Maintain Engine-Repair

Maintain
Training
Facilities
1
Date Developed: Document
No.
AUTOMOTIVE July 4, 2023
SERVICING Issued by:
(ENGINE Developed by: CSTC Page 1 of 28
REPAIR) NC II
Patrick E. Revision #:
Portales
HOUSEKEEPING SCHEDULE
Qualification : AUTOMOTIVE Station Practical/

SERVICING(ENGINE Assessment
REPAIR) NC II Area
Area / Section : Automotive Workshop Tools / Tool room

Eqpt. (screw,
assorted
wrench, rag,
socket,
rachet, SST)
In - Charge : Patrick E. Portales Services
2
Responsib
Schedule for the Month of May 2013 Prepared by:
le Weekl
ACTIVITIES Dail
Every y Every
Monthl
other 15th Remarks
Person y
Day Day
y
1. Cleaning Utility Activity is

of all engine person done Date:
nel/Tr x before and Patrick E.
ainees after Portales
using the
equipment
2. Cleaning Utility Activity is July 7, 2023
of floor, person done daily
X
walls and nel
windows
3. Cleaning Utility X Activity is
of chairs Person done daily
and table nel
4. Disposing Utility X Activity is

of waste Personn done daily
el
5. Checking Utility X Activity is
and cleaning Personn done
el
lightning monthly
fixtures

restroom Personn done daily
el/Train
ees
floors personn done daily
el
8. Cleaning Utility Activity is
and Personn done
el
checking X before and
equipment after
using the
equipment
9. Checking Utility X Activity is
the personn done
condition of el/Trai before and
each nees after
automotive using the
tools equipment
10. Utility X Activity is
Preparing of personn done
tools and el/Trai before and
equipment nees after
using the 3
equipment
EQUIPMENT MAINTENANCE SCHEDULE
EQUIPMENT TYPE Hydraulic press
EQUIPMENT CODE ATS 1004
LOCATION Automotive Workshop
Schedule for the Month of July 2023
ACTIVITIES MANPOWER Dail Ever Weekl Ever Monthly Remarks

y y y y
Othe 15th
r Day Day
1. Check oil Automotive X Activity is

leakage Trainer done before
and after
using the
equipment
2. Check X If a need
loose bolts arises make
Automotive an
Trainer adjustment
3. Check for X If a need

lubrication arises make
Automotive an
Trainer adjustment
4. Check the Automotive X If a need

ram and Trainer arises make
inspect the oil an
temperature adjustment
5.Turn off the Activity is

unit when not done before
in use Automotive X and after
Trainer/Train using the
ees equipment
Prepared by: Date:

Patrick E. Portales July 7, 2023
4
EQUIPMENT TYPE Valve grinder

y y y y
Othe 15th
r Day Day
1. Check the Automotive X Activity is

wires and Trainer done before
cables and after
using the
equipment
2. Lubricate X Activity is
bolts with done before
penetration Automotive and after
oil Trainer using the
equipment
3. Check the X If a need

position arises make
Automotive an
Trainer adjustment
4. Clean the Automotive X Activity is

equipment Trainer/Train done before
ees and after
using the
equipment

ees equipment
Prepared by: Date:

EQUIPMENT TYPE Training engine
5

y y y y
Othe 15th
r Day Day
1. Check Automotive X Activity is

screwed Trainer done before
connection and after
using the
equipment
valves arises make
Automotive an
Trainer adjustment
piston rings arises make
Automotive an
Trainer adjustment
4. Replace Automotive X If a need

piston pins Trainer arises make
and piston an
pin bearings adjustment

ees equipment
Prepared by: Date:

6
EQUIPMENT TYPE Training vehicle
EQUIPMENT CODE ATS1001
LOCATION Automotive Work Area

y y y y
Othe 15th
r Day Day
1. Check fluid Automotive X Activity is

levels Trainer done before
and after
using the
equipment
2. Clean any X If a need

dirt, grit and arises make
debris Automotive an
Trainer/Train adjustment
ees
3. Check tires Automotive X If a need

