Because

of the potential fire hazard, locate
this facility remotely.

 Hazardous waste accumulation

point

Functional Area Relationships for the Vehicle

Operations Administrative Facility.

7
 7/26/2017

TYPES OF
MAINTENANCE
Preventive maintenance or scheduled
maintenance
Predictive maintenance
Breakdown maintenance or unscheduled
maintenance

PREVENTIVE MAINTENANCE
It is a schedule of planned maintenance
actions aimed at the prevention of
breakdowns and failure.
Primary goal is to prevent the failure of
equipment before it actually occurs
Preserve and enhance the equipment or
vehicle reliability by replacing worn
components before they actually fail.

8
 7/26/2017

TYPE OF
PREVENTIVE MAINTENANCE
Preventive (scheduled) maintenance
 Daily Maintenance
 Weekly Maintenance
 Monthly Maintenance
 Quarterly Maintenance
 Half yearly maintenance or fitness certificate work
 Yearly maintenance or Full fitness certificate work

Daily Maintenance
 Clean vehicle

9
 7/26/2017

Daily Maintenance
 Check engine oil level and top up if necessary

Daily Maintenance
 Check radiator water level and top up

10
 7/26/2017

Daily Maintenance
 Inspect tyre for normal pressure and ensure that no
tyre is fist

Tyres could drop to less than half their recommended air-

pressure level before you’ll see a visual difference

Daily Maintenance
 Check for fuel in tank

11
 7/26/2017

Daily Maintenance
 Check up whether light and electrical accessories are
functioning well

Daily Maintenance
 Check up brake for normal functioning

12
 7/26/2017

Daily Maintenance
 Start engine and check up performance

Weekly Maintenance
 Check electrolyte level in battery and add distilled
water if necessary

13
 7/26/2017

Weekly Maintenance
 Clean battery terminals and apply Vaseline to prevent
corrosion

Weekly Maintenance
 Check tyre pressure and inflate if necessary to correct
pressure

14
 7/26/2017

Weekly Maintenance
 Check tyres for abnormal wear. If abnormal wear is
noticed check wheel alignment, chamber etc.

Weekly
Maintenance
• Check brake fluid level and top up if necessary

15
 7/26/2017

Weekly Maintenance
 Wash vehicle with water mixed with detergent or with
soap water.

Weekly Maintenance
 Check oil leak if any from engine, transmission and
differential and arrange to rectify.

16
 7/26/2017

Weekly Maintenance
 Check oil leak if any from engine, transmission and
differential and arrange to rectify.

Weekly Maintenance
 Clean plugs and refit if the vehicle is petrol driven

17
 7/26/2017

Weekly Maintenance
 Tighten joint bolts and axle bolts.
 Tighten spring and shackle bolts and nuts if necessary
 Adjust fan belt play if necessary.
 Check up water pump grease cup and repack, if
necessary
 Check whether Dynamo is functioning well. Adjust
regulator if necessary.
 Check oil in steering box gear box and differential
and top up if necessary.

MONTHLY MAINTENANCE

 Service vehicle at appropriate date

 Check up and adjust free play of brake

 Check up and adjust free play of clutch

 Soap wash vehicle, polish if the vehicle is station wagon

 Change engine oil at appropriate mileage.

18
 7/26/2017

MONTHLY MAINTENANCE
 Check up and tune up vehicle (minor) petrol driven

 Tighten engine gear box and body mounting bolt

 Remove all the wheels, check brake drums, brake

linings, change brake linings and turns up brake
drums if necessary

 Examine all wheel bearings for wear before refitment

 Remove old grease and repack with fresh grease

QUARTERLY MAINTENANCE
 Tighten body bolts and change packing if necessary
 Blow and adjust brakes
 Carry out engine tune up if petrol driven vehicle
 Check up pedals side play and rectify
 Check up and renew engine mounting beds
 During service, remove and clean shackle pin if necessary
 Check up steering linkages and play and adjust if necessary
 In case of diesel engines overhaul injectors
 All the items mentioned in the monthly maintenance
schedule should be carried out during quarterly maintenance
also

