Submitted in

PARTIAL FULFILLMENT FOR THE AWARD OF

BACHELOR DEGREE (B.Ed.) IN AUTOMOTIVE

TECHNOLOGY

BY

ABDUSEMED MUSTOFA

ADDISU BEKELE

AMELEWORK GETACHEW

AMINAT JEMAL

ANDARGIE GETAHUN

ASSEFA BEKELE

ASSEFA GULELAT

Advisor

ATO MELESSE HAILE (M.Sc)

ADAMA UNIVERSITY (AU)

26, June, 2006
5
 CONTENT

Page
Acknowledgment ......................................................................................................i
Background of the Vehicles .....................................................................................ii
Objectives of the project .........................................................................................iii
Introduction .............................................................................................................iv
CHAPTER ONE
1. MEANING AND IMPORTANCE OF MAINTENANCE
1.1. Definition of Maintenance............................................................................1

1.2. Types of Maintenance ..................................................................................1

1.3. Importance of Maintenance .........................................................................3

1.4. Maintenance Procedure ................................................................................4

1.5. The Maintenance Strategy............................................................................6

CHAPTER TWO
2. VEHICLE SERVICING

2.1. Activities of Vehicle servicing .....................................................................8

2.1.1. Reception .....................................................................................................8

2.1.2. Inspection .....................................................................................................8
2.1.3. Planning .......................................................................................................8
2.1.4. Work Execution............................................................................................9
2.1.5. Time Keeping ...............................................................................................9
2.1.6. On the Job Training .....................................................................................9
2.1.7. Safety ...........................................................................................................9
2.1.8. Reporting ......................................................................................................9
2.2. Vehicle Inspection Instruction / Cheek List/...............................................10

2.2.1. Maintenance program one for heavy duty equipments ...............................10

2.2.2. Maintenance program two for heavy duty equipments ...............................11
2.2.3. Maintenance program three for heavy duty equipments..............................11
2.2.4. Maintenance program four for heavy duty equipments ..............................12

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2.3. Vehicle Maintenance program and Plan......................................................13

2.3.1. Vehicle Maintenance policy .......................................................................14

2.3.2. Maintenance cycle of a vehicle ...................................................................14
2.3.3. Maintenance program and plan of a truck...................................................15
CHAPTER THREE
3. M1 and A1 services
PART I
3.1 Theory of parts and system to be maintained
3.1.1 Components and systems to be changed
3.1.1.1 Lubrication system.............................................................................16
3.1.1.2 Fuel system .......................................................................................19
3.1.1.3 Oil in oil bath air cleaner ..................................................................19
3.1.2 Vehicle parts and systems to be serviced and adjusted
3.1.2.1 Inter cooler coolant............................................................................20
3.1.2.2 Drive belts and belt tension bearings.................................................21
3.1.2.3 Truck U bolt and trailer eye bolt........................................................23
3.1.2.4 General greasing................................................................................24
3.1.3 Parts and systems to be checked
3.1.3.1 Brake shoe..........................................................................................24
3.1.3.2 All mechanical assemblies and clamps for leakage……...................25
3.1.3.3 Cooling system and cab tilting ..........................................................25
3.1.3.4 Clutch mechanism..............................................................................28
3.1.3.5 All electrical lines..............................................................................30
PART II
Report on practical experiences
3.2.1 Components to be changed
3.2.1.1 Replacing engine oil..........................................................................31
3.2.1.2 Changing oil filter..............................................................................31
3.2.1.3 Changing secondary and primary fuel filter......................................31
3.2.1.4 Changing oil in oil bath air cleaner....................................................32
3.2.1.5 Air drier filter.....................................................................................32
3.2.2 Parts and systems to be adjusted

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 3.2.2.1 Tight inter cooler clamps, air intake clamps and hoses......................32
3.2.2.2 Servicing air drier and belt tension bearing........................................32
3.2.2.3 Tightening truck U bolt and trailer eye bolt............................................33
3.2.2.4 General greasing.....................................................................................33
3.2.3 Checking vehicle parts and systems
3.2.3.1 Checking brake shoe wear.....................................................................33
3.2.3.2 Checking all mechanical assemblies and clamps for leakage................33
3.2.3.3. Checking electrical lines......................................................................33
PART III
Pedagogical Part..................................................................................34
Check list used by the enterprise .........................................................................37
CHAPTER FOUR
M3 and A2 services
PART I
4.1 Theoretical Back ground of systems and parts to be maintained
4.1.1 Vehicle components and systems to be changed
4.1.1.1. Engine coolant ....................................................................................39
4.1.1.1........................................................................ Oil from all mechanical systems
..............................................................................................................40
4.1.1.2........................................................... draw bar pin and all bushings in suspension sy
..............................................................................................................40
4.1.1.3.................................................................... automotive clutch and release bearing
..............................................................................................................41
4.1.2. Parts and systems to be serviced
4.1.2.1.................................................................Trailer wheel and all valves in brake syste
..............................................................................................................42
4.1.2.2....................................................................................Air compressor
..............................................................................................................44
4.1.2.3........................................................................... Alternator and Starter motor
..............................................................................................................44
4.1.3. Parts and systems to be checked

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 4.1.3.1................................................................................Head lamp alignment
..............................................................................................................45
4.1.3.2................................................................................. Suspension system
..............................................................................................................46
4.1.3.3.............................................................................. Flushing the differential
..............................................................................................................48
4.1.3.4....................................................................Dismantle and clean the 3
..............................................................................................................49
4.1.3.5........................................................................................ Road test
..............................................................................................................49
Part II
4.2. Practical Aspects
4.2.1. Replacing vehicle components and systems
4.2.1.1Changing engine coolant.....................................................................51
4.2.1.2 Changing oil form all mechanical parts..............................................52
4.2.1.3 All bushings and draw bar pin in the suspension system...................52
4.2.1.4 Changing clutch disk replaces bearing................................................52
4.2.2 Servicing components and systems
4.2.2.1 Clean all axle breathers........................................................................53
4.2.2.2 Servicing trailer wheel and all valves in the brake system..................53
4.2.2.3 Air compressor.....................................................................................53
4.2.2.4 Servicing alternator and starter motor..................................................54
4.2.2.5 Flushing gear box.................................................................................54
4.2.2.6 Dismantle and clean 3rd differential.....................................................54
4.2.2.7 Road test...............................................................................................54
Check list used by the enterprise..........................................................................55
Part III
Pedagogical Aspect..............................................................................57
Conclusion...............................................................................................................59
Recommendation.....................................................................................................60
Bibliography............................................................................................................61

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10
 Acknowledgement

The team would like to give its special thanks to its advisor, Ato
Melesse Haile (Msc) for his continuous assessment for the validity of
the project.

Great thanks to the department for providing all its bests for the
completion of the project.

The team would also like to expand its gratitude to Tikur Abay
Transport Share Company, all technicians specially, Ato Dessie
Mohammed and Ato Shimeles Tesfaye for their devoted effort.

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 Back Ground of the Vehicle

Most of the vehicles at Tikur Abay Transport Share Company are 6 cylinders, in line
heavy- duty diesel engines. These vehicles were manufactured 20 yeas ago by IVECO
Company, which is found in Italy, Torino, Vehicles are classified to undergo service
by classifying depending on batch. According to this batch service the company has
got 4 servicing batches.

1st bath, 480,000 K/M (kilometer)

2nd batch 420,000 k/m

3rd batch 300,000 k/m

4th batch 240,000 k/m

On this distance for example, 1st batch vehicles will be serviced 4 times, this is done
by classifying 480,000 k/m to one service k/m i.e. 120,000 which will give 4,

In particular all 1st batch engines have been serviced.

Before undergoing a preventive maintenance, the team along with Ato Dessie
Mohaammed asked the condition of the vehicles and the driver’s complain, then after
using the proper check list designed for that particular batch, technicians will start to
check, service and change vehicle component.

The company is restricted to undergo partial and top overhauling.

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 Objective of the Project

Even though the main objective of preparing this project is for partial fulfillment of
bachelor degree award (BEd) in automotive technology, it also comprises of the
following important objectives.

 To prove knowledge and skill that the group members have got in their education
(TTE) for the past four years in the real labor market.

 To maintain heavy duty vehicles before failure.

 To diagnose parts and components of the vehicle that may cause total failure of the
vehicle.

 To give Tikur Abay Transport Share Company due concern on following right
procedures of maintaining systems and components.

 To aware Adama University students of automotive technology what the labor

market looks like relative to real teaching.

 To provide the department a reference on maintenance of heavy duty vehicles.

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 Introduction

An automobile is constructed of 5,000 or more parts, with use; the performance of

the functional components is reduced due to wear, deterioration, corrosion, etc. These
changes occur gradually with many of the parts during normal operation. Because no
two vehicles are used under identical driving conditions, and because a vehicle is not
driven by the same person, uniform wear and deterioration of each functional
components can not be expected. The factories, there fore; specify certain periodic
inspection intervals and suggested adjustment or replacement of the parts and
components that can be anticipated to undergo these changes with time or use.

Thus, Euro trucker vehicles that are maintained at Tikur Abay Transport Share
Company have specified service intervals according to the kilometers at which the
vehicles are driven.

All enterprises try to do as good maintenance as possible. However, this is not so

easy. It is to forecast and do the right activities at the right time by the right people.
Modern maintenance management is not to repair broken equipments as fast as
possible, but it is to keep the equipment in operation and produce quality.

