• What is maintenance of motor vehicle.

1
Necessity of maintenance:
• Maintenance is used for obtaining high standards and
able to efficiently utilize , its operation and quality of
services.

2
• Maintenance in general is the process of keeping a
motor vehicle in good running condition.

3
• In general, maintenance includes oil change, chassis

lubrication , tire servicing, engine tune up, etc.,

4
 Quiz

1. By proper maintenance vehicle will have

a. More life.

b. Less life.

c. Less mileage.

5
• What are different types of maintenance?

6
Maintenance can be divided into four types

1. Preventive maintenance.

2. Break down maintenance.

3. Periodic maintenance or Schedule maintenance.

4. Operation maintenance.

7
Preventive maintenance :

• Prevention without break down (or) without giving trouble

on the road, some attention (or) maintenance provided to

the vehicle is called as preventive maintenance.

8
Preventive maintenance has following advantages :

a. Reduce the break down of vehicle.

b. Increased safety due to reduced break down.

c. Less expenses on repairs.

d. Good control on inventory of spare parts.

9
Break down maintenance :

• Break down maintenance is the attention

provided when a motor vehicle become immobilized

due to faults created during running.

10
Periodic maintenance :

• Periodic maintenance (or) Operative maintenance is the

attention provided to motor vehicle after operation for

a specified time (or) covered distance.

11
Operation maintenance :

• Daily maintenance by the operator for proper running

of the vehicle is known as operation maintenance.

12
 Quiz

1. Preventative maintenance is taken to avoid _________.

a. Break down.

b. Servicing.

c. Both a & b.

13
• Periodic maintenance may be included to the maintenance
done for a vehicle daily, weekly, quarterly, yearly.

14
• Periodic maintenance is the maintenance to be carried
after vehicle covering 500 kms, 1000 kms, 2000 kms,
4000 kms and 8000 kms.

15
Periodic maintenance :

• In garages this work is done on the basis of pre-set

schedules so as to avoid road failures and minimize
break down during use of a vehicle.

16
 Quiz

1. The maintenance carried out depending upon period

is known as _________________

a. Preventive maintenance.

b. Brake down maintenance.

c. Periodic maintenance.

17
Breakdown maintenance:

• It is a type of maintenance carried for a vehicle,

which becomes immovable (temporarily)

• This maintenance will occur due to sudden failure of

any running component of a vehicle

18
• Brake down maintenance includes the faults such as
starting difficulties, breakage of components.

Example:- Discharge of battery, then the self starter

does not crank the engine.

19
• Brake down maintenance includes electrical faults.

Example:- 1. Starting trouble due to problem in ignition

system

20
• Brake down maintenance includes problems due to over
heating.
Example:- If leakage of coolant from cooling system, level
of coolant decreases then engine becomes over
heat.
– Fan belt loose/ broken

21
Operation Maintenance:

• It is a type of maintenance in which, day to day

check-ups will be carried out

22
• Operation maintenance of a vehicle includes the
checking / inspection of the following

• Tyre inflation

• Battery

• Brakes

• Clutch

• Smoke colour

23
• Operation maintenance includes problems in Ignition
system, lights which are checked in these maintenance only.

24
 Quiz

1. Brake down maintenance is performed to a vehicle,

Immovable
when it becomes ____________

2. Day to day check-ups will be carried out in

Operation
____________ maintenance

25
 Operation Maintenance

• This maintenance needed to keep the vehicle in

proper working condition.

26
 Operation Maintenance

Operation maintenance also includes checking the

following:
• Tyre inflation.

• Starting system.

• Ignition system.

• Transmission check-up

27
 Servicing And Its Necessity

• Different parts of an automobile usually fail or get

out of adjustment due to long use.

• This long use and high speed running of the vehicle

have greatly increased the necessity of maintenance
and servicing of motor vehicle.

• By proper servicing, the vehicle ride become more

comfortable, safer and easier to drive.

28
 Servicing And Its Necessity

• servicing of vehicle should be done by skilled

technicians.

29
 Quiz

1. Operation maintenance includes_____________.

a) Tyre inflation

b) Engine overhauling

c) Clutch overhauling

d) None of the above

30
 Servicing And Its Necessity

• Servicing in general is the process of either

maintaining or restoring the vehicle to its original high
state of perfection and performance.

• The main aim of servicing is the desire of establishing

or maintaining various original qualities of motor
vehicle like appearance, performance, economy,
safety, and comfort.

31
 Servicing And Its Necessity

• Different parts of an automobile usually fail or get out

of adjustment due to gradual use.

• By proper servicing, motor vehicle will have better

appearance, performance, economy, safety, comfort
and control.

