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1
Necessity of maintenance:
• Maintenance is used for obtaining high standards and
able to efficiently utilize , its operation and quality of
services.
2
• Maintenance in general is the process of keeping a
motor vehicle in good running condition.
3
• In general, maintenance includes oil change, chassis
4
Quiz
a. More life.
b. Less life.
c. Less mileage.
5
• What are different types of maintenance?
6
Maintenance can be divided into four types
1. Preventive maintenance.
4. Operation maintenance.
7
Preventive maintenance :
8
Preventive maintenance has following advantages :
9
Break down maintenance :
10
Periodic maintenance :
11
Operation maintenance :
12
Quiz
a. Break down.
b. Servicing.
c. Both a & b.
13
• Periodic maintenance may be included to the maintenance
done for a vehicle daily, weekly, quarterly, yearly.
14
• Periodic maintenance is the maintenance to be carried
after vehicle covering 500 kms, 1000 kms, 2000 kms,
4000 kms and 8000 kms.
15
Periodic maintenance :
16
Quiz
a. Preventive maintenance.
c. Periodic maintenance.
17
Breakdown maintenance:
18
• Brake down maintenance includes the faults such as
starting difficulties, breakage of components.
19
• Brake down maintenance includes electrical faults.
system
20
• Brake down maintenance includes problems due to over
heating.
Example:- If leakage of coolant from cooling system, level
of coolant decreases then engine becomes over
heat.
– Fan belt loose/ broken
21
Operation Maintenance:
22
• Operation maintenance of a vehicle includes the
checking / inspection of the following
• Tyre inflation
• Battery
• Brakes
• Clutch
• Smoke colour
23
• Operation maintenance includes problems in Ignition
system, lights which are checked in these maintenance only.
24
Quiz
25
Operation Maintenance
26
Operation Maintenance
• Starting system.
• Ignition system.
• Transmission check-up
27
Servicing And Its Necessity
28
Servicing And Its Necessity
technicians.
29
Quiz
a) Tyre inflation
b) Engine overhauling
c) Clutch overhauling
30
Servicing And Its Necessity
31
Servicing And Its Necessity
32
Servicing And Its Necessity
33
Servicing And Its Necessity
34
Quiz
a) Trouble free
35
Types Of Servicing
• Adjustment.
36
Types Of Servicing
37
Types Of Servicing
INSPECTION AND REPAIR OF DIFFERENT PARTS:
2. fan condition
2. inspection of battery.
vehicle.
vehicle.
40
Types Of Servicing
41
Quiz
1. Which of the following come under type of servicing
____________.
a) Adjustment
b) Cleaning
c) Both a & b
42
Cleaning of motor vehicle and its parts
43
Cleaning of motor vehicle and its parts
cleaning operation
44
Cleaning of motor vehicle and its parts
45
Cleaning of motor vehicle and its parts
engine.
46
Cleaning of motor vehicle and its parts
impact.
47
Quiz
a) Grease
b) Paint
c) Both a & b
48
Lubrication of motor vehicle
49
Lubrication of motor vehicle
Engine Lubrication:
grade
50
Lubrication of motor vehicle
51
Lubrication of motor vehicle
Chassis lubrication:
• They are two methods for lubrication of chassis.
52
Lubrication of motor vehicle
used
53
Lubrication of motor vehicle
56
Lubrication of motor vehicle
57
Quiz
a) Decreased
b) Increased
c) Constant
58
Lubrication of springs
• prevents rust
59
Lubrication of springs
60
De-carbonizing of engine parts
61
Decarbonisation
62
Decarburization
• Oxygen method
• Chemical method
63
Precautions to minimize carbon
deposition
64
Quiz
a) Unnecessary idling
c) Both a & b.
65
Servicing of a petrol engine
66
Servicing of a petrol engine
67
Servicing of a petrol engine
68
Servicing of a petrol engine
a) Spark plug.
b) Carburetor.
c) Both a & b.
d) None of the
above
70
Servicing of petrol engine.
71
Servicing of petrol engine.
72
Servicing of petrol engine.
73
Servicing of petrol engine.
74
Servicing of petrol engine.
75
Servicing Equipment
Introduction
• For proper running and efficient performance of vehicle
effective maintenance is prerequisite.