The team of this project prepared the paper with this in mind. The paper is neither
too elementary nor too highly engineering oriented. It is merely basic concepts that we
got for the past four years through education at Adama University in Automotive
technology department and experience of Tikur Abay Transport Enterprise (TATE)
works in maintaining heavy duty vehicles i.e. Euro truckers.

This paper presents Meaning and importance of maintenance (that describes

definitions, types, procedures and vehicles serving (lists activities of vehicle serving,
cheek list, & maintenance plans), Maintenance program one and two (M1,Vs A1,) and
maintenance program three & four (M3 and A2) these describes the equipment parts,
systems to be replaced, serviced and adjusted distinctively and it also contains
practical report on the four maintenance programs.

The theoretical part of this paper is shared among the team members as follows.

Andargie, Aminat and Amelwork, Addisu and Assefa Gulelat, Assefa Bekele and
Abdusemed are responsible for, meaning and importance of maintenance and part of

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maintenance program 1&2, vehicle serving and part of maintenance program 1&2,
maintenance program 3&4 respectively. But the practical report is performed by all
the team members.

More over, despite the shortage of written materials and problems on mismatching
the time scheduled with the working time of TATE’s technicians, the team has made
tremendous effort to make this paper meet the desired objectives.

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 CHAPTER ONE

Meaning and Important of Maintenance

1.1. Definition of Maintenance

(By Andargie, Amelework and Aminat)

The term maintenance covers all activates under taken to keep equipments in
a particular condition or to return it to such condition.

Maintenance consists of three main parts i.e.

- Corrective

- Preventive

- Improvement

1.2. Types of Maintenance.

1.2.1. Corrective Maintenance. / CM/.previously CM has been defined as

emergency or break down maintenance. However, this is not exactly the right
definition, since corrective maintenance also can be planned. So it is defined as a
maintenance that covers all maintenance activities which is carried out in order to
correct/ repair/ a fault in equipment.

1.2.2. Preventive Maintenance (pm)

The term pm could be complicated to define. For many persons pm is to take

out the equipments of operation after a scheduled period of time for disassembling and
replacement of parts. When the equipments are assembled again and take in to
operation it often happens that problem occurs because the repair man has transferred
failures in to the equipments.

In modern maintenance management the pm activity is some thing else than

disassembling equipments for replacement of parts. Hence, the maintenance policy is
“never touch the running machine.”

PM covers all programmed maintenance which carried out in order to

prevent the occurrence of failure or to detect failures before they develop to a break
down or interruptions in production.

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N: B. PM Jobs are always programmed / scheduled/ it means that all PM activities are
decided in advance. CM activities, on the other hand, are difficult to forecast where
they are going to happen. Perhaps, it is known that CM will happen some times, but no
one knows when.

Preventive maintenance is divided in to two other parts

 PM to prevent the occurrence of failure

 PM to detect failure before they develop to a break down or

disturbance in the performance of the vehicle /equipment/.

The parts were measures are taken to prevent the occurrence of failure is
called DIRECT PM because, the equipment will improve directly. Example of DPM is
programmed replacements of parts, overhauls, lubrication, oil change and cleaning etc.

The DPM activities are always controlled by the time which can be calendar
time, operation time or number of kilometers driven.

The other part of PM is called indirect preventive maintenance (IDPM), and

is carried out in order to find the failures in an early stage of their development. The
IDPM can be made by measuring the condition of the equipment or inspect it to find
out the condition level.

IDPM will not directly impact on the condition of the equipment; further
activities have to be taken. IDPM also called condition monitoring and its
performance, also controlled by the time but it is done in order to find out the actual
need of maintenance. IDPM system, based on condition monitoring normally 70% of
all activities is done subjectively and 30% objectively. The reason is that all failures
that can occur can not be detected by instrument.

1.2.3. Improvement Maintenance [IM]

The term IM is used when to modify the equipment so that the condition
improves. IM includes only activities which are carried out once. The objectives of IM
are to design out the failure i.e. the failure will never occur again or to extend to the
life time of parts.

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1.3 Importance of Maintenance

The maintenance activity with in a plant could be alike with a fire brigade.
When a fire occurs, is it to extinguish it as fast as possible? But this is not the main
task of the fire brigade of course the main task for them is try to avoid fires as far as it
is possible.

Exactly the same direction of work must have the maintenance department.
The work must be, as priority one, directed on to avoid failures and by this reduce the
risk for unplanned stops. Modern maintenance is not to repair broken equipments as
fast as possible but to keep the equipments in operation and produce quality.

The demand of maintenance was started to grow from ancient human life,
they were used to keep the tools intact to carry out their work efficiently.

The importances of maintenance will considerable increase because of that a

high productivity and quality can be achieved by means of well developed and
organized maintenance.

Maintenance must be organized in the direction that the equipment /vehicle/

is stopped due to maintenance, i.e. planned stop. If the vehicle stops when we don’t
want it stopped, i.e. un planned stop, it is not acceptable.

To achieve the right productivity and quality on the product, it is important to

produce the right equipment from the vehicle /equipment is delivered and installed, it
start at an early stage in the project and procurement work.

There are many reasons why maintenance is becoming more and more
important. In developing countries where they are operating old machine, the spare
part problems are arising it is difficult to find spare parts for different vehicle models
and if it is possible, they are expensive and must be bought by foreign currency.
Because of the great distance to the supplier and routines for applying foreign
currency it is also very common that they increase the stock of spare parts to be safe.
Avery essential part is to reduce the need of spare parts as well as keep the level of
spare parts in stock at a minimum level for effective production and sowing of foreign
currency. A well developed maintenance strategy is necessary; otherwise the problem
will accelerate in the future.

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Apparent factors impacted by maintenance

Quality loses- it will occur when equipments are poorly maintained. If

decision is taken to change maintenance situation, the quality impact must be
considered since quality cost can be impacted by the maintenance cost.

Energy losses- Higher power consumption could be the case when

maintenance is not carried out properly. A well maintained unit will consume less
energy.

Capital cost- when poor maintenance is practiced, a lot of break down will
occur, break down are often connected to consequential damages and require more
spare parts stocked.

Capacity loss- A long period with poor maintenance will reduce the capacity
of the equipments due to deterioration and worn outs, reduce capacity means lower
production out put. (K.K, EMI 1-3,12)

1.4 Maintenance procedures,

When a maintenance strategy is going to be formulated, there are many

procedures that could be chosen. From sophisticated to low level procedures. In reality
there is a mix between different procedures due to variety of equipments in the plant
and because of the economical consequence the equipment causes if unscheduled stop
occurs.

Operate to break down/ un planned Corrective Maintenance/O.T.B.D

If all maintenance jobs carried out in the plant are O.T.B.D maintenance will
result in low availability of performance and high maintenance cost.

Maintenance effectiveness is low maintenance work is pressing and

sometimes dangerous due to the fact that safety procedure are often neglected.

Some times this maintenance procedure has to be practiced purposely,

because of economical or technical reasons but only for equipment which this
procedure has been decide for.

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Fixed time maintenance [FTM]

It will result in less expensive maintenance. FTM means that scheduled

stoppage for maintenance work. Components whose life- time can be estimated are
replaced or reconditioned.

PM based only on the fixed time maintenance procedure will not give the
expected result since parts are having individual life time. Some parts will be replaced
too often, and result in unnecessarily costs. Some parts will go to break down and
creates high down time costs.

Conditioned based maintenance [CBM]

CBM will result in optimized availability and maintenance cost and is giving
the best profitability. This procedure can be considered as just in time maintenance
procedure. Condition monitoring of equipment while in operation will make possible
corrective maintenance and a flexible maintenance planning coordinated with
production planning.

Design out maintenance [DOM]

This maintenance procedure means that actions are taken to design out
failures completely. The failure newer occurs again after the design out actions has
been taken. Follow up of carried out maintenance is crucial to be able to practice this
procedure. It must be known what is going on with the components /system/ of the
vehicle. If there are any repetitive failures and the reason there of when the failure is
designed out, the need of maintenance will decreased and the availability performance
arises.

Life time extension [LTE]

LTE shall always be in mind of maintenance people. If the life time of parts
can be extended by making some modification, renewal of material etc. the demand
for both PM and CM will decline. Follow up of maintenance carried out is essential to
practice the LTE procedure.

Redundancy [RED]

RED means that a spare part is installed in parallel with the original. This
means that the spare part can be started and connected to the production line, if the
original stops un fore seen. This procedure very expensive to apply as it requires
20
double function of equipment. If un planned stop create big losses or others
consequences and is inevitable, this procedure must be practiced if it is economically.

1.5 The Maintenance Strategy

Every body in the organization from the top managers to the people on the
floor must know the maintenance policy. Production and maintenance people must be
able to analyze the maintenance problems arising. If a fault occurs, the operator,
maintenance person or any other person must ask the question “can anything be done
to avoid this failure happening, again by making modifications, redesigns or any other
maintenance procedure?”

 Can the failure be designed out?

If it is not possible to design out the failure, the next step in the maintenance
strategy model must be to try to extend the life time of the part.

 Can the lifetime of the part be extended

If it is not possible to intend the life-time of the part, next step must be to try
to apply condition monitoring during operation to find the failure early in the failure
development phase, and to be able to plan the repair to reduce the consequence of the
failure.

 Can condition monitoring be applied during operation?

Some times condition monitoring can not be done during operation. In that
case condition monitoring has to be done during a planned stop.

 Can condition monitoring be applied during a planned stop?

It is not possible to apply condition monitoring at all because of no failure

developing time is present, you have to go for fixed time replacement.

 Can fixed time replacement be applied?