19
 7/26/2017

HALF YEARLY MAINTENANCE

OR FITNESS CERTIFICATE WORK
 Remove gear box and check the components
 Check differential
 Overhaul all four wheel brakes and the Universal
joints
 Top over haul engine end decarbonizes
 In diesel engine, overhaul injectors and pumps and
recalibrate (This should be done by the authorized
agencies and preferably in air conditioned rooms)

HALF YEARLY MAINTENANCE

OR FITNESS CERTIFICATE WORK
 Overhaul water pump
 Overhaul dynamo and self starter
 Overhaul exhauster or air compressor
 Check all wirings and switches
 Carryout body repairs, including linear work
 Repaint vehicles, if lorry or van

20
 7/26/2017

VEHICLE INSURANCE
 Motor insurance gives protection to the vehicle owner
against
 (i) damages to his/her vehicle and
 (ii) pays for any third party Liability determined as
per Law against the owner of the vehicle

VEHICLE INSURANCE
Types of Motor Insurance Cover

 Liability Only Policy (statutory requirement)

 Package Policy (Liability Only Policy + Damage to
owner’s vehicle usually called OD Cover)

21
 7/26/2017

VEHICLE INSURANCE
What Motor Insurance Covers ?
 Fire, Explosion, Self-ignition, Lightning
 Burglary/Housebreaking/Theft
 Riot & Strike
 Earthquake
 Flood, Storm, Cyclone, Hurricane, tempest, indentation, hailstorm,
frost
 Accidental external means
 Malicious Act
 Terrorism Act
 While in transit by Rail/ Road, Inland waterways, Lift, Elevator or
Air
 Land slide / Rock slide

VEHICLE INSURANCE
What Motor Insurance Excludes?
Not having a valid Driving License

Under influence of intoxicating liquor/drugs

Accident taking place beyond Geographical limits

While vehicle is used for unlawful purposes

Electrical / Mechanical Breakdowns

22
 7/26/2017

Road Test Report

This report contains the vehicle registration number,
chassis number; job no, data of test etc
1. Front side and rear side abnormal noise
2. Steering and brake caliper noise
3. Misfiring, sudden stoppage of vehicle
4. Brake condition
5. Wheel and bearing check
6. Pick up of the vehicle
7. Mileage of the vehicle etc

Road Test Report

Before After
S. No. Parameter to check Remark
work work

1 Front side abnormal noise

2 Rear side abnormal noise

Front/rear suspension
3
noise
4 Steering noise
5 Brake caliper noise

6 Misfiring / starting

Hunting problems /
7
Stopping problems

23
 7/26/2017

Check list
A checklist is a type of informational job aid used
to reduce failure by compensating for potential
limits of human memory and attention. It helps to
ensure consistency and completeness in carrying
out a task.
 A basic example is the "to do list." A more
advanced checklist would be a schedule, which
lays out tasks to be done according to time of day
or other factors.

CHECK LIST

24
 7/26/2017

CHECK LIST

LOG BOOK

25
 7/26/2017

LOG BOOK

LOG BOOK
The logbook of a vehicle gives the details
of the vehicle, which will be useful not
only for the owner of the vehicle but also
to the mechanic who might take the job
of vehicle maintenance latter

26
 7/26/2017

Details of log book

Distance covered
Fuel consumption
Average fuel consumption
Best and worst mileage
Total maintenance cost
Running costs
Faults in the vehicle
Likes and dislikes
Date of the previous maintenance report

27
 7/26/2017

SAMPLE JOB CARD

28
 7/26/2017

REPAIR ORDER

REPAIR ORDER
 Repair order is used for legal, tax and general
recordkeeping purposes
 Technician copy gives the listing of the repairs needed
and is used for making notations of repairs completed and
items needing attention
 Customer copy includes the cost estimate
 Copy for the shop’s files