• Vehicle hoist
• Air compressor
76
Scrubbing and Cleaning With Pressurized Water
Fig 1
77
Washing In Progress
Fig 2
78
Car Washing Machine
Fig 3
79
Car Washing Machine:
deposits
80
Construction
and nozzle
81
Working
• The motor driven pump lifts and compresses water from tank
be regulated
82
There are two types of car washer :
• Car washer with single hose, which can be used to wash only
83
The following pictures shows the washing of a vehicle
84
Washing Room
Fig 4
85
Scrubbing Brushes Through Which Vehicle
Moves
Fig 5
86
Scrubbing Operation After Applying Cleaning
Solvent To Vehicle
Fig 6
87
After Completion Of Washing
Fig 7
88
Quiz
a) Three
b) Four
c) One
89
Quiz
a) Electric motor
b) Generator
c) Starter
d) All of above
90
Vehicle Hoist
• Hydraulic hoist is one of the essential equipment of service
station
• Types of hoists used in Automobile workshop are
91
Vehicle Hoist
Fig 1
92
• The hoist comprises a platform, which is fixed on the top of
93
• The pressurised oil enters the bottom of cylinder and lifts the
plunger up
lifted up
94
• For lowering the vehicle, valve ‘b’ is brought to the original
position
95
Two post hoist :
and defects
96
Two Post Hoist
Fig 2
97
Rare View of two Post Hoist
Fig 3
98
Four Post Hoist
Fig 4
99
Four Post Hoist
• This type of hoist is generally used for removal of wheels
• The removed wheels are generally sent for the purposes like
wheel balancing, replacing new tyres, throwing of rims etc
• In this type of hoist there is a provision for the vehicle to enter
on to the platform with the help of angular extension platform
• This type of hoist is also used for inspecting the vehicle
components under the chassis
100
Typical Four Post Hoist
Fig 5
101
Folding Type Four Post Hoist
Fig 6
102
Folding Type Four Post Hoist
• Folding type four post hoist is used in the garages where the
pressure
• After folding down the hoist, the area can be used for parking
vehicle
103
Quiz
a) Washing Purpose
c) Both
d) None
104
Quiz
ram working on :
a) Hydraulic cylinder
b) Master cylinder
c) Oil cylinder
d) All of them
105
Air Compressor:
Principle of operation :
Fig 7
106
Air Compressor
•Principle of operation :
• It is a machine capable of compressing and delivering
107
Air Compressor
• Principle of working :
108
Air Compressor
Fig 8
109
Air Compressor
Fig 9
110
Air Compressor
Function :
111
Air Compressor
Uses of compressed air :
Compressed air is one of the best sources of energy and has
numerous applications
112
Air Compressor
Uses of compressed air :
113
Air Compressor
1.Reciprocating compressor
2. Rotary compressor
114
Air Compressor
Reciprocating compressor
Fig
115
10
Air Compressor
Rotary compressor
Fig
11 116
Air compressor
1.Reciprocating compressor :
117
Air compressor
Rotary compressor :
118
Quiz
119
Air Compressor
120
Air Compressor
Uses of compressed air:
• To spray paint
• To inflate tyres
121
Air Compressor
122
Air Compressor
• Classification :
• The reciprocating compressors may be classified as below:
• Depending on operation:
a) Single Acting: Air is compressed by one side of
piston
123
Air compressor
• Method of cooling:
a) Air cooled compressor.
b) Water cooled compressor.
124
Air Compressor
Fig 1
125
Fig 2
Twin cylinder compressor
126
Air Compressor
127
Air compressor
Construction :
128
Air compressor
Construction :
Reciprocating air compressor
Fig 3 129
Air compressor
Construction :
Reciprocating air compressor
Fig 4
130
Air compressor
Construction : (Reciprocating type)
131
Air Compressor
Construction :
132
Air Compressor
Working :
When electric motor is switched on, it drives the
crankshaft of the compressor by a belt and pulley
arrangement
133
Air Compressor
Working :
Fig 5
134
Air Compressor
Working :
The crank shaft inturn,causes the piston to reciprocate
135
Air compressor
Working :
136
Air Compressor
Working :
Fig 6
137
Air Compressor
Working :
138
Air Compressor
Working :
• As the piston reaches T.D.C , delivery valve opens
• Compressed air is discharges to a receiver
• Receiver is a storage tank , from where air is disposed
to other applications
• The cycle repeats in this way
139
Air Compressor
Working :
• It is to break the circuit when the pressure inside the air tank
reaches a maximum value.
140
Air Compressor
Working :
141
Specifications of Air compressor (For automobile
service station )
adopted for auto servicing unit :
142
Air Compressor
143
Air Compressor
Specifications of Air compressor (For automobile
service station )
144
Quiz
1. Compressor draws air into the cylinder during which stroke
(a) Suction
(b) Compression
(c) Both a & b
(d) None ( )
a
145
Quiz
2. Which one of the following gauge is used to check
the pressure of compressed air in the tank
a) Feeler gauge
b) Plug gauge
c) Pressure gauge
c
d) None ( )
146
General Lubrication
• This reduces friction in its parts and thus prolongs its life.