If the interval b/n the failures occurring are difficult to find, the failure is
random and you have to go for operation to break down and, if economically, install
redundancy.

21
  Can redundancy be applied?

If nothing of the above mentioned maintenance procedure can be applied,

redundancy has to be considered before decision is taken to go for break down
maintenance. This procedure must carefully be examined due to economical
circumstance.

 Operation to break down?

This procedure is only allowed when other maintenance procedures are not
possible to apply, e.g. when the failure is random failure, with out failure developing
time. However, the economical consequences have always to be taken in to
consideration. Some times this procedure is the most economical one because of low
price of the equipment and no impact on the production loss. [K.K.EMI,70-73,12]

22
 CHAPTER TWO

Vehicle Servicing

2.1 Activities of Vehicle Servicing

(By Assefa G. & Addisu)

2.1.1 Reception

The initial step in the maintenance activity is reception, which is the

function of receiving vehicle coming to the work Shop. The receptionists make
remarks on the condition of the vehicle for which repair maintenances requested.
Receptions opens work orders to all incoming jobs in chronological order and passes
them to the concerned maintenance foreman.

After the jobs are completed, the receptionist ensures that all bills are settled
and the vehicles are collected by the right owners.

2.1.2 Inspection

Each maintenance section must have an inspector who reports directly to

the work shop manager. The inspector must be interested and qualified staffs who are
trained on maintenance of all models.

He must also be a qualified driver, able to accurately list down the works to
be performed and able to execute quality control function on completed repair works
both within own workshop and outside workshop regarding contracted out works.

2.1.3 Planning

The workshop must be well planned and equipped with facilities such as
inspection lifts and pits cranes, open work-literatures, testing equipment special and
common tools etc.

Daily jobs must be planned for an efficient utilization of work of space and
coordination of works between the different shops.

It must be ensured that all known required spare parts and special tools are
available before starting any work .Priorities of works to be done within own shops
those works contracted out should be decide as quickly as possible.

2.1.4 Work execution

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 In order to effective complete specified works agreed by the owner of the
vehicle, work area should be well equipped and planned. The foreman must see to it
that repair works are carried out as specified on work order and time consuming jobs
should be facilitated. Time to be spent on collecting tools and spare parts should be
minimized.

If additional defects are identified during repairs, the owner should be

informed in order to finalize the job as per argument.

2.1.5 Time keeping

The workshop must record the time spent on each work order.

The total work hours recorded per month or per year indicate the amount of
productive hours.

2.1.6 On-the-job training

Due to fast technological development and wide Varity of vehicle types and
models, regular staff training is necessary. This is to continually improve the out put
of the work shop.

After clearly identifying the needs, it must also initiate refresher and up
grading courses. The courses may be conducted by own staff or by representatives of
the manufacturer on request

2.1.7 Safety

For un interrupted and safe operation of the workshop, all resources of the
workshop must be safe guarded. The workshop must available equipment for personal
safety and must ensure that sufficient precautions are taken to minimize risks. The
workshop must devise a means to follow up the availability and utilization of
equipment such as Goggles, Protective clothes, face masks etc.

2.1.8 Reporting

It is part of duty of the workshop to report on its activities for either internal
or external purposes. Reports help follow up over all performance and facilitate
planning. The number of reports should be kept to minimum and should be simple to
understand and compressive preferably in a related manner.

2.2 Vehicle Inspection Instruction \Check list/

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 For most of vehicles and field equipments, inspection and programs have to
be prepared based on information available on manuals and maintenance of vehicle
and filed equipment usually consists of three or four stages inspections and service,
partial, overhaul and full overhaul.

Maintenance program 1

Maintenance program 2

Maintenance program 3

Maintenance program 4

For each stage, detailed instructions indicating what to check and replace or
recondition have to be prepared based on information available.

It is assumed that the inspection will be carried by an inspector assisted by a

mechanic and a foreman, the trucks considered are EUROTRUCKERS.

2.2.1 Maintenance programs one for heavy duty equipment (MP1-HDE)

This type of maintenance shall be conducted every 10,000 Km operation of

equipment. The main activity performed while this type of maintenance is applied
shall be presented as

 Checking of battery electrolyte

 Checking steering oil filter element

 Cleaning of crank case breather element

 Checking and cleaning of full strainer

 Inspecting and adjusting of fan belts

 Changing of engine oil and oil filter

 Checking of differential and final drive oil level

 Cleaning of air cleaning element

 Inspecting of break system

 Changing of transmission oil filter element

 Grease all ball joints, brace joints, support brackets, pullies,

25
 hydraulic transmissions

 Inspect and rectify all leakage

 Check tightness alternator and other drive belts

 Inspect and retighten track shoe bolt

2.2.2 Maintenance program two for heavy duty equipment (MP2-HDE)

This type of maintenance program is equipped to be conducted every 40,000

km operation of equipment. The main activities performed in MP2 – HDE shall be as
fallows

 Maintenance MP1 –HDE

 Changing of corrosion resister cartilage

 Changing of by –pass filter element

 Changing of fled filter

 Checking and tightening of drive shaft belts

 Changing of transmission oil

 Changing of hydraulic oil filter and transmission oil filter

2.2.3 Maintenance program three for heavy duty equipment (MP3-HDE)

This type of maintenance program shall be conducted on heavy duty equipment at

about every 60,000 km of operation. Those activities which are expected to be
performed with this regard are

 Maintenance program MP2 HDE

 Adjust engine valves

 Change hydraulic oil

 Change axle or differential oil

 Check and change, if necessary Cooling water temperature

regulator

 Change radiator coolant

26
  Check and Adjust injector and fuel injection pump

 Change air cleaner element

 Change and check high pressure hoses, if necessary

 Check and repair brake lining

 Inspect and repair hydraulic system

 Inspect and repair under carriage parts

2.2.4 Partial Overhaul (MP4-HDE) for heavy duty equipment

This is conducted to prolong the equipment engine performance before

conducting full overhaul. Partial overhaul is implemented on heavy duty equipment at
about every 120,000 k/M. However, depending on the equipment status observed
during inspection program, the activities required to be performed include
 MP3-HDE,
 Facing valve seats
 Changing valve seat
 Changing valve guides, if necessary
 Changing head gasket
 Changing piston ring
 Cleaning combustion chamber
 Facing cylinder head (If necessary)
 Change injector nozzles
 Check and change if necessary, wheel bearings
 Overhaul water pump

 Check and change if necessary connecting rod and journal bearings

27
2.3. Vehicle maintenance programs and plans

The main purpose of maintenance on any vehicle is to assure the proper

functioning of its various components and the reliability of the vehicle as a whole.
Therefore the user (the driver) can play a great role to this end and thus must follow up
the performance of the vehicle and report if any symptom of malfunction is notice.
When the vehicle comes to the workshop for service it must be inspected by an expert.
But the extent and frequency of inspection depends on the expected problems and
failures of parts or components. Of course, this will be based on own experience and
/or manufacturer’s recommendation. A vehicle which has started service in a perfect
condition and which is due for the first stage service needs washing/cleaning and
greasing. Then change of engine oil and filters is done to be followed by simple check
ups such as the conditions and levels of other fluids, the operation of levers/pedals,
steering system, cooling system , air conditioning suspension electrical components
and the conditions of body safety equipment, drive belts, joints, etc

At the vehicle covers more kilometers, the extent of inspection increases and,
in addition to the first stage service , the functions of more important components must
be checked in the second stage more closely and if necessary by opening them. The
engine must be tuned up and all mountings/supports of components must be checked.
Depending on the work environment filters and cleaners must be replace and bolts and
nuts tightened. Valves, lamps, wheels, brakes, and bearings must be checked and if
necessary adjusted at this stage.

In addition to regular maintenance, un expected repair will have to be done in

between as required and over hauls of components has to be performed on the basis of
condition checking. Apart from accidents, the usual symptoms that indicate need of
overhauls are excessive oil consumption, strange, noise, leakage, ineffective
performance, low out put, bad smoke, inoperative component etc.

The condition of components deteriorate mainly due to mishandling,

overload, wrong bearing clearance, wrong grade lubricating oil and contamination of
lubricating oil. Contamination occurs because of oxidation, dilution, water, formation
of carbon, lead components, metals, dust and dirt.

28
 After having decided the stages of maintenance needed on a vehicle, it is
advisable that the inspector uses a check list which is useful to access the vehicle
quickly and effectively.

2.3.1 Vehicle Maintenance Policy

Preventive maintenance incorporates inspection and servicing tasks that have

been preplanned to be accomplished at a specific point in time or retain productivity of
vehicle and equipments. Preventive maintenance can based on combination of fixed-
time replacement and condition based replacement. In case of the latter, a parameter
indicating the wear stage of a component is monitoring during inspection. Condition
monitoring includes subjective methods such as noise monitoring, visual inspection
and monitoring with aid of instruments which fall under the category testing. The
advantages of this maintenance policy are:

-Unnecessary replacement of parts are avoided

-Down-time is reduced by replacing worn-out parts before failure.

2.3.2. Maintenance Cycle of a Vehicle

The interval between the different maintenance stages is determined from the
information, from the vehicles and equipment machinery suppliers and is presented in
the maintenance program. A complete maintenance cycle is a period between two
overhauls. In one cycle, there can be more inspections and one partial overhaul. For
heavy duty vehicles, one stage involves checking or repairing of fuel injection system,
air compressor, hydraulic systems and attachments.