32
 Servicing And Its Necessity

• By proper servicing, the vehicle can be maintained in

a completely trouble free condition, attending to parts
subjected to deterioration.

• The servicing of a motor vehicle can be done as per

manufacturers specifications mentioned in service
manual , as it will provide with the detailed
procedures .

33
 Servicing And Its Necessity

By proper servicing the vehicle will have following

advantages:

• Reduce break down of the vehicle

• Increased safety due to reduced break down

• Less expenses on repairs

• Good control on inventory of spare parts

34
 Quiz

1. By proper servicing the vehicle will be_____________.

a) Trouble free

b) Having more troubles

c) Break down may be increased

d) None of the above

35
 Types Of Servicing

The different types of servicing required for a

motor vehicle are:
• Cleaning of motor vehicle and its parts.

• Inspection and repair of different parts.

• Adjustment.

• Greasing and lubrication.

36
 Types Of Servicing

• Cleaning of motor vehicle and its parts.

• A layer of oil , grease and dirt gets coated to the

motor vehicle and its different parts with passage of

time and usage.

• Before performing servicing of the vehicle the

unwanted layer should be removed.

37
 Types Of Servicing
INSPECTION AND REPAIR OF DIFFERENT PARTS:

• During servicing of a vehicle each part must be

inspected for proper running of vehicle.

• The inspection of vehicle includes:

• Inspection of cooling system:

1. water hose condition

2. fan condition

3. radiator for leaks etc.

38
 Types Of Servicing
INSPECTION AND REPAIR OF DIFFERENT PARTS:

• Inspection of engine lubrication:

1. inspection of oil level indicator.

2.leakage of engine oil.

• Inspection of ignition system:

1. inspection of spark plug.

2. inspection of battery.

3. inspection of distributor condition etc.

39
 Types Of Servicing
ADJUSTMENT:
• All types of adjustments should be made during proper

running of motor vehicle.

• For example, during servicing of a motor vehicle idling

adjustment should be made for proper running of motor

vehicle.

• Brakes must be adjusted during servicing of a motor

vehicle.
40
 Types Of Servicing

GREASING AND LUBRICATION:

• During servicing of motor vehicle grease must be

applied for necessary parts.

• During servicing of a vehicle lubrication oils condition

must be observed if necessary it must be replaced

after checking the condition of oil.

41
 Quiz
1. Which of the following come under type of servicing
____________.

a) Adjustment

b) Cleaning

c) Both a & b

d) None of the above

42
 Cleaning of motor vehicle and its parts

• A layer of oil , grease and dirt gets coated to the

motor vehicle and its different parts with passage of

time and usage.

• Before performing servicing of the vehicle the

unwanted layer should be removed.

43
 Cleaning of motor vehicle and its parts

• The cleaning of motor vehicle is done by hand

cleaning which is cheap and easy

• The cleaning equipment selected and the method

used greatly influence the speed and economy of

cleaning operation

44
 Cleaning of motor vehicle and its parts

• method of cleaning a motor vehicle, depends on

nature of accumulations on the engine and its parts.

• The various cleaning methods used for automobiles

and its parts are steam cleaning, water pressure

cleaning, solution cleaning.

45
 Cleaning of motor vehicle and its parts

• Steam cleaning consists of a compact and mobile

source of high pressure vapor and spray.

• Steam cleaning removes oil, grease and dirt from

engine.

46
 Cleaning of motor vehicle and its parts

• When the steam is directed from a pressure nozzle it

cleans excellently due to high temperature and

impact.

• For cleaning the outside of engine kerosene may be

applied with the help of brush

47
 Quiz

1. Steam cleaning removes which of the following

material_____________.

a) Grease

b) Paint

c) Both a & b

d) None of the above

48
 Lubrication of motor vehicle

Lubrication of motor vehicle involves five

main components:
• Engine lubrication
• Chassis lubrication
• Rear axle and differential lubrication.
• Transmission lubrication
• Universal joint lubrication.

49
 Lubrication of motor vehicle

Engine Lubrication:

• Engine must be lubricated with engine oil of suitable

grade

• For this, petroil system of lubrication for two wheelers

(two strokes) and pressure lubrication for light and

heavy vehicles and two wheelers (four strokes).

50
 Lubrication of motor vehicle

• lubrication of the engine reduces wear and tear

between moving parts .

• This reduces the heat developed during the operation

51
 Lubrication of motor vehicle

Chassis lubrication:
• They are two methods for lubrication of chassis.

• low pressure grease guns.

• high pressure grease compressors.

52
 Lubrication of motor vehicle

• In the first method low pressure grease guns are

used

• In the other method known as high pressure system,

an air compressor is used to force the lubricant into

the bearing under high pressure.