147
Lubricating points of a vehicle are :
• Engine
• Clutch
• Propeller shaft
• Gear box
• Rear axle
148
Points of Lubrication
• Steering system
• Suspension system
• Braking system
• Miscellaneous
149
Points of Lubrication
Engine :
150
Points of Lubrication
151
Points of Lubrication
Clutch :
152
Points of Lubrication
Gear box :
153
Points of Lubrication
Propeller shaft :
• At universal joints
154
Points of Lubrication
Rear axle :
155
Points of Lubrication
Steering system :
156
Points of Lubrication
Suspension system :
157
Points of Lubrication
Braking system :
158
Points of Lubrication
Wheels :
159
Points of Lubrication
Miscellaneous parts :
• Hinges of doors
• Hinges of bonnet
• Seats, etc.,
160
Quiz
161
Time of lubrication
162
Time of lubrication
163
Time of lubrication
• The driver should check daily, whether the oil in the engine
sump is at the correct level.
164
Time of lubrication
166
Type of lubricant
167
Type of lubricant
168
Quiz
• The lubrication time varies depending upon the amount of -----
---- a part does and --------- it will take to wear out.
169
Methods Of Lubrication
170
• For this purpose an oil can or oil gun or grease gun is used .
• This depends upon the type of oil and type of points provided
in the vehicle.
171
The following diagram shows the various parts of the chassis
which need to be lubricated
172
Lubrication Points Of A Car
Fig 1
173
Different parts of a chassis which are to be lubricated are
shown in the following table:
174
Typical Lubrication Chart
No .as Parts to be Work to be carried Type of
found in lubricated/ out lubricant to be
diagram checked used
Daily
1 Engine oil Check the oil level. SAE 20W40
sump If the level is engine oil
reduced, add fresh
oil so as to bring it
to the required level
Every 500 km run
1 Engine oil Check the oil level SAE 20W40
sump and top up if engine oil
necessary
175
Every 3000 km run
No .as Parts to be Work to be Type of
found in lubricated/check carried out lubricant to be
diagram ed used
1 Engine oil sump Check the oil SAE 20 w 40
level and top up engine oil
if necessary
2 Distributor Turn the grease Grease which
container cap can melt at
by two or three very high
rotations temperature
3 Clutch pedal Apply the Chassis
shaft grease in the grease
joints
176
No .as Parts to be Work to be Type of
found in lubricated/ carried out lubricant to
diagram checked be used
178
No .as Parts to Work to be carried out Type of
found in be lubricant to
diagram lubricate be used
d/
checked
7 Gear Check the oil level in SAE 90 oil
box the gear box. If the
level of oil is reduced,
add fresh oil so as to
bring it to the required
level
179
No .as Parts to be Work to be carried Type of
found in lubricated/ out lubricant to
diagram checked be used
180
No .as Parts to be Work to be carried Type of
found in lubricated/ out lubricant to be
diagram checked used
181
Every 12000 km run
182
No .as found in Parts to Work to be Type of
diagram be carried out lubricant to be
lubricated/ used
checked
Front Lubricate the Wheel bearing
12 wheel wheel grease
bearing bearings
using grease
13 Generator Use a few SAE 30 engine
/ drops of oil oil
Alternator
183
Every 24000 km run
No .as Parts to be Work to be carried Type of
found in lubricated/ out lubricant to be
diagram checked used
7 Gear box Remove the oil and SAE 90 oil
flush it with
9 Rear axle kerosene, when the
kerosene is also
emptied, fill up with
fresh oil
14 Starter Apply motor grease Special starter
motor on the motor motor grease
bearing parts
184
• Along with lubrication, the water level in the radiator should
be checked.
• Tyres should be checked for proper inflation.
• If all this is done, the vehicle will run properly and last long.
185
Quiz
186
2) Gear box oil should be replaced at every:
a) 6000KM ( ) d
b) 8000KM
c) 12000KM
d) 24000KM
187
Methods Of Lubrications
188
• For this purpose an oil can or oil gun or grease gun is used .
• This depends upon the type of oil and type of points provided
in the vehicle.
189
Lubrication Equipments
190
Lubrication Equipments
191
Lubrication Equipments
192
Grease Guns
193
• Several types of hand operated grease guns are available
They are :
• Push type
• Handle type
• Bucket type
194
Push Type Grease Gun
2 Push rod
2
nozzle spring
cylinde piston
r
Fig 1
195
Push Type Grease Gun
• It consists of casing.