Maintenance cycle of a truck

MP1 ------- 10,000 km

MP2 --------- 40,000 km
Mp3 -------- 60,000 km
Mp4 -------- 120, 000 km
Number of classes in a sub-cycle (equal to four) = 4
Sub- cycle MP1- MP2- MP1- MP2- MP1- MP3- MP1- MP2-
MP1 – Mp2- MP1- MP4

Time of completion of a sub- cycle 120,000 km mileage for planning of

order of parts for an engine overhaul partial overhaul= 200,000 km.
29
 Complete overhaul = 40,000 km

2.3.3. Maintenance Program and Plan of a Truck

MP1 ------------10,000 km

MP2 ------------ 40,000 km

PM3 ------------ 60,000 Km

MP4 ------------- 120,000 Km

No of classes in a sub cycle = 3

Sub- cycle MP1- MP2- MP1 – MP2 – MP1- MP3- MP1- MP2- MP1- MP2-

MP1- MP3

Time of completion of sub – cycle 120,000 km

Mileage for planning of over of parts for an engine overhaul partial overhaul =
180,000 km

Complete over haul = 360,000 km

 Planning example

 Monthly mileage is 5,000 km

 Last maintenance on December 1, 1999= MP2

 Position if in sub-cycle is four

 Maintenance plan for year 2000

Feb 1, 2000 = MP1

April 11, 2000= MP3

June 1, 2000= MP1

August 1, 2000 = MP2

October 1, 2000 = Mp1

Dec 1, 2000 = MP2

30
 CHAPTER THREE

M1 and A1 Services

Part I

3. Theory of systems and parts to be maintained

(by Andargie, Amelework & Aminat)

3.1.1 Components and systems to be changed

3.1.1.1 Lubrication system

The engine has many moving parts. If these parts rub against one another
they will wear out quickly.

The purpose of the engine lubricating system is to minimize friction and

wear. This system performs this job by supplying oil to prevent metal from rubbing
against metal.

If the engine parts are not properly lubricated, serious engine troubles are
likely to occur for example scored cylinders, burnt out bearings, dirty spark plugs,
excessive oil consumption, stuck piston ring and sludge formation. To avoid all these
troubles, lubrication is indispensable for the engine, as well as for all the moving parts
of motor vehicles. (S Sri, 252, 2)

Troubleshooting of Lubrication system

The two problems mainly encountered in a lubrication system are

1. Excessive oil consumption and

2. low or high pressure

The cause of these problems and the trouble shooting of a lubrication system are: -
excessive oil consumption.

The engine loses oil in three ways;

i. combustion of oil in the combustion chamber

ii. Leakage of oil

iii. Oil leaving the crank case in the form of vapor or mist.

31
 Oil consumption is also affected by speed and engine wear. High speed gives
rise of high temperature which changes the viscosity of oil. The viscosity of oil
becomes low and it easily escapes past the piston rings in to the combustion chambers.
Due to high speeds, oil control rings also do not function properly. There fore,
crankcase ventilation allows more air to pass through the crankcase quickly. Thus
more oil is lost as vapor or mist.

Due to the wear of engine parts, oil consumption increase. Replacement of

the work out piston, cylinder liner, piston rings, defective valve seals, worn out valve
steam and guide effectively reduce oil consumption.

Low pressure oil

There may be several causes for the low pressure of oil in a lubrication
system. Some of these causes and the methods of correcting them are given as follows,
i. If the oil level is low, the pressure of the oil also becomes low. In that case,
the crank case should be filled up with oil to the required level case.
ii. If the oil pump is worn out, it should be replaced.
iii. If the relief spring is defective, it should be replaced.
iv. The oil line should be checked for any problems which should be
taken care of immediately.
v. If the oil is diluted, it should be changed.

High pressure of Oil

The reasons for the high pressure of oil and the ways in which the pressure can be
brought to the correct level are
i.) If the oil if of to high a viscosity, the pressure in the lubricating system will
be high. To correct this, oil of recommended viscosity should be used.
ii.) Clogged oil lines and galleries should be cleaned.
iii.) If the relief value spring is too stiff, it should be changed.
iv.) If the oil pressure gauge is defective, it should be repaired or replaced.

32
Servicing of lubricating system

Oil level

A dipstick is used to check the level of the oil in the oil pan. To use the
dipstick, allow the engine to sit 1 minute after running. This allows the oil to drain
back to the pan. Then pull the dipstick out, wipe it off, and put it back in place. Then
pull it out again so that you can check the level of the oil shown on the dipstick.

If the oil level is low, more oil should be added. If the oil dirty the dirty oil
should be drained and clean oil should be sued.

Oil changing

To cheek if the oil is dirty, put a few drops of oil on your finger and then rub
it with your thumb. If the oil is found to be dirty, it should be changed. Usually, oil is
changed after every 1000 km. The instructions of the manufacturer should be followed
in this regard.

For changing the oil, first the engine should be warmed. The oil should be
drained while the engine is still warm. The system should be flushed by light flushing
oil and new lubricating oil should be used to refill, as recommended by the
manufacturer.

Oil filters

The oil filter is the engine’s main protection against dirt. The oil from the oil
pump must first pass through an oil filter before the oil goes up to the engine. The
filter removes particles of carbon and dirt so they do not get in to the engine and
damage engine bearings and other parts. The filter contains a filtering element made of
pleated paper or fibrous material. The oil passes through the filter, and the paper or
fibers trap the dirt particles.

The filter element is housed in a disposable can. It is removed and thrown

away at periodic intervals specified by the manufacturers. The filter has a by pass
valve. If the filter element becomes so clogged that all the oil needed by the engine
can not pass through the filter, the increased pressure from the oil pump causes valve
to open. Now, some of the oil from the pump can bypass the filter and go directly to
the engine to prevent oil starvation. However, this is unfiltered oil. The filter should be
changed before this happens.
33
 The oil filter should be replaced before it stops working properly car
manufactures recommend that oil filters be replaced periodically. The usual
recommendation is that the filter be replaced at the first oil change and then every
other oil change after that.

3.1.1.2. Fuel system

The fuel system has jerk type injection pump with six separate pumping
elements each elements of the pump supplies fuel to one of the injectors .For
automotive engines the elements are contained within a single pump housing inline
and so are referred to as in line pump for large diesel engine such as those used in
marine work each element is made in to a separate pump. The fuel is taken from the
fuel tank by the lift pump or supply pump which is mounted on the side of the
injections .Pump housing fuel is supplied throughout the fuel filter to the injection
pump the injection pump both meter the fuel and pump at high pressure to the
appropriate injectors at the right time.

Fuel filter service- filter is renewed or of the replaceable type element type,
where only the element is renewed, the filter mounting should be cleaned and annual
filter and seal installed after installation and following priming and bleeding at the
system the filter should be checked for leaks. Care must taken to ensure that poor
handling and storage particles do not cause contamination before the fuel reaches the
engine .Clean lines is important for all liquid fuels but it is particularly important for
diesel fuel. Contamination will damage the injection components resulting in costly
repair only lint free rags should be used for cleaning the parts of the fuel system.
Cotton waste should not be used.

3.1.1.3 Oil bath air cleaner

Contained woven metal mesh filter elements with space for a quantity for oil
beneath it. This type of air cleaner has the advantage of being self cleaning. The oil
bath air cleaner has a longer operating period as a result of its self cleaning effect
when the oil has become thick and dark as the result of its dust contents. It must be
removed and the air cleaner body cleaned out adds fresh oil only up to the level
indicating mark clean the filter elements with diesel fuel or some other suitable
solvents.

34
 Oil both air cleaner service- air cleaner should be serviced at a regular
period in recommended by the engine manufacturers and often the air cleaner is
service will depend to some extent on the type of air cleaner but more importantly it
will depend on the operating condition at the vehicle and its engine. The method of
servicing the air cleaner and its elements depend on the type of cleaner.

The air cleaner is dismantled and the elements removed the oil as drained from the
body of the cleaner and the dirt in the bottom thoroughly cleaned out. The filter
elements is cleaned by immersing it in kerosene and agitating it to remove the oil and
dirt .After drained and carefully blowing with air at a low pressure. The elements can
be re oiled with engine oil. Petrol should not be used for cleaning as it is highly
volatile fuel which could cause explosive damage with in the engine. Before
reassembled the air cleaner the oil container should be filled to the level marke the
indicator level should not be exceeded as an excess could be drawn up in to the engine
leading to un control engine speed.

3.1.2. Vehicle parts and systems to be serviced and adjusted.

3.1.2.1. Inter cooler coolants

(Turbo charger with water cooled type inter cooler)

The water cooled type intercooler is used to cool the high temperature air
pressurized by the turbo charger and make the air denser. This acts to raise the engines
air intake efficiency. The water cooled type inter cooler system consists of the sub-
radiator water pump, coolant reservoir and piping. The system is filled with coolant.

To prevent rusting of these components, it is necessary to use an anti rust

agent in the coolant. In areas where there is danger of the coolant freezing, an anti
freeze type coolant must be used. The anti rust performance of the coolant as well as
its anti – freeze performance drops gradually as it is used, so it is necessary to replace
it periodically.
Changing inter cooler coolant
 Drain inter cooler coolant

 Fill inter cooler with coolant [TM,2-44,6]

3.1.2.2 Drive belt tension bearings and Belts

35
 . All accessories driven by the belt has bearings to avoid actual contact
between the rotating and sliding parts there by preventing heating and seizing.
Thus bearings requires lubrication
- for lubricating the operating surfaces-
- to protect the parts from rust and corrosion
- to keep out foreign matter
- To reduce bearing temperature
- so to ensure these all conditions of the bearings, it is necessary to
inspect the bearings periodically.