53
 Lubrication of motor vehicle

Rear axle and differential lubrication:

• Rear axle and differential may be lubricated with the
help of suitable grade of oil for reducing the heat
generated during the operation of differential.

• During the servicing of a motor vehicle differential oil

condition must be observed, if it looses its viscosity it
must be replaced.
54
 Lubrication of motor vehicle

Rear axle and differential lubrication:

• The following oils are used for rear axle and
differential.
• Spiral bevel :- (cars) SAE 90 OIL.
• Hypoid axles:- SAE 70 OIL
• Oil forming a protective film due to reaction with
heated surface resulting in reducing metal contact.
55
 Lubrication of motor vehicle

Transmission and universal joint lubrication:

• Gear oil in the transmission acts as lubricant as well as
coolant

• Gear oil is subjected to churning and hence should

have oxidation stability

56
 Lubrication of motor vehicle

• Gear oil should reduce the heat generated during the

operation of gear box

• Oil should be replaced when it looses its viscosity.

• Universal joint may be lubricated with grease

57
 Quiz

1. By lubrication of an engine the heat generated will

be __________.

a) Decreased

b) Increased

c) Constant

d) None of the above

58
 Lubrication of springs

• Lubrication of various components of leaf spring

provides

• smooth riding qualities by permitting the leaves

to slide easily

• prevents rust

59
 Lubrication of springs

• For lubrication of springs compressed air is used to

spray the lubricating oil for penetrating between the
leaves

• While lubricating, the spring defects like broken

leaves or loose clips or nuts should be properly
checked and tightened or replaced.

60
 De-carbonizing of engine parts

Carbon is formed in the engine due to the

following reasons:-
1. Improper idling
2. using wrong grade engine oil.
3. Using more oil than required quantity.
4. Worn out parts
5. Prolonged usage of vehicle, without servicing

61
 Decarbonisation

Carbon deposition in engine leads to :

• Less pick-up
• Poor mileage
• Black color smoke

62
 Decarburization

Carbon deposits can be removed by the

following methods:
• Scraper method

• Oxygen method

• Chemical method

63
 Precautions to minimize carbon
deposition

• Avoid too rich petrol and air mixture by properly

adjusting carburetor.
• Avoid to use wrong grade or poor grade of oil.
• Avoid unnecessary idling.
• Proper maintenance of engine components

64
 Quiz

1. Which of the following is the reason for carbon

formation to an engine _____________.

a) Unnecessary idling

b) Rich mixture of supply

c) Both a & b.

d) None of the above

65
 Servicing of a petrol engine

The following components need inspection/service :

• clean, inspect and install spark plug.

• Test the battery charge , recharge (or) replace the

battery if required.

66
 Servicing of a petrol engine

• Test the cylinder compression

• Clean the battery and check cables for cracks,

worn out cable insulation

67
 Servicing of a petrol engine

• Tighten water pump belt

• Clean air filter element and reinstall.

• Test the fuel pump vacuum

68
 Servicing of a petrol engine

• Inspect and clean fuel pump screen and sediment

trap.

• Tighten cylinder head nuts and manifold bolts to

specified torque.

• Test the fuel pump, pressure should be as per

specifications
• repair the pump after removal from the engine.
69
 QUIZ

Petrol engine consists of the following

a) Spark plug.

b) Carburetor.

c) Both a & b.

d) None of the
above

70
 Servicing of petrol engine.

• Check spark plug lead wires for any damage.

• Test and adjust (or) repair the distributor according to

the requirements.

• Inspect ignition primary circuit for faulty insulation (or)

poor connection.

71
 Servicing of petrol engine.

• Remove, clean and adjust carburetor

• remove gum deposit from the throttle valve.

72
 Servicing of petrol engine.

• Adjust the carburetor idle and make correction for

any vacuum leak at inlet manifold
• The idle speed (or) the idle fuel adjustment should
also be set
• Adjust ignition timing

73
 Servicing of petrol engine.

• Adjust valve tappet clearance with the help of feeler

gauge.

• Test the cylinder compression.

• Check the bendix drive condition of starting motor for

any damage of teeth of bendix drive.

74
 Servicing of petrol engine.

• road test the vehicle.

• If any problem encountered during road test may be

rectified

• Then wash the vehicle.

75
 Servicing Equipment
Introduction
• For proper running and efficient performance of vehicle
effective maintenance is prerequisite.