29
 7/26/2017

IMPORTANCE OF REPAIR ORDER

 It fully identifies the customer and the vehicle
 It gives the technician an idea of the reason the car is the
shop for repairs
 It tells the shop’s hourly labor rate
 It gives the customer an estimate of the cost of the repair
 It gives the time the vehicle will be ready for customer
 The signature of the customer gives approval for the
repair and agrees to pay for the shop’s services when the
job is completed
 It is a legal document

IMPORTANCE OF REPAIR ORDER

 It is numbered for future reference
 It includes the odometer reading giving the car’s mileage
 It includes the make, model and model year of the vehicle
 It includes the vehicle identification number
 It includes the customer identification details
 Space for labor’s instructions – This area will be filled in
with the customer’s compliant, possible causes(s), and
repairs to be performed. The customer has to be
questioned carefully about the symptoms

30
 7/26/2017

VEHICLE IDENTIFICATION NUMBER

 Vehicle Identification Number (VIN) is the identifying
code for a SPECIFIC automobile
 VIN serves as the car's fingerprint, as no two vehicles in
operation have the same VIN
 Prior to 1981, VINs varied in length from 11 to 17
characters
 After 1981, VIN is composed of 17 characters (digits and
capital letters)
 VIN displays the car's unique features, specifications and
manufacturer
 VIN can be used to track recalls, registrations, warranty
claims, thefts and insurance coverage.

VEHICLE IDENTIFICATION NUMBER

31
 7/26/2017

VEHICLE IDENTIFICATION NUMBER

VEHICLE IDENTIFICATION NUMBER

32
 7/26/2017

SAFETY
HAZARDS DUE TO FAULTY WORK HABITS OR CONDITIONS
 Smoking while handling dangerous materials such as
gasoline or solvents
 Careless or incorrect handling of gasoline, alcohol, solvents
or other flammable fluids
 Blocking exits
 Spilled oil or antifreeze not cleaned up
 Lack of shop exhaust system or failing to connect the system
to the tail pipe of a vehicle with a running engine
 Allowing dangling hair, ties, sleeves or jewelry to fall into
the engine fan, drive belt or other moving part

SAFETY
HAZARDS DUE TO EQUIPMENT DEFECTS OF MISUSE

 Incorrect safety guarding of moving machines

 Asbestos dust from brake and clutch lining
 Misuse of compressed air
 Flexible electric cord with worn or forward insulation
 Compressed-gas cylinders improperly stored or missed
 Hand-held electric tools not properly grounded
 Automotive lifts not properly used
 Jacks or safety stands improperly placed

33
 7/26/2017

SAFETY
HAZARDS DUE TO EQUIPMENT DEFECTS OF MISUSE

 Using a wheel-and-tire balancer, without the hood in place

 Letting tester leads fall into the engine fan
 Sudden startup of the electric fan for the engine cooling
system
 Leaving a running power tool unattended
 Playing with a fire extinguisher

SAFETY

34
 7/26/2017

SAFETY
FIRE PREVENTION

 Do not smoke or light cigarettes around gasoline or other

flammable liquids
 Leaking or spilled gasoline quickly vaporizes. Keep the shop
doors open and the ventilating system running. Wipe up the
spilled gasoline at once. Put the rags or towels outside to dry.
 Sometimes you must work on a vehicle that is leaking
gasoline. Be very careful. Catch the leaking gasoline in a
container or on rags. Put the soaked rags outside to dry. Do
not make sparks, such as by connecting a test light to the
battery.

SAFETY
FIRE PREVENTION

 Store gasoline in an approved safety container. Never store

gasoline in a glass jug. The glass could break. An explosion
and fire could result.
 Oily rags can catch fire, without a spark or flame, by
spontaneous combustion. To prevent this, always store oily
rags and waste in a fireproof safety container. The lid should
close completely.