196
Push Type Grease Gun
Working :
• After filling the grease push rod assembly with piston is fitted.
197
Push Type Grease Gun
Working :
198
Push Type Grease Gun
199
Push Type Grease Gun
Limitations :
200
Quiz
• In a push type grease gun the compressed grease will exit out
through ---------
(Ans: nozzle)
201
Hand Operated Grease Gun
202
Filling
cap Pressing
handle
spring
Flexible
hose
casing
Greasing
end Push rod
Fig
203
1
Hand Operated Grease Gun
Construction:
• It is a portable type of grease gun.
204
Hand operated grease gun
Construction:
205
Hand Operated Grease Gun
Construction:
206
Hand Operated Grease Gun
Construction:
207
Hand Operated Grease Gun Operation
Fig 2
208
Hand Operated Grease Gun
Operation:
209
Hand Operated Grease Gun
Operation:
• Now press the handle of the gun, so that the grease from
the casing will be emerge out.
210
Hand Operated Grease Gun
Operation:
211
Hand Operated Grease Gun
Operation:
212
Types of greasing nipples:
• Straight
• Inclined
213
Straight Nipple Ball loaded end
through which grease
enters
Threaded end
which in turn
connects the
greasing part
Fig 3
214
Inclined Nipple
Inclined end
Ball loaded end
through which grease
enters
Threaded end
which in turn
connects the
greasing part
Fig 4
215
Types of greasing nipples:
• Straight type:
216
Types of greasing nipples:
• Inclined type:
217
Quiz
• In a hand type grease gun the handle return back to its position
by -------------
(Ans: spring pressure)
218
Lever operated Grease gun
Central tube
Fig.1
219
Lever operated Grease gun
clamps
Adaptor
Handle & lever
valve Flexible
pipe
cap
Steel
container
Fig.2
220
Lever operated Grease Gun
Construction:
221
Lever operated Grease Gun
Construction:
• To the top of the central tube a valve and hand lever are
connected.
given.
222
Lever operated Grease Gun
Construction:
• At the end of the flexible pipe an adaptor and nozzle are
connected.
223
Lever operated Grease Gun
Operation:
• Initially, the clamps of the cap are loosened.
224
Lever operated Grease Gun
Operation:
• Fill suitable grease in the container.
225
Lever operated Grease Gun
Operation:
• press the handle for few strokes.
226
Lever operated Grease gun
Operation:
• Further operation of handle, the grease will enter into the valve
• From the valve the grease will reach the nozzle through
flexible pipe.
227
Lever operated Grease Gun
Operation:
component.
lubricated.
228
Lever operated Grease Gun
Operation:
229
Compressed air operated grease gun
230
Handle with trigger
valve cap
Connection to
compressed air
Nozzle pipe
Nozzle
Fig.3
Rollers 231
Compressed Air operating Grease Gun
Construction:
232
Compressed Air operating Grease Gun
Construction:
– universal joints
233
Compressed Air operated Grease Gun
Construction:
• It consists of steel container.
234
Compressed Air operated Grease gun
Construction:
• On the top of the central tube a two way non return valve is
fitted
235
Compressed Air operated Grease Gun
Construction:
provided.
236
Compressed Air operated Grease Gun
Construction:
compressor.
237
Compressed Air operated Grease Gun
Operation:
238
Compressed Air operated Grease Gun
Operation:
239
Compressed Air operated Grease Gun
Operation:
component.
240
Compressed Air Operated Grease Gun
Operation:
• Press the trigger until the fresh grease appears at other end of
the vehicle component.
241
Quiz
1. In lever operated grease gun the grease from central tube
Flexible pipe
goes to nozzle through________________
242
High pressure lubrication equipment
243
Air regulator
valve
Electric
motor
Figure 1
244
High pressure lubrication equipment
Construction :
pressure.
245
High pressure lubrication equipment
Construction :
of air compressor.
246
High pressure lubrication equipment
Construction :
247
High pressure lubrication equipment
Construction :
248
High pressure lubrication equipment
Construction :
249
High pressure lubrication equipment
Operation :
• Compressor sucks air from atmosphere, compresses it.
250
High pressure lubrication equipment
Operation :
Note:
251
High pressure lubrication equipment
Operation :
• If air under pressure is supplied to grease tin.
252
High pressure lubrication equipment
Operation :
• Connect the nozzle of the grease gun to the nipple of the
component to be greased
253
High pressure lubrication equipment
Operation :
• Continue this process till fresh grease appears at opposite
end of the component.
254
Quiz
255