Belts

The drive belts transfer engine power from the crank shaft pulley to drive
other auxiliary parts of the engine such as the water pump, cooling fan, alternator
generator, power steering vane pump, and air conditioner compressor. Drive belts are
usually most elastic when they are new. As they are used, they gradually become worn
and harden, then begin to crack. There fore, it is necessary to check and replace the
drive belts periodically.

1. Inspect drive belts for damage

Visually check the belts for cracks, wear, Separation, tearing or oiliness, if
necessary replace the drive belts.

Fig 3.1 shows condition of drive belts

2. Inspect drive belt installation check if the drive belt fits properly in ribbed
grooves.

36
 Fig 3.2 Shows ways of installation

3. Inspect drive belt tension

- using a belt tension gauge, check the drive belt tension.

- If the gauge is not available check the belt deflection by pressing on the belt
between the specified pully with certain kg of pressure specified by the manufacturers.

4. Adjust alternator drive belt tension if necessary

- loosen the alternator pivot bolt and lock bolt
- tight the lock bolt as much as possible with out allowing the alternator position
to shift
- Insert pray bar between the cylinder block and alternator then pry back the
alternator to apply tension to the drive belt.
- Holding the pry bar, tighten the lock bolt and check the belt tension using a
belt tension gauge

5. Adjust power steering pump drive belt tension

- Use the same manner as alternator drive belt to adjust PSPDBT

6. Adjust air conditioning compressor drive belt

a. loosen the idle pully lock nut so that the pully can wobble back and forth
slightly
b. Turn the idle pully adjusting bolt to adjust the belt tension
c. Tight the idle pully lock nut and check the belt tension.

Replacement of drive belts

- To replace the drive belts, start with the belt which is farthest from the engine
and work to ward the inside when installing the new belts, start with the belt
which is nearest to the engine and work toward the outside. [TM,2-25_29,6]

37
 Fig 3.3 showing method of replacement of drive belts

3.1.2.3. Truck U- bolt and eye bolt

(By Addisu & Assefa G.)

This bolt, as its name indicates it is formed in the form of u shape. The main
aim of constructing this U- bolt is to avoid lateral movement of the leaf spring while
the vehicle is in road or in driving condition by doing this on the suspension system
the bolt it self can add strength to carry the load and avoid un necessary shocks and
vibrations from the load and vehicle itself, there fore; proper maintenance of U-bolt is
necessary. Its problem may be as a result of

- crack

- Loss ness

- Brakeage and deformation etc

Similarly eye bolt is also very important part of the suspension system. The
leaf spring is suspended on it. If not the vehicle will be exposed to un necessary /
expected/ problems. There fore, continual maintenance should be taken. Because the
spring is suspended on it at the front and at the back it can easily damage and exposed
for hazard like the problem mentioned under the U-bolt.

3.1.2.4. General greasing

Most moving parts of the vehicle must be lubricated with grease and this
allows moving the parts freely up and down as the vehicle is driven. However, this
great deteriorate over time as the vehicle is used, which could lead to in adequate
lubrication of the moving parts. If this happens, the moving parts could wear,

38
generating abnormal noise during driving and making the vehicle Un stable as it is
driven.

3.1.3 Parts and systems to be checked

3.1.3.1. Brake shoe

The brake system is one of the most important safety systems on the
automobiles. The ability of the brake system to bring a vehicle to a safe controlled
stop is absolutely essential in preventing accident, vehicle damage, personal injury and
loss of life.

Several types of maintenance are required in brake system to keep the

vehicles safely and functioning. The parts should be maintained as fallows

Inspect brake shoe and lining.

Un even lining wear can indicate improperly mounted parts, drum destruction
or wear lining should be replaced before lining wear leads metal to metal contact.

Fig 3.4 showing Inspection of Brake Lining

Clean and inspect all springs and linkage

Adjust spring and linkage for wear or destruction. Springs should not be
discolored from over heating and should not be stretched or distorted. Adjuster treads
and sockets should be cleaned and lubricated with a good grade brake lubricant,
replace any faulty parts.

Clean the brake shoe lining with sand paper to remove oil strains and also
clean the inside surface of the break drum.

3.1.3.2. Mechanical Assemblies

39
 The assemblies that mostly used on the vehicle are mechanical assemblies
even if there are additional assemblies used. This system mainly uses to connect or
join two or more parts. Its purpose may be, to transfer power from one component to
another easily, to create safe or comfortable situation and to create light weight.

For example,

1) Using propeller shaft, release mechanisms use for transferring of power.

2) Using universal joints slip joints, yokes, differential gears use for safe
drive condition

. Several parts of the vehicles systems liked with mechanical assembles

 Power transfer system (drive shift, propeller shaft)
 Steering system linkages ( tie rod, pitman arm, universal joints etc)
 Engine power generating system ( connecting rod, piston, crank shaft
valve mechanism
 Clamps for leak

Either of leaks is prevented by using clamps (i.e. external and internal) If leak
is there in the system it invites for the other problems, for example; if the clamps on
the upper or lower hoses loosen the problem of cooling systems will happen.

3.1.3.3. Cooling system

Peak combustion temperature in an engine exceeds the melting point of cast

iron. Thus, cooling system is needed to protect the engine from self- distraction.
Although cooling is needed, over cooling is un desirable because corrosive
compounds from an engine that runs at low temperature. The cooling system must
maintain the engine temperature with in desirable range.

Several types of maintenance are required to keep water cooling system in

good working order

Cooling system inspection and service

It is recommended that cooling systems be given thorough visual inspection

before the engine removal. First, if the system is visually dirty and shows signs of rust
or scales a chemical cleaner may be circulated though the system to loosen scale and
deposits within the engine. It is not necessary to flush the system after circulating the
cleaner.
40
 Considering the last of overhauling or rebuilding, many mechanics prefer to
replace all belts, hoses and frequently the water pump. This is a reasonable practice,
with perhaps the exception of vehicles that have been regularly maintained and for
which the mechanics has some knowledge of their history.

Belts and hoses

At very least , inspect belts for wear, cracking or fraying and inspect hose
inside and out side for cracking or hardening if in doubt about their condition replace
them.

Water pump

Water pump will require closer inspection. First, inspect visually for stains
indicating that the pumps has been leaking past the seal also check for worn bearings
by turning the pump manually and feel for roughness or wobble in the shaft. Water
pump impellers some times erode because of solid circulating with in the coolant or
because of cavitations. Whether the pump is to be reused or replaced be sure that the
cooling system is cleaned before installation.

In replacing water pumps, problems are occasionally encountered with belt and
pulley alignment.

Radiator

A thorough cleaning frequently requires removing radiator tanks from cores

so that cores may be run through the core tubes to clean them also, any soldering of
minor leaks is done more successfully when seams have been cleaned to base metal. If
radiators are being considered for reuse look in to the core tubes for blockage and
pressure test the system for leaks, then check for blockage after the engine has been
brought up to normal operating temperature. this done by shutting of the engine and
checking quickly for temperature difference at the radiator feel with your hand for hot
and cold spots in the radiator core. Cold spot indicate core blockage and that the
radiator requires cleaning.

Fan clutch

To check the fan clutch, first see if the fan turns freely when the engine is off
and cold. If the clutch is engaged when cold, it must be replaced. Also check for
wobble in the clutch assembly exceeding one over four inches (6mm) at the tips of the
41
fan blades. Keep in mind that slight motion in the clutch is normal. Excessive wobble
indicates a worn clutch bearing. This may also be heard as bearing noise when the
engine is first shut off and the fan is causing to stop.

Thermostat

The thermostat may become stuck in the closed position and case the engine
to over heating. Stacking in the open position causes the engine to warm up very
slowly and run too cool. Therefore, if a thermostat is defective replace it with a new
one.

To complete the inspections of cooling system add water at least 50%

ethylene glycol coolant, and pressure test the system for leaks. Adjust the heater
controls so that water circulates freely through the heater core when filling the system .
[G.L, 202, 13]

Cab titling

This means the tilting of cab to make service the parts which are mounted
under cab like:

 Cooling system

 Charging system

 Drain and replace engine oil filter

 Replace fuel filter

 Replace oil for air filters in oil bath etc

Cab tilting mechanism is working with the principle of hydraulic pressure it

contains pistons, cylinder, fluid, and pressure developing seals and levers.

3.1.3.4. Clutch mechanism

The clutch is an important part in the power transmission system of auto

mobiles. It transmits power from the engine to gear box at various seeds.

Inspection and service of clutch

After disassembling clutch various components are inspected and serviced

Clutch disc facing

42
 Inspecting the clutch disc facing for wear, incase it is worn out up to the rivet
heads, the same as to be replaced. When large quantity of oil reaches the facing, it
burns there and causes clutch sleep. There fore, the disc faces are to be replaced.

Inspecting the clutch disc facing for wear, incase it is worn out up to the rivet
heads, the same as to be replaced. When large quantity of oil reaches the facing, it
burns there and causes clutch sleep. There fore, the disc faces are to be replaced.

Fig 3.4 shows checking friction disc run out

Clutch Plate Spring

Inspect the cushioning and torsion springs on the clutch plate. If they are
weak or cracked, complete plate should be re placed.

Pressure Spring

Check the pressure spring for stiffness. If there is variation in a particular

spring from the specification value, the same spring should be replaced.

Pressure plate

The surface of
this plate should be smooth.
If it is found to be distorted
by more than 0.3mm or
is body scored it should be
replaced.