Trainer/Train arises make
ees an
adjustment
4. Check all Automotive X If a need

light bulbs Trainer/Train arises make
ees an
adjustment
5. Check the Activity is

horn done before
Automotive X and after
ees equipment
7
Prepared by: Date:
EQUIPMENT TYPE Chain block

y y y y
Othe 15th
r Day Day
1. Check for Automotive X Activity is

broken or Trainer / done before
cracked Trainee and after
chains using the
equipment
2. Check X Activity is
loose, damage done before
or missing Automotive and after
parts Trainer using the
equipment
3. Clean the Activity is

rust done before
Automotive X and after
ees
8
equipment
4. Check the Automotive X Activity is

cup nuts Trainer/Train done before
ees and after
using the
equipment
5. Check the Activity is

mounting done before
plate rotation Automotive X and after
lock Trainer/Train using the
ees equipment
Prepared by: Date:

HOUSEKEEPING INSPECTION CHECKLIST
Qualification AUTOMOTIVE SERVICING (ENGINE REPAIR) NC II
Area/Section Automotive Workshop
9
In-Charge Patrick E. Portales
YES NO INSPECTION ITEMS
X Are the engines well organize and clean?
X Are tables, chairs and whiteboard clean?
X Is all materials, accessories and devices are in proper

arrangement?
X Are the tools and equipment are in good working condition?
X Are PPE's clean?
X Is all floors, walls, windows and ceiling cleaned and checked from
dust and rust?
X Is all work shop ventilation and illumination by dusting

lamps/bulbs are cleaned and checked?
X Are the tool cabinet cleaned, checked and maintained?
X Is the washing area cleaned and checked?
X Are the waste disposals of electrical wiring materials are in proper

segregations?
Remarks:
The working area is cleaned and free from a possible hazard.
Inspected by: Date:
10
EQUIPMENT MAINTENANCE INSPECTION CHECKLIST
Equipment Type : Hydraulic press
Property Code/Number : ATS 1004
Location : Automotive Workshop
Trainer-In-Charge : Patrick E. Portales
X Is there any loose bolts and screws around the tooling area?
X Are the oil levels correct?
X Is there any oil leaks?
X Is the control switch functional properly?
X Is the equipment accessories cleaned and stored accordingly?
X Is the Air dust gun switching are in the good working condition?
Remarks:
The equipment is free from hazards and it is in good working condition.
Inspected by: Date:
11
Equipment Type : Valve grinder
Location : Automotive Work Area
X Is the valve grinder is in the normal operation?
X Are all the wires and cables are no damage?
X Is the valve grinder functioning properly?
X Is the control switch working properly?
X Is the valve grinder prone to hazard?
Remarks:
Inspected by: Date:
12
Equipment Type : Training engine
13
X Are the training engine is in the normal operation?
X Are the training engine clean and check?
X Are the ignition timing correct?
X Are the injection pump working?
X Are the parts complete?
Remarks:
Inspected by: Date:
14
Equipment Type : Training vehicle
X Is the training vehicle properly maintained?
X Is the bumper and hood no damage?
X Is the training vehucke can use daily without any trouble?
X Are oils and coolant levels good?
X Are tire pressure good?
X Is the equipment in good working condition?
Remarks:
Inspected by: Date:
15
Equipment Type : Chain block
X Is the chain block in the normal operation?
X Are the chains not damage?
X Are the equipment working properly?
X Is hand chain runs smoothly over the wheel without jumping
X Are the cup nut complete?
Remarks:
Inspected by: Date:
16
EQUIPMENT RECORD W/ CODE AND DRAWING
Eqpt. PO Drawing
No. Location Qty Title Description
No. No. Ref.
Hydraulic Press
machine-
1. Automotiv ATS Cylinder PO ATS
e 1004 Machine -Pillar 0004 1004
Workshop type – Stand
Press – Hand
Press Manual –
Punching – 100
Ton Capacity.
1 Hydraulic
unit press
M-300 DN80-
300mm (3-
13Inch) Portable
17
2. Automotiv ATS 1 Valve Gate Valve PO ATS
e 1009 unit grinder Grinding 0009 1009
Workshop Machine
Petron and
diesel engine
3. Automotiv ATS PO ATS
e 1007 1.0-Liter 3- 0007 1007
Workshop Training Cylinder 1KR-
engine VE Gasoline
5
sets
Toyota Wigo
Automotiv Hatchback 3-
4. e ATS Training cylinder, In- PO ATS
vehicle Line, 12-valve 1001
Workshop 1001 0001
DOHC with VVT
1
unit
Working
Capacity = 8 x
5. Automotiv ATS 0.625 x 0.625 = PO
e 3.125 tons or
1005 Chain 0005 ATS
Workshop block 6,250 pounds 1005
1
unit
Prepared by: Date:

DANGER/CAUTION TAG-OUT INDEX AND RECORD AUDITS
18
LOG DATE TYPE DESCRIPTION DATE
SERIAL ISSUED ( Danger/Caution) (System Components, COMPLETED

Test reference ,etc.
01 7/5/23 Caution On-going replacement September 11,

of new oil of hydraulic 2023
press
02 3/12/13 Caution Pull out the defect September 13,

loose stud bolts and 2023
nuts
03 7/19/23 Caution Pull out the connecting September 22,

rod and loss thread 2023
bolt
04 7/24/23 Caution On-going replacement September 25,

of newly tire 2023
05 7/29/23 Caution Pull out the defect September 29,

chains 2023
Prepared by:
Patrick E. Portales
Trainer
19
BREAKDOWN / REPAIR REPORT
Area / Section : Automotive Work Area
In-Charge / : Patrick E. Portales
NATURE OF
FACILITY TYPE RECOMMENDATION
BREAKDOWN
For replacement of oil

specification;
Hydraulic press Oil leak
Mobil DTE 24 or an
equivalent
For replacement of stud

bolt and nut
Valve grinder Loose stud bolt and nut
ASTM A193
8 threads per inch (“thread

per inch”)
For replacement of
Training engine Corroded, loose battery Corroded, loose battery

cable and nuts cable and nuts
6-gauge cable
12-volt power supply
20
For replacement of tire
Specification;
Training vehicle Flat tire
Size: 175/65 R14
For replacement of chain

Specification;
Chain block Cut off chains
Shuang-ge (HS-J series)
Signature Over Printed

Name
WORK REQUEST
Unit Description:
No.
Hydraulic press
Observation:
Date Reported:
Cause of oil leak July 09, 2023
For replacement of training engine Reported by:
Specification; Patrick E. Portales
Mobil DTE 24 or an equivalent
Date completed:
Activity: For replacement of oil and nuts is same as the July 29, 2023
specifications.
21
Sign: Portales
Spare parts used:
None
Inspected by: Date:

WORK REQUEST
Unit No. Description:
Valve grinder
Observation:
Date Reported:
Cause of loose stud bolt and nut July 09, 2023
For replacement of valve grinder Reported by:
Patrick E. Portales
22
Specification;
ASTM A193
8 threads per inch (“thread per inch”)
Date completed:
Activity: July 29, 2023
● Replacement of stud bolt and nut
Sign: Portales
Spare parts used:
None
Inspected by: Date:

WORK REQUEST
Unit
No.
Training engine
23
Observation:
Date Reported:
Cause of loose thread bolts and connecting rod July 09, 2023
Reported by:
For replacement of training engine Patrick E. Portales
Specification;
6-gauge cable
12-volt power supply
1.0-Liter 3-Cylinder 1KR-VE Gasoline
Date completed:
Activity: For replacement of hose and nuts same as the July 29, 2023
specifications.
Sign: Portales
Spare parts used:
Install the new stud bolts and nuts properly
Inspected by: Date:

24
WORK REQUEST
Unit
No.
Training vehicle
Observation:
Date Reported:
Cause of poor tire life July 09, 2023
Reported by:
For replacement of training vehicle
Patrick E. Portales
Specification;
Size: 175/65 R14
R14 in,R14
2.4-2.5 Bar
Date completed:
Activity: For replacement of tire same as the specifications. July 29, 2023
Sign: Portales
Spare parts used:
Install the new tire properly
Inspected by: Date

25
WORK REQUEST
Unit
No.
Chain block
Observation:
Date Reported:
July 7, 2013
Cause of defect of cut off chains
Reported by:
For replacement of chains Patrick E. Portales
Specification;
Working Capacity = 8 x 0.625 x 0.625 = 3.125 tons or 6,250

pounds
Date completed:
Activity: For replacement of chain block is same as the
specifications.
Sign: Portales
Spare parts used:
Reinstall the chain properly
Inspected by: Date:

26
SALVAGE REPORT
Area / Section : Automotive Work Area
In-Charge : Patrick E. Portales
FACILITY TYPE PART ID RECOMMENDATION
1. Hydraulic press Lubrication/oil The oil are-installed to

hydraulic press
2. Valve grinder Stud bolts and nuts The stud bolts and nuts are
re- installed to valve grinder
3. Training engine Thread and connecting The thread and connecting

rod rod are-installed to training
vehicle
4. Training vehicle Tire The tire will re-installed to

training vehicle
5. Chain block Chain The chain are-installed to

chain block
Reported by:
Patrick E. Portales Date: July 7, 2023
Signature Over Printed