35
 7/26/2017

SAFETY
FIRE EXTINGUISHERS

 A fire extinguisher is a portable container filled with

chemicals which can be discharged in a stream to put out
small fires
 The most common shop fire extinguisher is the multipurpose
dry chemical type
 It can be used to fight ordinary combustible fires, flammable-
liquid fires and electrical fires

SAFETY
TYPES OF FIRE EXTINGUISHERS
 Class A - fires involving solid materials such as wood, paper
or textiles
 Class B - fires involving flammable liquids such as petrol,
diesel or oils
 Class C - fires involving gases
 Class D - fires involving metals
 Class E - fires involving live electrical apparatus.
(Technically ‘Class E’ doesn’t exists however this is used for
convenience here)
 Class F - fires involving cooking oils such as in deep-fat
fryers

36
 7/26/2017

SAFETY
TYPES OF FIRE EXTINGUISHERS

SAFETY
TYPES OF FIRE EXTINGUISHERS

37
 7/26/2017

SAFETY
TYPES OF FIRE EXTINGUISHERS

SAFETY
HOW TO USE A FIRE EXTINGUISHER

Are you taller than fire?

Do you have the right fire extinguisher for the type
of fire?
Is the fire extinguisher pressurized?
Get in Position

38
 7/26/2017

SAFETY
HOW TO USE A FIRE EXTINGUISHER

Measuring Instruments

39
 7/26/2017

Measuring Instruments

SAFETY NOTE
Keep tools maintained in safe working condition
 Do not use worn or broken tools
 When using screwdrivers, do not hold small
components in your hand
 Do not put sharp tools in your pocket

40
 7/26/2017

WRENCHES

41
 7/26/2017

How to use an open end

wrench

42
 7/26/2017

Box Wrenches
Box wrenches are either
six point or twelve point.
Twelve point is more
versatile, fitting on the
head of a bolt in more
positions.
 To fit the wrench on in
a different position
requires only 30° of
movement of the wrench
head.
Axis point box end is
more difficult to use
because it must be moved
60°.

Ratcheting Box Wrench

A ratcheting box wrench also called a boxocket,
is sometimes used for special applications such
as muffler clamps: or tie rod end clamps in the
steering linkage.
This tool is especially handy when a nut is used
on a very long bolt where a deep socket wouldn't
be deep enough.
The highest quality box sockets are very
compact and can fit into tight spots. To change
the direction of rotation, turn the wrench over.

43
 7/26/2017

Ratcheting Box Wrench or Boxocket

 Used for muffler clamps or tie rod end clamps in the steering
linkage
 This tool is especially handy when a nut is used on a very long bolt
where a deep socket wouldn't be deep enough.
 The highest quality box sockets are very compact and can fit into
tight spots. To change the direction of rotation, turn the wrench over.

screwdrivers
The two most common screwdrivers are

The standard flat tip

The Phillips head

44
 7/26/2017

Miscellaneous screwdriver
tips

STANDARED FLAT TIP SCREWDRIVER

45
 7/26/2017

AN ASSORTMENT OF
RATCHETS

Ratchet
A ratchet has teeth inside its head. The parts that
make up the inside of a ratchet head.
 The teeth allow a small amount of movement of
the head of a bolt before the ratchet handle is
moved back to its starting position.
 This allows tightening when little room is
available for the ratchet handle to move.
When a nut or bolt is extremely tight, a breaker bar
is used so that the teeth in the Ratchet head are not
damaged

46
 7/26/2017

a) Internal parts of a ratchet head make up a ratchet repair kit (b) A

breaker bar prevents the need for a ratchet repair kit.

SOCKET
 Sockets are available in many sizes and styles.
 There are two size designations; one refers to the square
ratchet drive end and the other refers to the hex socket end that
fits the bolt head.
 The most common drive sizes used on automobiles are the
1/4", the 3/8"and the 1/2".
 The 3/8" drive is the most versatile for automobile work.
 A set of 3/8“ drive sockets usually includes hex (bolt head)
sizes ranging from 3/8"to 3/4".

47
 7/26/2017

Sockets

48
 7/26/2017

Extension Bar
Common sizes of extensions are 1 ",3 ",6" and 10 ". Very long
extensions (two or three feet) are used with a swivel socket in
transmission R&R (remove and replace) jobs and other
specialized applications.