43
 Fig 3.5 shows checking pressure plate warpage

Air servo brake system

The air servo brake system consists of an air compressor, air reservoir, air
servo brake booster pressure regulator and compressed air lines in addition to the
master cylinder, wheel cylinders and hydraulic lines.

In an air servo brake system, as opposed to a vacuum booster, in order to

reduce the brake pedal’s pedal source, the deference between the pressure of
compressed air generated in the air compressor and that of atmospheric air is utilized.

If the air servo brake system is not operating properly assistance to the
brakes cease. Therefore, it is necessary to check the air servo brake system
periodically.

Inspection of air servo brake system

 Drain water from air reservoir

 Check air servo brake operation

 Check air servo brake air tightness

 Check air compressor function

 Check pressure regulator function

 Check safety valve for closing

44
 Fig 3.6 Air servo brake system

3.1.3.5. All electrical lines

Electrical lines are the main cells for proper functioning of vehicles.

On heavy duty vehicles until clear indication of the problem is observed and
general service time is reached there is no need for maintenance but as required some
electrical parts would be maintained. The parts which require maintenance are
brushes, bushings, bearings and regulating parts etc.

45
 PART II

3.2 Report on practical Experience

3.2.1 Components to be changed

3.2.1.1 Replacing engine oil

The Tikur Abay Transport Share Company technicians replace engine oil at
every 10,000 km.

To do so,

Warm up the engine and allowing the engine off for some min (this able to
settle the oil to the sump).After draining the oil

Add new oil at its operating condition

They use no flushing for engine oil and also they do not test the oil in oil lab.

3.2.1.2. Changing oil filter

The oil filters are changed according to their service intervals whenever the
engine oil is changed, hence the euro truckers do not use box type oil filters.

The technician’s gives care for cleaning the mountings of the oil filter

3.2.1.3 Changing secondary and primary fuel filter. In diesel engine; too, dirt or
moisture can get mixed in to the diesel fuel. If this dirt or moisture passes as is through
the injection pump or injection nozzles, it could cause clogging, wear or seizing of
precision parts.

The fuel filter separates the impurities from the fuel and prevents the above
mention problems.

However, if the impurities accumulate in the fuel filter, the filter performance
of the filter will drop. For these reasons, the fuel filter must be replaced periodically.

The secondary fuel filter is replaced at every 10,000kms, hence the finest
particles are screened out on it and they give priority to replace the secondary fuel
filter than the primary fuel filter (which filters course particles and less to clog) and
suggested to replace at every 40,000kms.

46
3.2.1.4 Changing oil in oil bath air cleaner

All types of air cleaners required service due to their susceptibility to dust and
foreign maters, the filters mostly available in the euro truckers are oil bath types and
the oil will replaced at every 10.000 & 40,000km after cleaning components of the air
cleaner thoroughly

3.2.1.5 Air drier filter

The air drier filter has changed at every 40,000km, but the enterprise allows
service of air drier filter at every 10.00km. Refer the service (3.2.2.2).

3.2.2. Parts and systems to be adjusted

3.2.2.1 Tight inter cooler, air intake clamps & hoses

Inter cooler clamps are tightened at each maintenance program 1&2 to prevent
leakages of the boost air. Air intake clamps and hoses also tightened at this
maintenance period to ensure loss of engine power (if the leakage is after the turbo
charger) and failure of compressors and engine (if the leakage is before turbo
changer).

3.2.2.2. Service air drier filter and belt tension bearings

After removing the air drier they used to cleaned all its components and
replace kits and seals if there is any damage and deformation this is done at every
10,000 km.. They allow the leakages of compressor oil past through air drier until
maintenance program three is reached due to considering cost analysis. But this is not
suggested because the oil may pass through all the brake system valves which in turn
cause less response of braking and probably mal functioning of the brake system not
only the brake systems, but also all the systems that are governed with pneumatic
system.

While servicing belt tensioner bearings thumb method is used to cheek the belt
tension. The bearings used in euro truckers are double row ball bearings which are
sealed & self greased and hence the maintenance is condition based the enterprise
faces repeated failures by doing so. They execute the maintenance by disassembling
sealed self lubricated bearing after cleaning new grease will be replaced which is
different in quality and property that has been used by manufactures. It is due to

47
different load carrying capacities and properties of these greases that the enterprise
faces different problems.

The enterprise (TATE) has no tension gauge to test belt tension and don’t use
specified pressure to press on the belts that gives uniform decision. This affects good
maintenances quality.

3.2.2.3. Tightening truck u bolt and trailer eye bolt

The enterprise technicians suggest that tightening bolts does not require for
thus bolts that has been tightened once. Even though the check list includes it the
technicians do not execute this maintenance. But they shall check the truck U bolt and
the trailer eye bolt at each recommended service interval and should tightened them as
required.

3.2.2.4. General Greasing

All moving parts which use greases to their operation like propeller shafts,
universal joints, all axles and others will be greased at every maintenance program of
PM1, and PM2
3.2.3. Checking vehicle parts and systems
3.2.3.1. Checking brake shoe wear

At every 10.000 km the condition of brake shoe are cheeked using the
inspection hole on the wheel. But the enterprise shall remove the wheels to have a
good look at of the shoe that ensures quite inspection of their condition.

3.2.3.2 Checking all mechanical assemblies and clamps for leakages

All the mechanical assemblies such as shock absorber, stabilizer bars, engine
supports, differential supports and the likes are checked and adjusted thoroughly at
every 10,000Km and 40,000 Km.

3.2.3.3 Checking all electrical lines

The enterprise doesn’t give emphasis on the checks of these electrical lines by
tracing, hence the vehicles got un plan stop due to the short circuiting of the wire
harness and failures of starter motor and alternator.

So the enterprise shall adapt checking all electrical lines to ensure un planed
stops.

48
 PART III

Pedagogical aspect

Work sheet

Vehicle type

Vehicle manufacturer

Model

Vehicle capacity

Actual service km

Next service

Objective: - To learn how to inspect and maintain engine cooling system.

Material: - Diesel engine

- Appropriate hand tools

- Radiator pressure tester

A. Inspection of Cooling System

1. Inspect for coolant leakage

With the engine warm up, check for coolant leakage from the following parts.

. Radiator and radiator hose

. Water pump and hoses connected to it

. Radiator and cylinder block drain plugs.

N.B:- If there is leakage, traces of coolant or corrosion can be found around the leak
area.

2. Inspect rubber hoses

- check all rubber hoses for cracks and abnormal swelling

3. Inspect hose clamps

- check all hose clamps for proper installation

4. Inspect coolant level

49
 - check that the reservoir coolant is with in the specified level

Conclusion

Q1. What is the need of warming the engine to inspect coolant leakages?

Q2. What is the reason for low level of coolant in the radiator?

B. Changing Engine Coolant

1. Drain engine coolant from Radiator and cylinder block.

N.B Pressure builds up in the cooling system when the radiator and engine are hot,
so allow the coolant to cool before draining it out.

- Place drainage pans under the radiator

. Remove the drain plug from both the radiator and engine cylinder block and

let the coolant drain out.

2. Flush cooling system with water

- insert a water hose in to the radiator filler hole and allow water to flow in under
pressure
- Flush the radiator out until the water coming out of the drain holes becomes clear

3. Remove and flush reservoir tank

- Remove the reservoir tank

- Take off the tank cap and turn the tank up side down to allow the coolant to

drain out

- Flush the tank with water then reinstall the tank

4. Refill systems with engine coolant

N.B use a good brand of engine coolant, mixed with

Water in the ratio of

5. Fill the reservoir tank with engine coolant up to the full mark

50
- Road test the vehicle to confirm the fault is cured and that no other problems have
occurred.

6. Inspect for coolant leakage

Check the following points for coolant leaks

- Radiator drain plug

- Cylinder block drain plug

- Heater inlet hose connection

Conclusion

What s the necessity of flushing the system?

51
 CHAPTER FOUR

M3 AND A2 SERVICES

PART 1

4.1 Theoretical back ground of systems and parts to be maintained

(by Assefa B. & Abdusemed)

4.1.1 Vehicle components and systems to be changed

4.1.1.1 Engine coolant

An engine coolant is used to cool the operating vehicle that may heated up to
8000oc and above, so this excessive heat has to be taken out from the system by the
engine coolant for efficient and lengthen operating parts.

Therefore, while maintaining heavy duty vehicles (light duty also) the
following parts has to be checked and serviced

 Hoses and connections for scratch, pierced, damage or misconnections or

collapsed hoses
Remedy: replace damaged hoses and connections.
 The condition and level of the coolant
Remedy; if it is below level fill it to its level and replace it if the coolant is
dirty or contaminated.
 Check the strength of the antifreeze and test it with a pressure tester if desired.
 Check the thermostat for proper operation
Remedy check it using hot water opening at 250F and proper closing below
100F.
 Check and service water pump and loose or worn drive belt.
Remedy: - service the pump and replace the belt for slack.
 Check for exhaust gas leakage in to cooling system that may cause due to a
defective head gasket.
 Check and service internal and external leaks.

Remedy: replace head gasket and seals. [W.H.C 312,1]

4.1.1.2. Oil from all mechanical systems

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 Engine Oil is used to:

 Lubricate moving parts to reduce wear

 Pick up heat from the engine

 Fill clearance between bearings and rotating Journals.

There fore; servicing lubricating system will provide to keep the above
advantages.

 Engine oil- changes it by draining the pan clear it properly and fills it
with fresh oil.

 Change oil filters whenever the oil changed or every other oil change
according to the operating conditions.