Name
27
INSPECTION REPORT
FACILITY TYPE INCIDENT ACTION TAKEN PROGRESS/

REPORT
REMARKS
Replaced of
Cause of oil leak hydraulic press oil
1. Hydraulic Specification; Excellent
press simulations
Mobil DTE 24 or an
equivalent
Replaced of valve
Cause of loose stud grinder stud bolt
2. Valve grinder bolts and nuts and nut
Specification:
ASTM A193 Work Properly
8 threads per inch

(“thread per inch”)
Replaced of thread
3. Training Cause of loose tread bolts and
engine bolt and connecting connecting rod
rod Specification: 6-
gauge cable 12-volt Work Properly
power supply
4. Training
vehicle Replaced of tire
Specification: Size:
175/65 R14, R14
Cause of poor tire
in,R14, 2.4-2.5 Bar
life
28
Work Properly
5. Chain block
Replaced of switch
Cause of defect and wheel guard
chain Specification:
Work Properly
Shuang-ge (HS-J
series)
Inspected by: Date:

OPERATION OF EQUIPMENT
Equipment Type : Hydraulic press
Property Code/Number: ATS 1004
Person-In-Charge : Automotive Trainer
Inspected by : Patrick E. Portales
Date of Inspection : July 7, 2023
Operation Procedures:
1. Safety Precautions: Before using the hydraulic press, ensure that you are
familiar with all safety precautions and have appropriate personal protective
equipment (PPE) such as safety glasses and gloves. Make sure the press is in good
29
working condition and properly maintained.
2. Positioning the Workpiece: Place the workpiece or material to be pressed

between the press plates. Make sure it is centered and aligned correctly to avoid
any uneven pressure distribution.
3. Adjusting Pressure and Speed: Set the pressure and speed on the hydraulic
press according to the requirements of the specific task. Be cautious not to exceed
the press's capacity or the material's load-bearing capacity.
4. Operating the Hydraulic Press: Activate the hydraulic press using the control
lever or buttons. The hydraulic ram will move downwards, exerting pressure on the
workpiece. Make sure to monitor the process closely to prevent overloading or
potential issues.
5. Monitoring and Inspection: As the press operates, continuously monitor the

process and inspect the workpiece for any abnormalities. If you notice any
unexpected noises, vibrations, or other irregularities, stop the press immediately
and investigate the cause.
6. Releasing Pressure and Removing the Workpiece: Once the pressing

operation is complete, release the pressure gradually by activating the press in the
opposite direction. Carefully remove the finished workpiece from the press plates.
7. Shutdown Procedure: After completing the pressing tasks, turn off the
hydraulic press and relieve any residual pressure. Perform necessary maintenance,
such as cleaning the press and inspecting components for wear or damage.
Equipment Type : Valve grinder
30
1. Set up the Grinder: Adjust the valve grinder to the correct angle according to
the manufacturer's specifications. This is crucial to achieve proper valve sealing.
2. Grinding Process: Gently place the valve against the grinder wheel and start
the grinding process. Move the valve back and forth evenly to ensure an even grind
and avoid uneven surfaces.
3. Check and Measure: After grinding, carefully inspect the valve for any
imperfections or unevenness. Use a micrometer to measure the valve's dimensions
and ensure it matches the manufacturer's specifications.
31
Equipment Type : Training engine
1. Disassembly: Carefully disassemble the engine, following the manufacturer's

guidelines or a repair manual. Start by removing external components, then
proceed to internal parts like the cylinder head, pistons, crankshaft, and camshaft.
2. Inspection and Measurement: Examine each component for signs of wear,

damage, or misalignment. Use precision measuring tools to check critical
dimensions, such as cylinder bore, piston clearance, and valve clearances.
3. Reassembly: After inspecting and possibly repairing or replacing worn parts,