49
7/26/2017

50
 7/26/2017

Pliers
Pliers come in many types and sizes.
Examples of this are the rib joint pliers, called Channel locks,
and locking pliers, called Vise grips. Other Pliers include
cutting pliers, needle nose, and slip Joint utility (combination)
pliers.
Most often a plier is for cutting, bending, or positioning a part
(such as a cotter pin) or for stripping an electrical wire. The
use of too Small a plier for the size of the job can result in
damage to the plier's jaws.

51
 7/26/2017

High Leverage
Combination Pliers
High leverage combination pliers are also popular for cutting or
gripping. They require only one quarter the normal effort on
the handle. Much movement of the handle results in little
movement at the jaws. These are excellent pliers when a very
strong grip is needed.

High Leverage Combination

Pliers

52
 7/26/2017

Snap Ring Pliers

53
7/26/2017

54
7/26/2017

55
 7/26/2017

Pullers
 Pullers are used to remove or install pressed-fit gears bushings,
bearings, or other parts from shafts
 Pullers are either hydraulic or manual
 Manual pullers have a bridge or a bar type yoke
 A slide hammer or a pressure screw is threaded through the
yoke
 Abridge type yoke pushes against the outside of the part being
pulled.
 Some bar type yoke pullers have jaws and others use bolts or
collets
 Jaw type pullers sometimes have an adjustable clamp bolt,
which holds the jaws against the work for a more reliable pull
 The end of the pressure screw has a replaceable hardened point

56
 7/26/2017

Puller

57
 7/26/2017

Puller

 Jaws of different lengths and sizes may be

installed to make the puller more versatile
 The size of the jaw depends on the reach
and spread required for the pulling
application
 The jaws can be turned around to
accommodate inside and outside pulls
 Pressure screws of different lengths make
it possible for the puller to use different
length jaws

58
 7/26/2017

• A larger puller is the Hydraulic

type puller, often Called a
"porta-power"

One of the most versatile

pullers used in engine repair
is the bearing separator and
bar-type puller set-up

59
 7/26/2017

STUD PULLER
 A stud is a fastener that is threaded on both ends
 It therefore lacks a provision for using a wrench to turn it
 The stud puller wedges against the stud (usually in an area in
the center that has no threads) and loosens it
 The tool works best if it is held all the way down against the
work surface

Safety note
 Wear eye protection
 When heating a part to help free it, do not heat the jaws of the
puller. This could change the temper of the metal
 Be sure the pressure screw is clean and lubricated before using
an impact wrench
 Be sure the removable point is installed on the puller
 Be sure the puller is aligned perpendicular to the part being
pulled
 DO not use a puller with damaged or worn parts
 Use the correct size puller so overloading is avoided
 Use a three jaw puller instead of a two jaw puller when
possible

60
 7/26/2017

Air tools
 Air tools are great time savers and used in all automotive shops
 Examples - air drills, air valve seat grinding motors, air operated
valve spring compressors, and air hydraulic jacks
 The air compressor provides air at a regulated pressure of 90 to
150 psi (pounds per square inch)
 90 psi gives the best performance and reliability from air tools

Compressed Air Safety Pre

cautions
 Always wear eye protection when blowing off parts. Pieces of
debris can be blown into eyes. Always blow down and away
from yourself
 Do not blow air against your skin; the high pressure
compressed air used in auto repair shops can penetrate skin
 Compressed air is used to power chassis grease guns.
Pressurized grease can penetrate skin also

61
 7/26/2017

Safety note
Be careful of loose clothing or hair that might
become tangled in the tool.
 Use approved impact sockets, not chrome
sockets.
 Be sure that the socket is secured to the air tool.
A clip at the end of the tool's square drive can
become worn so that it no longer holds the tool.
 When the impact wrench fails to loosen a
fastener, use a large breaker bar.

62
 7/26/2017

Air Ratchet
Another popular
tool is the air
ratchet, It is an
excellent tool for
use in confined
places.
 A disadvantage
of this tool is that
it is noisy.

Air Chisel
 The air chisel is a miniature
jackhammer
 It is often used to drive valve
guides out of cylinder heads,
and it is useful in front end
repair and muffler work.
 There are many attachments
available for a variety of uses.