 Oil pumps- require no service in normal operation if badly worn a

pump will not maintain pressure. So remove it for service or replace it.

 Change the oil in the oil bath air cleaner for proper trapping of dirties
or impurities

 Change the transmission oil and clean breathers

 Change axle hub oil

 Change rear axle hub oil

 Change steering gear box oil and clean the parts properly.

 Change transfer case oil.

Remedy: all the time M3 and A2 heave duty vehicles service time, it is a must
to change the oil listed in the above parts.[ W.H.C, 312, 9]\

4.1.1.3. Draw bar pin and all bushings.

While serving or maintaining heavy duty vehicles, it is a must to change the

draw bar pin even if damage or breakage is not happening on to it. This is mainly to
provide a safe guard for the total vehicle operation after maintaining.

Bushings – are clearly plain bearings, protecting damp, observe noise and
reduce improper clearance, so all the time a preventive maintenance has to be done on
all the busing specially, the following bushings has to be changed or replaced.

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  Draw bar pin bushing

 Leaf spring bushing

 Stabilizer bushings

 A wing arm bushings

4.1.1.4. Automotive clutch and release bearings

The clutch transmits motion from one shaft to another while permitting
engagement or disengagement of the shaft during rotation. While the clutch is
engaged, the disk is clamped tightly between the machined surface of the fly wheel
and the pressure plate.

Several types of clutch troubles may occur such as slipping, chattering or

grabbing when engaging, dragging when disengaging, clutch noise, clutch pedal
pulsation and rapid wear of the friction disk facing.

Fig 4.1 disassembled clutch and related parts

So, while maintaining check and service the following

 In correct pedal linkage adjustment remedy readjust

 Broken or weak pressure springs remedy replace it

 Binding in clutch release linkage free, adjust and lubricate

 Broken engine mount remedy replace it

 Worn friction disk facing remedy, replace facing or disk

54
  Grease or oil on disk facing remedy replace facing or disk

 In correctly adjusted release levers remedy readjust

 Warped clutch disk remedy replace it

 Broken disk facing, disk hub or pressure plate remedy replace it

 Improper release level adjustment remedy readjust it

 Misalignment of engine and transmission remedy readjust

 Bent clutch pedal remedies straighten it.

 Fly wheel out of run out

 Warped pressure plate

Release bearing

Check the release bearing of dirty, stuck, or proper working and replace it if
excessively damage [W.H.C, 33, 8]

4.1.2 Parts and systems to be serviced

4.1.2.1. Trailer wheel and all valves in brake system

When the trailer has been thoroughly cleaned and washed it will be brought
in to the preventive maintenance work area. The following inspection and service
process will be followed.
A. Lubricate all grease fittings.
B. Check brake shoe for wear, damage remedy replace it if
excessively damaged
C. Adjust brakes and check slack adjuster angle
D. Check springs hangers, u- bolts. and cross members
E. Check for air leaks and brake application leaks
F. Inspect air lines and glad hands washers
G. Drain tanks
H. Check grease in wheel ( if applicable)
I. Check fifth wheel plate and pin remedy replace it if
excessively damaged

55
 J. Check landing gear, braces and supports remedy clean them
and change if damaged.
K. Check tender slide and latches, if so equipped.
L. Check mud flaps remedy; clean it properly
M. Check for damage to front side’s and rear remedy; replace it.
N. Check for damage to roof, floor and doors remedy service it
and reshape or replace.
O. Check door hinges, rollers, cables and straps remedy service it.
P. Check all lights, reflectors and light plug for damage, shorted etc.
Q. Air all tires and check for wear, mated properly and separation.

Brake Valves to be checked and serviced

These valves have different functions to the kind of operation they are
designed for. Consequently; it is very important to check and service valves (T.M, 2-
119, 6).

 Piston stroke controlling valve

- Check it for proper seating

- Clean carbon deposit, if any and replace if damaged.

 Relay valve check relay valve and replace if damaged or clogged

 Check and service trailer valve control proportioning valve, mattering

valve, load sending valve, combination and all other valves for

- dirty

- Carbon deposit.

- Broken.

- Warped

- Stuck etc: remedy, service it and change it for damage.

4.1.2.2. Air Compressor

Compresses air necessary for brakes, defects in compressor may also result
in total failure of braking

56
 A. Governor out of adjustment.

Remedy: adjust it properly

B. restriction in line from governor to un loader

Remedy: clean the line from governor to un loader reamed clean the

line or install new tubing

C. Too much clearance on un loader

Remedy: adjusts to 0.25 mm clearance.

D. Broken un loader diaphragm

Remedy replaces it

E. Stuck compressor un loader valve

Remedy: replace it

F. Lock drive pulley

Remedy: correct it

G. Worn out bearings

Remedy: change them

H. Excessive carbon deposit

Remedy: clean it

I. Excessive back lash in drive gears

Remade: readjust to proper backlash [S.Sr, 364, 2]

4.1.2.3. Alternator and sartor motor

The starter motor is used to crank the engine. Many starting motors requires
no maintenance between major engine repairs or overhaul .However, brushes, bearings
and brush wear the solenoid, over running clutch, and other parts can fail.

If the starter motor has to be removed and repaired or exchanged for new or
rebuilt one

- check the armature and field coil

- Check starter motor for failures due to shortage or ground

57
 - Wipe, clean or replace over running clutch drive.

- Replace contacts in solenoid switch

Alternator

Converts mechanical energy from the battery in to electrical energy

 The drive belt, bearings, brushes and slip rings cause most alternator problems
these are moving parts that wear with usage.

 Diodes also fail from heat and shock when a charging system fails, find and
correct any conditions that cause the failure.

 Lock to wiring harness, damaged connectors, end terminals and an open fuse
and fusible link.

Remedy: test the diodes starter and rotor replace the brush, diodes and other
components, if excessively damage replace the alternator.[C.A, 385, 10]

4.1.3. Parts and systems to be checked.

4.1.3.1. Head lamp alignment

- For proper lighting systems and to avoid the cause of blind for an on coming
driver and series accidents as well,

Head light aim should be checked and adjusted

- every 12 months

- when a head lamp is replaced

- when there are special situations of vehicle rear loading or

- when front end sheet metal is repaired or adjusted

Check the aiming of head light using

 aiming screen

 mechanical aimer aiming screen

58
  optical aimer , and replace damaged bulbs and re correct head light
aiming

Fig 4.4 floor type head light aiming screen

4.1.3.2. Suspension system

The suspension system is used to provide comfort and safe guard the
occupants from road shocks, prevent the transmission of the road shocks to the vehicle
components, gear stability, provide the particular height to body structure and to bear
the torque and braking reactions. However, the suspension system may fail if the
following major defects occur and should be maintained on its recommended time.

i. harsh Suspension

A) Normal suspension system

a) The spring leaves corroded, causing excessive friction.

Remedy: lubricate them

b) Extra load or rebound fitted wrong way up,

Remedy: adjust them properly.

c) Shackle pins seized.

Remedy: replace with bushes

d) lubricate pads at the tip of levels worn out,

Remedy: replace the concerned shock absorber.

59
 e) Defective shock absorber.

Remedy: replace the concerned shock absorber

f) Tips of leaves have worn depressions in leaves

Remedy: repaired the spring assembly

B. Independent suspension system.

a) Seized suspension arm pivots

Remedy: lubricate them

b) Great coil spring tension

Remedy: replace with a proper spring

c) Incorrectly adjusted torsion bar

Remedy: adjust it properly

d) Any defect out of the defects of normal suspension system.

ii) Over flexible suspension.

This defect may be due to the following reasons.

a) Lack of friction in the suspension system due to applying un due lubricants

Remedy: clean the undesired lubricant.

b) Weakened spring

Remedy: replace them

c) Broken few leaves

Remedy replaces broken leaves

d) Incorrectly adjusted coil spring or weakened

Remedy: adjust properly or replace the spring

e) Weakened torsion bar

Remedy – replace them

iii) Sagging of vehicle to one side

a) Weak spring

60
 b) broken spring

c) in correct adjustment of torsion bars or springs remedy the same as listed

above

d) Breakage of springs

e) Over loading

Ready: decrease load

f) Violet breaking or grabbing brakes

Remedy: apply brakes very gradually

g) Loose U bolt

Remedy tight it

h) head of the center bolt or dowel does not fit in to recess in axle

Remedy: set them

i) seized shackle

Remedy repair the shackle

v) Noises

The cause of noise may be due to either of the above defects and the remedy
is the same. [T.R banga, 160-162, 4]

4.1.3.3. Flushing the differential

After draining all the oil inside the differential, the differential has to be
flushed using gasoline, or any other washings: this provides a neat cleaning for the
differential.

Flushing the differential provides the following

 Safe cleaning to safe guard new oil from contamination

 Removes remaining dirt or in putties after the oil is drained.

61
 Then fill the differential with new oil to improve working efficiency.

4.1.3.4 Dismantle and clean the 3rd differential

All the time servicing heavy duty diesel vehicles need to be dismantled and
clean the 3rd differential to remove dirties, mud, impurities or any other foreign
materials inside it.

Check for warped, damage, stuck components of the differential.

Remedy: - needs proper dismantling and replace damaged parts.

- lubricate and clean it.

4.1.3.5. Rood test.

After all the listed check and service points have done with proper manual
and procedures make sure you have done the necessary checks and services.

- Make sure you assemble each part,

- Set ready the vehicle on road test for proper operation.

A vehicle is meant for travel on the road. If there is trouble in any of the
basic functional systems of the vehicle, it may not be possible to discover what the
trouble is by checking the vehicle, while it is stopped.

