1.

MAINTENANCE CONCEPTS
In order to set up a maintenance strategy for an
enterprise, it is necessary for everybody in a company to
understand the maintenance concept and speak the same
language in maintenance.
The term maintenance comprises a lot of activities e.g.
preventive maintenance, corrective maintenance,
conditioned monitoring etc.
The term maintenance covers all activities undertaken to
keep equipment in a particular condition or to return it to
such condition.
From the definition we can see that maintenance consists
of three main parts.
1. Corrective maintenance:
Corrective maintenance covers all maintenance
which is carried out in order to correct (repair) a
fault in equipment.
As soon as there is a fault in equipment, and a
repair work is on to correct the fault, the job is
classified as corrective maintenance. Thus, it is not
necessary that all corrective maintenance is break
down-or emergency maintenance. Some times there
is a fault in equipment before it is breaking down
and an emergency job happens.
2. Preventive maintenance: -
Preventive maintenance covers all programmed
maintenance which is carried out in order to prevent
the occurrence of failures or to detect failures before
they develop to a breakdown or interruptions in
production.
preventive maintenance job is always
programmed/scheduled; it means that all preventive
maintenance activities are decided in advance.
Corrective maintenance activities are on the other hand
difficult to forecast when they are going to happen.
Perhaps it is known that corrective maintenance will
happen some times, but nobody knows when.
Preventive maintenance can be divided in to two
1. Direct preventive maintenance
preventive maintenance which is done to prevent
the occurrence of failures
2. Indirect preventive maintenance
preventive maintenance which is done to detect
failures before they develop to a break down or
disturbances in the production.
The condition monitoring can be done in two different ways
1. Subjective condition monitoring is when the monitoring is
done by the senses (inspections) such as listen, look, touch, taste
and smell and from that estimate the condition.
The subjective condition monitoring is putting great demands
on the person who is doing it. The results achieved are very much
dependent on the doer because individuals comprehend
situations different. A great portion of experience is therefore
required for persons being recruited for this type of job, if the
results from the subjective condition monitoring are to be
reliable.
2. Objective condition monitoring is when the
condition of equipment is measured in some other
way than using the senses. The measures can be done
in different ways: both with advanced and simple aids.
The common thing is that this type of condition
monitoring will give a measured value of the condition
and therefore give an objective and more reliable result
of the condition monitoring.
The objective condition monitoring can be carried out
in two different ways.
1. Off-line condition monitoring means that a person
is walking around and take measurements by a hand
held instrument. The reading is noted down or stored
in the instrument for later analysis. This method
demands a qualified person to perform the
measurement because he must have the knowledge to
operate the instruments and be able to interpret the
information from the instruments and analyze if the
present condition is good or bad.
 2. Continuous monitoring also belongs to objective
condition monitoring. When the failure developing time
is too short for on-line condition monitoring it is
advisable to apply continuous monitoring. At the same
time it requires less people.
In a preventive maintenance system based on condition
monitoring normally 70% of all activities are done
subjectively and 30% objectively. The reason for this is
that all failures that can occur can not be detected by
instruments.
3. Improvement maintenance
The term improvement maintenance is used when to
modify the equipment so the condition improves.
Improvement maintenance includes only activities
which are carried out once. The objectives of
improvement maintenance are:
To design out the failure i.e. the failure will never
occur again or to extend the life time of parts.
 2. Purpose of periodic
maintenance
The purpose of periodic maintenance is to restore a
vehicle’s performance to the best possible condition, in
order to prevent small problems from becoming bigger
in the future, and to ensure that the vehicle is safe and
conforms to local laws and regulations.
Through performance of the specified periodic
maintenance, the customer can be assured of longer
vehicle life, better driving economy, and more reliable
operation.
 Maintenance precaution
When doing a maintenance job, be sure to observe the
following precautions. During a job, follow these
precautions thoroughly and cultivate an “improvement
consciousness”. Be aware of work safety at all times.
(a) It is necessary to have a good understanding of the
work to be done and to carry out each job precisely. If there
is any job that is not understood, or if you are not sure of
how to use a tool or instrument, etc. or of what judgment
to make in a check, discuss it with your superior or with an
expert. In such a situation, do not rely on your own
judgment to do the job.
b) Fender covers, seat covers and floor mats must be
used to prevent dirt from getting on the customers’
vehicles and keep them from getting scratched.
Before starting a job, be sure to place the necessary
fender covers, seat covers and floor mats in or on the
vehicle.
C) When using wheel chocks, set the chocks in front
of and behind each of the front or rear wheels.
Normally, the parking brake is applied during a job,
but if the parking brake is weak, and there is danger
that the starter could be operated while the vehicle is
in gear, etc., give adequate consideration to safety,
making sure that all vehicle movement is prevented
during the job.
 d) When using a jack, always use jack stands.
Take the following precautions.
• Jack the vehicle up and down carefully and precisely:
• When setting the jack under a cross- member or an
axle, the jack plate should be centered on the part to
be supported, and adequate care should be taken so
that the plate will not slip off.
• When using jack stands to support the body, the stands
should be placed in the positions shown in the figures
after their height has been adjusted. (The support
positions are indicated by two notches in the rocker
panel.)
 • The jack-up position and jack stand support position
differs depending on the vehicle model, so see the
guidance of an expert or refer to the repair manual.
(e) Observe the following precautions when using a car lift.
• Move the vehicle onto the car lift so that the vehicle’s
center of gravity is located over the plates of the car lift.
• When raising or lowering a vehicle on a car lift, be sure to
check all around the vehicle, making sure that all
necessary safety precautions have been taken.
Is there a tool stand located too close to the lift?
Are any of the vehicle’s doors open?
Is anyone underneath the vehicle?
(f) When carrying out a job, doors may be opened and
closed a number of times, so when opening or closing
a door, take particular care to prevent it from hitting
the vehicle next to it, the walls of the garage, etc.
 (g) SST is the abbreviation for Special Service tool.
These special tools are made for use in cases when a
job is difficult to perform with regular tools, when
there is danger of damaging parts or for considerations
of safety or workability, as well as for the purpose of
improving efficiency in the job.
Be sure to master the use of the SSTs called for in each
job procedure and be prepared to use them in every
job where they are needed.
(h) There are many types of oil and grease used in
periodic maintenance.
These lubricants differ depending on the place where
they are to be used. The type of lubricant may also
differ depending on the vehicle model.
(I) Road tests to determine the condition of the
engine, steering system, suspension, brakes, etc., are
difficult to perform as they depend largely on feeling
or intuition. Until a technician becomes skilled in
judging each condition, an expert should ride along
and give advice.
 (j) When carrying out jobs related to the electrical
system, the negative terminal of the battery should be
disconnected to prevent burning out of wiring
harnesses due to short circuits. Since the memory of
radio tuners and other devices in some models is
erased when the battery cable is disconnected, be sure
to make a record of the contents of the memories
before disconnecting the negative terminal.
ASSIGMNET ONE(individuals)
Write the purpose of the following manuals
1.Owner manuals
2. Service manuals
3. Repair manuals
4. Part catalogs
EFFICIENT MAINTENANCE