63
 7/26/2017

Die Grinder
 Die grinders turn at very high
speeds (about 20,000 rpm)
 They remove burrs, using
either small cutters or grinding
wheels
 Carbide tipped cutters are also
available.
 Use a cutter rather than a
grinding wheel if the work
piece is a soft metal

Air Drill
 An air drill fitted with a
small wire brush is very
effective for removing
gaskets or carbon
 A special wire wheel is
available for high rpm use.
Called an "encapsulated
wire
 wheel," it has molded
plastic in between the wires
of the brush.
 The plastic material wears
away to expose only the tips
of the wire.

64
 7/26/2017

Stethoscope

Examination with a
stethoscope can reveal valve
train noises or spun bearing
locations in toasted motors

Valve spring commpressor

65
 7/26/2017

Piston ring Compressor

Piston Ring Expander

66
 7/26/2017

OIL FILTER

VEHICLE PREVENTIVE
MAINTENANCE
Properly maintained equipment last longer, cost
less to operate, are involved in fewer accidents
and provide more trouble-free service.
 Effective preventive maintenance (PM) services
must be performed repeatedly as governed by
preventive maintenance intervals and schedules

67
 7/26/2017

VEHICLE PREVENTIVE
MAINTENANCE
Properly maintained equipment last longer, cost
less to operate, are involved in fewer accidents
and provide more trouble-free service.
 Effective preventive maintenance (PM) services
must be performed repeatedly as governed by
preventive maintenance intervals and schedules

VEHICLE PREVENTIVE
MAINTENANCE
Properly maintained equipment last longer, cost
less to operate, are involved in fewer accidents
and provide more trouble-free service.
 Effective preventive maintenance (PM) services
must be performed repeatedly as governed by
preventive maintenance intervals and schedules

68
 7/26/2017

PM-4 Perform all items listed on the pm-4 schedule

every 4,000 miles.

PM-12 Perform all items listed on the pm-12

schedule every 12,000 miles.

PM-24 Perform all items listed on the pm-24

schedule every 24,000 miles.

VEHICLE PREVENTIVE RECORD

PREVENTIVE MAINTENANCE SURVEILLANCE
MILEAGE DUE INSPECTION
DATE DUE
COMPLETE
EVERY
6 MONTHS
PM 4 PM 12 PM 24

69
 7/26/2017

PREVENTIVE MAINTENANCE SCHEDULE

PM-4
VEHICLE RAISED
1.Drain engine oil and change oil filter.
2. Lube front axle spindle pins/ball joints.
3. Lube U-joints and check drive shaft components.
4. Lube steering linkage.
5. Check differential lube level.
6. Check standard/automatic transmission oil level, fill
as needed.
7. Clean differential breather.
8. Check for wear and damage on all wheels and tires.
9. Inflate tires to proper pressure.

VEHICLE
IS OFF THE GROUND
(a) Fluid leakage of all types at all
locations.
(b) Brake and exhaust systems components.
(c) All springs, shock absorbers and
fasteners.
(d) Engine and transmission mounts.

70
 7/26/2017

PM-4 (CONT’D)
VEHICLE LOWERED
ENGINE COMPARTMENT
1. Install oil filter and engine oil.
2. Clean air cleaner and oil cap.
3. Lube distributor shaft oil cup(if equipped).
4. Test throttle and kick down linkages.
5. Lube hood, doors and wheelchair lift/ramp
hinges, latches and rails.
6. Check brake master cylinder fluid level.
Refill as needed.
7. Lube exhaust control valve. Check for proper
operation.

8. Check radiator coolant level and protection.

Refill as needed.
9. Check windshield washer reservoir. Refill as
needed.
10. Clean battery posts and terminals. Check for
volt leakage. Load test battery. Fill battery water.
11. Check brake pedal reserve.
12. Check foot (service) brake assist.
13. Check steering wheel play.
14. Check power steering reservoir. Fill as
needed.