Therefore, it is necessary to conduct road tests periodically. Road tests are

also necessary in order to confirm the results of maintenance operations which have
been performed.

Brake system

1. Check brake pull

2. Check brake effort

3. Check brake pedal feeling

Parking brake system

1. Chech parking brake pull

2. Check parking brake effort

Clutch system

1. Cheek clutch pedal feeling

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 2. Cheek releasing of clutch

3. Cheek for clutch slippage

Steering system

1. Cheek steering wheel free play

2. Cheek straight line position of steering wheel

3. Cheek steaight line characteristics

4. Check controllability

5. Check for shimmy shake and flutter

Automatic transmission

1. Check up – shift and down- shift operations

2. check for shock, Jeruing and slipping

Vibration and abnormal noise

Check for vibration and abnormal noise from the engines, drive train,
suspension system, steering system, brake system and body while the vehicle is in
motion.

63
 Part II

4.2. Practical aspects of M3 and A2

4.2.1. Replacing vehicle components and systems

4.2.1.1 Changing engine coolant

Coolant has to be changed at the recommended time. However, before

changing the coolant, check the strength of the antifreeze. But the technicians do not
have a testing unit; they simply change the coolant following the right procedure

To do this,

1st – check the radiator for leakage, crack, clogged core or fins

- flush the radiator using radiator flush

- fill it with coolants

Fig 4.6 radiator flushing

Challenge: some drivers use tomato’s fluid and some other mechanisms to clog
cracked cores (of the radiator), but this in turn causes engine over heating by
decreasing the circulating effort of the coolant)

The company also uses to block cracked cores by brazing with lead which
may lead to over heating.

4.2.1.2. Change oil from all mechanical parts

64
 As for as engine oil is changed the oil from all mechanical parts has to be
changed following the necessary procedures

- check for leakage

- drain the oil

- flush all mechanical parts using 1/3 of pure oil and 2/3 of
diesel oil

- run the engine for some time

- drain it

- fill with pure oil

Problems: no oil laboratory

4.2.1.3. All bushings and draw bar pin

As for as the manual recommends, all bushings in the suspension system has
to be changed. However; the company does not use to replace it unless the bushings
are severely damaged. This may help them to reduce cost, man power, time of
servicing and the like.

Problem; unchanged bushings may lead to damage components of the vehicle

and driving effect as well

The draw bar pin must be serviced. However; they do not service it in most cases.

4.2.1.4. Changing clutch disk and release bearing.

Always on the recommended time, check the clutch and its parts depending
on what the theory orders. But, the TATSC, technicians use to check the rivets for
wear or burn, cohesion and torsion spring bend etc and in most cases, since they do
not have the checking and serving materials, they do not tend to change or replace it
unless it is severely damaged.

Release bearings are checked and since they are sealed, no need for grassing.

How ever, as the release bearing lacks oil, it may be susceptible to noise. So
they oil it properly

4.2.2 Servicing components and systems

65
4.2.2.1. Clean all axle breathers

Axle breathers have to be cleaned for proper breathing. This is because as

every oil in the moving parts get hot during operation it will be changed to vapor as a
mist, so to protect blockage it has to be cleaned, if not blocked breather damages kits
and seals.

Challenge: - the technicians do not use this trend for they assume it as a simple cause.

4.2.2.2 Trailer wheel, all values

The trailer has to be serviced depending on what the check list states
following the right procedures. How ever, the technicians check and service only on
few components by assuming the others may last long.

Challenge: - it may cause total failure for the over the entire trailer.

N.B trailer components in which technicians mostly concentrate

- track adjuster

- Brake shoe

- Self stuck

- return spring

- Backing plate and the like.

4.2.2.3. Air compressor

Tikur Abay Transport Share Company technicians need to cheek and service
air compressor for proper operation following the necessary procedure. However,
instead of servicing according to the servicing check list they concentrate only on.

Oil ring failure

Compressor ring

Damage gasket and cleanings

N.B- This partial checking and servicing may tend to fail the total compressing unit

4.2.2.4. Servicing alternator and starter motor.

66
 - the electric section technicians are responsible to service the alternator and
starter motor, they do not mostly change but checking its efficiency, brush wear,
continuity, shorted or grounded.

Problem: they undergo rough checking’s.

4.2.2.5. Flushing the differential

- drain oil in the differential

-dismantle the differential, clean washers, seals, spiders and gears and inspect
the conditions.

- flush it using 1/3 oil and 2/3 diesel oil

-drive the vehicle to flush it

- Then fill fresh oil

4.2.2.6 Dismantle and clean the 3d differential

Conditions of the brushes, eccentric, compression spring are also checked at

each 120,000 k/m.

4.2.2.7. Road test,

Wile doing or executing rod test, both the tractor and the trailer are checked
by the inspector, during this test the maintenance activities that has been serviced and
adjusted will be checked to ensure maintaining activities and probably if there is any
new failure. It will help to re- service.

Challenge: the company technicians do the checking and servicing system

nearly almost by trial and error hence it was a problem for us to analyze and observe
the necessary steps and checking.

In addition the time given was not enough for us to follow the scheduled
maintenance programs.

67
 PART III

Pedagogical Aspect

This part is prepared to evaluate the effectiveness of the project. Therefore,

regarding the head light aiming which determine, the driver ability to see the road
properly and blinding of an on coming driver.

The worksheet below prepared and performed by “Abdu Technical School”

Students who were practicing at TATE. They can perform each task guided by the
work order given. The activity can be preformed by 50 minutes.

Worksheet- 1

 Vehicle manufacturer

 Vehicle type

 Model

 Vehicle capacity

Work order

1. Drive the vehicle on to a smooth flat portion of pavement or lab area

2. Select the proper head light aiming adapters

3. Attach the adapters to the headlights

4. Adjust both head lights vertically so that bubbles on the adapter are centered
by adjusting the screws at the top or bottom of the headlight assembly

Both ok

One needed adjustment

Both needed adjustment

5. Turn the adjusting screw on the left or right side of the headlight assembly to
align the marks in the headlight aiming adapter

Both ok

One needed adjustment

Both needed adjustment

68
Observation

Conclusion

Q1. What is the need to drive the vehicle on smooth flat portion of lab area?

69
 CONCLUSION

Careful observation and data collection have been taken by the team to pin
point the causes of unplanned stops and the main preventive maintenance to be
taken by for failure on heavy duty vehicles especially on EURO TRUCKERS
which are the properties of Tikur Abay Transport Share Company. Based on the
findings the main causes of unplanned stops and vehicles failures are:-

 Ignoring the entire check list to be followed

 Ineffectiveness while discriminating the equipments, components

parts and systems to be touched for maintenance and working until to
break down. i.e mismatching the strategy of maintenance due to
disability of forecasting the problems leading to unplanned stop based
on scientific approaches instead of trail and error. E.g. Alternator,
starter motor, belt tenssoiner bearings which have to be let to work to
break down.

 Carelessness of technicians while checking and inspecting the

equipments. E.g. during checking break show wear, tightening clamps
and all mechanical lines and electrical lines.

Generally, heavy duty vehicles were maintained at their specified time

however, the enterprise faces lots of unplanned stops due to tire burning,
failure on starter motor, alternator, belt tensioner bearings, short on electrical
lines and the likes due to carelessness trial and error method of maintaining
equipments.

70
 RECOMENDATION

Depending on the study conducted at Tikur Abay Transport Share Company,

the team of this project recommends the following.
The technicians and the company should follow the entire check list to
under go proper checking ,and changes for this eliminates unexpected
problems resulted from jumping the check list. e.g. Air driver, draw bar pin,
electrical lines, etc.
The enterprise should fulfill appropriate and sufficient engine
measurements like pressure tester, oil job, tension belt gauge etc.
The company should fulfill not only partial and top overhaul but also a
complete overhauling or servicing system.
Neatness in every aspect of the work followed by technicians has to be
there.
Should develop technician’s capacity.
Better to follow scientific methods and procedures rather than trial and
error e.g. Belt tension bearings should not be touched
The quality and quantity for spare parts should be kept as desired.
Technicians should flush parts required flushing and check oil in oil
labs.
The enterprise should have an organized work shop.

71
 BIBLOGRAPHY
1. William H..Crouse. Donald L.Anglin , 1984
Auto Study guide U.S.A, 3rd edition 1974.
2. S srinivasan, 2003 Automotive Mechanics , India 2nd edition 1981.
3. V.A.W. Hillier, 1991 Fundamentals Of Motor Vehicle Technology,
London 4th edition
4. T.R Banga Nathu Singhi 1987 Automobile Engineering,
India 2nd Edition 1982
5. Tom Weather Jr./Claud Hunter , 1986 diesel engine,
U.S.A 2nd Edition 1981
6. Training Manual Periodic Maintenance, Step 1, Vol.3
7. M.J Nunney 1998 Light And Heavy duty vehicle Technology
England 3rd Edition 1988
8. William H .Cruse Donald L Anglin 1983 Automotive Manual Transmission
And Power Trains U.S.A 6th Edition 1955
9. Crouse Anglin 1993 Automotive Mechanics
U.S.A 10th Edition 1946
10. Crouse Anglin 1985 Automotive mechanics
India 9th Edition 1985
11. Society of Ethiopian Automotive Engineers , Maintenance of Light And
Heavy duty Vehicles
12. Kasahun Kebede, Modern maintenance management
Ethiopian maintenance institute (PMD) booklet no 1-3
13. Gary Lewis, 1986 ENGINE SERVICE U.S.A second edition

72