In order to carry out maintenance efficiently, the

number of motions within the working area required
to check the engine compartment, suspension (with
the vehicle on the lift), the exterior, and interior, etc.,
should be kept as low as possible
Flow work of efficient maintenance
 JOB CARD
A job card is a sheet that contains details about the
customer, vehicle, customer repair requests, and
instructions by service advisors, time and cost estimate,
vehicle inventory and vehicle handover.
PURPOSE OF PRE-DELIVERY SERVICE
PDS (Pre-delivery Service) consists of an inspection of
the finished condition and the operation of the
functional components and mechanisms, etc., of a
new vehicle shipped from the factory.
PDS is carried out before the vehicle is delivered to the
customer to ensure that the vehicle is in top condition
and that it can be used right away when the customer
receives it.
 WHY PREDELIVERY SERVICE IS NECESSARY
1. Confirmation of vehicle finish after transit from the
factory
 The vehicle will then pass through several distribution
processes before it is finally delivered to the purchaser, and
during this time unforeseeable problems (damage during
shipping, theft, etc.) may arise. Therefore, PDS is an
important step in insuring that the vehicle’s condition
meets the customer’s satisfaction.
2. Restoring vehicle to proper condition for use
the vehicle leaves the factory, it undergoes various
protective measures to reduce the likelihood of
problems occurring en route. Consequently, it is
necessary that the vehicle be restored to its original
condition during PDS. If this is not done, there is a
possibility that it will not function as intended or that
an un restored item may lead to an unforeseen
incident
The following are some examples of these protective
measures which may vary depending on the vehicle
model, market destination, etc. At times, other special
measures are also taken which are not listed here.
a) Over-inflation of Tires
To prevent changes in the tire tread during shipment,
the tires are inflated above the standard inflation
pressure. If this excess pressure is not released, it
would result in an uncomfortable ride, cause poor
steering stability and promote uneven tire wear.
b) Anti-rust Cover on Brake Discs (for certain
destinations only)
To reduce the occurrence of rust during shipment,
anti-rust covers are placed on the brake discs by the
factory at the time of assembly. These covers must be
removed before delivering the vehicle to the customer
or the brakes will overheat due to lack of cooling
efficiency. If all four wheels are equipped with disc
brakes, these covers will be on all discs.
c) remove Plastic Covering
For protection against damage or soiling during
shipment, the seats, door trim and sun visors are
protected by a plastic covering.
As this covering is flammable, it must be removed
prior to delivery of the vehicle to the customer.
d) Wax Coating on Body Exterior
To protect the exterior paint and chrome components
from the damaging effects of soot, smoke, dirt,
industrial fallout and other harmful articles, the
vehicle is given a wax coating in the final process at the
factory.
As dirt, sand, etc. may have penetrated the wax,
careful not to scratch the paint when de-waxing.
Follow the instructions provided by the manufacturer
of the de-waxing agent (optionally supplied with the
vehicle).
e) Mirrors, Wheel Covers Separately Packed
On some models, the outside rearview mirrors wheel
covers (hub ornaments), etc., are Packed separately to
protect them from damage during transit.