71
 7/26/2017

PM-4 (CONT’D)
START ENGINE
1. Check for oil leaks.
2. Check automatic transmission fluid level.
3. Road test brakes and check for proper operation
of all other systems.
4. Record PM service in permanent vehicle
records.
5. List required repairs as separate operations and
acquire necessary authority clearance or
arrangements before repair is undertaken.

SERVICING THE IGNITION SYSTEM WITH

CONTACT BREAKER POINTS

1. Clean, recap or
Replace spark plugs.

clean with wire brush

check for cruel in insulation.

72
 7/26/2017

2.Clean and inspect

the ignition coil.

• If the tower (Top) is cracked

replace the coil.

3.Replace the primary wire (coil) to distributor and

coil to switch it is broken make sure that the
connections are clean and Tight.
4.Clean and inspect the distributor cap.
5.Examine the Rotor.
6.Twist the distributor shaft in the direction of
rotations and release. It should snap back it if
Does not the distribute advance mechanism must
be repaired.

73
 7/26/2017

7.Inspect the contact points replace them it

necessary check and set the gap.
0.4 to 0.5 gap is maintained in the contact points.
8.put a small amount of cam lubricant (white silver
lube) on the distributor com.
9.check and set the Dwell using a Dwell meter
10.Adjust the timing using a Timing light and
Tachometer
11.check whether the advance mechanism works
using the timing light.

Emergency
Information Panel

74
 7/26/2017

(a) the goods carriage has a valid registration to

carry the said goods;
(b) the vehicle is equipped with necessary first-aid,
safety equipment and antidotes as may be necessary
to contain any accident;
(c) that the transporter or the owner of the goods
carriage has full and adequate information about the
dangerous or hazardous goods being transported;
and
(d) that the driver of the goods carriage is trained in
handling the dangers posed during transport of such
goods.

FIXING EMERGENCY INFORMATION PANELS ON

VEHICLES AND DIMENSIONS

75
 7/26/2017

1. The correct technical name of the dangerous or hazardous

goods in letters not less than 50mm high;
2. The united nations class number for the dangerous or
hazardous goods as given in column 1, table 1 appended with
rule 137, in numerals not less than 100 mm high;
3. The class label of the dangerous or hazardous goods of the size
of not less than 250mm square;
4. The name and telephone number of the emergency services to
be contacted in the event of fire or any other accident in letters
and numerals that are not less than 50 mm high.

All dimensions are

expressed in millimeters

76
7/26/2017

77
7/26/2017

78
7/26/2017

79
 7/26/2017

Towing

80
 7/26/2017

Towing – Tow Dolly

 Towed vehicle may take some of the load off the towing vehicle by letting
the rear wheels rest on the ground while you tow the vehicle
 This works better when towing is front wheel drive vehicle
 Disconnect the drive shaft of a rear wheel drive, or four wheel drive, while
traveling long distances
 The vehicle you are towing with must weigh, at a minimum, 750 pounds
more than the vehicle it is towing, plus the towing device

Towing
Step 1 Connect the tow dolly
 Attach the tow dolly coupler to the hitch ball on the towing vehicle
 Properly seat the coupler on the hitch ball and hand tighten the coupler until
a tight and secure connection is made
 Check that the coupler is securely fastened by moving the tow vehicle
forward slightly or pushing the dolly to the rear
 Attach the safety chains from the dolly to the tow vehicle. This keeps the
dolly connected to the tow vehicle even if the coupler comes off the hitch
ball

Step 2: Load the towed vehicle

 Drive the towed vehicle onto the dolly ramp facing forward.
 Warning: Facing the vehicle to the rear can cause the towed vehicle to whip
and sway.
 Ensure that the entire width of the towed vehicle fit on the ramps.
 Also, check all clearances, such as for spoilers, air dams, and other vehicle
parts while loading.

81
 7/26/2017

Towing

Step 3: Secure the towed vehicle.

 Continue driving onto the dolly until both the front tires are firmly against
the wheel stops.
 Using the tire straps on the tow dolly, secure both front tires.
 Loop the towed vehicle security chains around a frame member on the
towed vehicle.
 Keep the chains away from fuel and brake lines to prevent damage to these
components.