reassemble the engine in the correct order. Lubricate moving parts as needed, and
ensure all connections, gaskets, and seals are properly installed.
32
Equipment Type : Training vehicle
1. Insert the Key: Insert the key into the ignition switch, which is usually
located on the right side of the steering column.
2. Turn the Key: Turn the key clockwise or as per your car's specific model to
the "ON" position. You should see various dashboard lights illuminate. Do not
crank the engine just yet.
3. Check Indicator Lights: Before starting the engine, check that all the
warning lights on the dashboard turn off after a few seconds. This indicates that
the car's systems are ready.
4. Start the Engine: Once the indicator lights have turned off, turn the key
further clockwise or press the "Start/Stop" button (if your Wigo has one) while
keeping your foot on the brake pedal. The engine should start.
33
Equipment Type : Chain block
Location : Automotive Workshop
1. Safety Precautions: Before using the chain block, ensure you have received
proper training on its operation and safety guidelines. Wear appropriate personal
protective equipment (PPE) such as safety gloves and a hard hat. Inspect the chain
block to ensure it is in good working condition.
2. Selecting the Proper Chain Block: Choose a chain block that is suitable for
the weight of the load you need to lift. Ensure the chain block's capacity is higher
than the weight of the load to be lifted.
3. Securing the Load: Rig the load securely using appropriate slings or
attachments. The load should be balanced and properly centered under the lifting
point of the chain block.
4. Attaching the Chain Block: Fasten the chain block to a suitable support
structure, such as an overhead beam or a gantry crane, using a sturdy, rated lifting
point or hook.
5. Inspecting the Chain and Hooks: Check the condition of the chain and hooks
for any signs of damage or wear. Ensure that the hooks are properly latched and
engage the load securely.
6. Lifting the Load: Use the hand chain to lift the load slowly and steadily. Pull
the hand chain in a straight line, and avoid any jerking or sudden movements.
7. Monitoring the Lift: As the load is lifted, keep a safe distance from the load
and avoid standing directly underneath it. Continuously monitor the lift for any
signs of instability or shifting of the load.
34
35

Maintain Engine-Repair

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Maintain

Qualification : AUTOMOTIVE Station Practical/

Area / Section : Automotive Workshop Tools / Tool room

In - Charge : Patrick E. Portales Services

1. Cleaning Utility Activity is

4. Disposing Utility X Activity is

6. Cleaning Utility X Activity is

EQUIPMENT TYPE Hydraulic press

EQUIPMENT CODE ATS 1004

LOCATION Automotive Workshop

Schedule for the Month of July 2023

ACTIVITIES MANPOWER Dail Ever Weekl Ever Monthly Remarks

1. Check oil Automotive X Activity is

3. Check for X If a need

4. Check the Automotive X If a need

5.Turn off the Activity is

Prepared by: Date:

EQUIPMENT MAINTENANCE SCHEDULE

EQUIPMENT CODE ATS 1009

LOCATION Automotive Workshop

Schedule for the Month of July 2023

ACTIVITIES MANPOWER Dail Ever Weekl Ever Monthly Remarks

1. Check the Automotive X Activity is

3. Check the X If a need

4. Clean the Automotive X Activity is

5.Turn off the Activity is

Prepared by: Date:

EQUIPMENT MAINTENANCE SCHEDULE

EQUIPMENT TYPE Training engine

LOCATION Automotive Workshop

Schedule for the Month of July 2023

ACTIVITIES MANPOWER Dail Ever Weekl Ever Monthly Remarks

1. Check Automotive X Activity is

4. Replace Automotive X If a need

5.Turn off the Activity is

Prepared by: Date:

EQUIPMENT TYPE Training vehicle

EQUIPMENT CODE ATS1001

LOCATION Automotive Work Area

Schedule for the Month of July 2013

ACTIVITIES MANPOWER Dail Ever Weekl Ever Monthly Remarks

1. Check fluid Automotive X Activity is

2. Clean any X If a need

3. Check tires Automotive X If a need

4. Check all Automotive X If a need

5. Check the Activity is

EQUIPMENT MAINTENANCE SCHEDULE

EQUIPMENT TYPE Chain block

EQUIPMENT CODE ATS 1005

LOCATION Automotive Workshop

Schedule for the Month of July 2013

ACTIVITIES MANPOWER Dail Ever Weekl Ever Monthly Remarks

1. Check for Automotive X Activity is

3. Clean the Activity is

4. Check the Automotive X Activity is

5. Check the Activity is

Prepared by: Date:

HOUSEKEEPING INSPECTION CHECKLIST

Qualification AUTOMOTIVE SERVICING (ENGINE REPAIR) NC II

Area/Section Automotive Workshop

YES NO INSPECTION ITEMS

X Are the engines well organize and clean?