Towing
Step 4: Disconnect the driveshaft
 On rear-wheel-drive and four-wheel-drive vehicles, you need to disconnect
the driveshaft to keep from damaging the transmission of the towed
vehicle.

82
 7/26/2017

Towing - Trailer

 Material Needed - Nylon straps or wheel nets

 Safer than other methods
 Main drawback is that the combination of the towed vehicle and trailer
might be too heavy for the towing vehicle to handle.

Towing
Step 1: Attach the trailer
 First, you must securely attach the trailer to the hitch ball of the tow
vehicle.
 Make sure the trailer coupler is securely attached to the hitch by driving the
tow vehicle forward slightly.
 Attach the safety chains from the trailer to the tow vehicle.
 Connect the trailer wiring harness to the tow vehicle sockets.
 If the trailer comes with a brake battery, check its charge before setting out
on a trip.

Step 2: Load the vehicle

 Next, extend the trailer ramps and drive the towed vehicle onto the trailer.
 Center the towed vehicle and drive it slowly up the ramps.
 Continue driving until the front tires are resting against the tire stops at the
front of the trailer.
 Place the vehicle in park and set the parking brake.

83
 7/26/2017

Towing

Step 3: Secure the vehicle.

 The last step involves securing the towed vehicle to the trailer.
 Using nylon straps or wheel nets, position the straps over the center of the
front tires. Ratchet the strap down until tight.
 Fasten the security chains to the front and back of the vehicle frame,
making sure to avoid brake and fuel lines.

Towing – Tow Bar

 Tow bars allow all four wheels of the towed vehicle to rest on the ground
while moving.
 When using a tow bar, you need to disconnect the driveshaft to keep from
damaging the transmission.

84
 7/26/2017

Towing
Step 1: Secure the brackets.
 Using the tow bar as a guide, find a strong part of the vehicle frame to attach
a bracket on each side of the front of the towed vehicle.
 This requires you to drill into the frame of your vehicle.
 The end result is two brackets to which you can attach and detach the tow
bar quickly.

Step 2: Check the brake lights.

 Before hooking up the tow bar, make sure that the brake lights and turn
signals of both vehicle work in tandem, or use removable tail lights.
 Purchase a wiring system that connects and coordinates the brake lights and
turn signals of both vehicles.
 If you do not plan on towing the vehicle that often, then you can opt to use
removable tail lights.
 Removable tail lights attach to the rear of the towed vehicle and use the
electrical system of the tow vehicle for braking and signaling turns.

Towing
Step 3: Attach the tow bar
 Next, attach the tow bar to the towing vehicle.
 Start by attaching the tow bar brackets on the towed vehicle.
 You can do this by sliding the bolts through the ends of the tow bar that
attach to the brackets attached to the car.
 Further secure the bolts using washers and nuts that correspond to the bolts
size. Use a socket wrench to tighten.
 Next, attach the two tow bars coming from the brackets on the towed vehicle
to the pivot bracket using the bolt, nuts, and washers that come with the tow
bar.
 The pivot bracket connects to the part of the tow bar that either inserts
directly into the hitch receiver or has a coupler that attaches to the hitch ball.
 Further secure the tow bar by attaching safety chains from the tow vehicle to
the pivot bracket and from the base plate of the pivot bracket to the towed
vehicle.

85
 7/26/2017

Tools Of The Industry A Well Maintained Toolbox

Indicates "Pride In Workmanship."

What are the special tools and basic instruments

required for maintenance

Basic Instruments Needed

For Engine
1) Compression Gauge
2) Vacuum Gauge
3) Tachometer

For Ignition System

1) Power Timing Light
2) Dwell meter
3) Voltmeter
4) Ohm meter

86
 7/26/2017

For Electric System

1) Voltmeter
2) Ammeter (0-30 Amps)
3) Tachometer
4) Hydrometer
5) Batter Load Tester

For Fuel System

1) Fuel pump Pressure Gauge

For Emission Checking

1)Exhaust Gas Analyzer

For Cooling System

1)Coolant Thermometer

87