• Therefore Automobile maintenance shop should be equipped

with important Installations, such as
• Car washing machine

• Vehicle hoist

• Air compressor
76
Scrubbing and Cleaning With Pressurized Water

Fig 1
77
Washing In Progress

Fig 2
78
Car Washing Machine

Fig 3
79
 Car Washing Machine:

• It is most essential that cars and commercials vehicles should

be cleaned for removal of grease, oil, mud and other corrosive

deposits

• It is generally done by a spray of water with a solvent at high

pressure i.e. 25kg/cm2

80
 Construction

• Car washer comprises a pump driven by electric motor, water

tank, suction and delivery valves, float, pressure gauge, hose

and nozzle

81
 Working

• The motor driven pump lifts and compresses water from tank

• High pressure water is delivered to nozzle through hose pipe

• Nozzles can be adjusted so that water pressure and spray can

be regulated

82
 There are two types of car washer :

• Car washer with single hose, which can be used to wash only

one vehicle at a time

• Car washer provided with two hoses, which can be used to

wash two vehicles at a time

83
The following pictures shows the washing of a vehicle

automatically with washing equipment in a washing room:

84
Washing Room

Fig 4
85
Scrubbing Brushes Through Which Vehicle
Moves

Fig 5
86
Scrubbing Operation After Applying Cleaning
Solvent To Vehicle

Fig 6
87
After Completion Of Washing

Fig 7
88
 Quiz

1) Car washer with single hose, can be used to

wash______ Number of vehicles at a time

a) Three

b) Four

c) One

d) None of the above

89
 Quiz

2) Car washer comprises a pump which is driven by

a) Electric motor

b) Generator

c) Starter

d) All of above

90
 Vehicle Hoist
• Hydraulic hoist is one of the essential equipment of service
station
• Types of hoists used in Automobile workshop are

• Drive on lift or single post hoist

• Two post hoist
• Four post hoist

• Usually single post hoist is found in most of the Automobile

workshops

91
Vehicle Hoist

Fig 1
92
• The hoist comprises a platform, which is fixed on the top of

plunger working in hydraulic cylinder

• Normally the platform will be at ground level and will be

raised with hydraulic pressure acting on the ram

• High pressure air from the compressor acts on oil surface

when valve `a’ is actuated

• Oil rushes through pipe line into hydraulic cylinder through

another pilot valve `b’

93
• The pressurised oil enters the bottom of cylinder and lifts the

plunger up

• The vehicle on the platform attached to the plunger is thus

lifted up

• Raising of vehicle from ground level will provide accessibility

for washing, cleaning and servicing

94
• For lowering the vehicle, valve ‘b’ is brought to the original

position

• Due to self weight of vehicle and platform, plunger descends,

gradually pushing oil back into reservoir through the

restriction valve `c’

• The speed at which the vehicle to be lowered can be adjusted

regulating the flow.

95
 Two post hoist :

• This type of hoist is generally used for inspecting various

transmission components under the chassis for any leakages

and defects

96
Two Post Hoist

Fig 2
97
Rare View of two Post Hoist

Fig 3
98
Four Post Hoist

Fig 4
99
 Four Post Hoist
• This type of hoist is generally used for removal of wheels
• The removed wheels are generally sent for the purposes like
wheel balancing, replacing new tyres, throwing of rims etc
• In this type of hoist there is a provision for the vehicle to enter
on to the platform with the help of angular extension platform
• This type of hoist is also used for inspecting the vehicle
components under the chassis

100
Typical Four Post Hoist

Fig 5
101
Folding Type Four Post Hoist

Fig 6
102
 Folding Type Four Post Hoist
• Folding type four post hoist is used in the garages where the

working area is limited

• This type of hoist can be stopped at any height we required

with the help of linkages which are operated by hydraulic

pressure

• After folding down the hoist, the area can be used for parking

vehicle
103
 Quiz

1) The four post hoist is generally used for

a) Washing Purpose

b) Inspecting Various Components

c) Both

d) None

104
 Quiz

2) The hoist comprises a plat form, which is fixed on the top of

ram working on :

a) Hydraulic cylinder

b) Master cylinder

c) Oil cylinder

d) All of them

105
 Air Compressor:
Principle of operation :

Fig 7

106
 Air Compressor

•Principle of operation :
• It is a machine capable of compressing and delivering

air at desired pressure

• Drive by prime mover (engine or electric motor)

107
 Air Compressor

• Principle of working :

• It takes in atmospheric air, compresses it and delivers the

high pressure air to receiver (storage vessel)

• From storage vessel it may be conveyed by pipe line to

where it is required

108
Air Compressor

Fig 8

109
Air Compressor

Fig 9

110
 Air Compressor

Function :

• The function of air compressor is to compress the

atmospheric air thereby increasing its pressure , which can
be used for other applications

111
 Air Compressor
Uses of compressed air :
Compressed air is one of the best sources of energy and has
numerous applications

• For operating pneumatic hand tools

• For spray painting

• Equipments like grease guns

112
 Air Compressor
Uses of compressed air :

• To inflate automobile tyres

• Spark plug cleaner/tester

113
 Air Compressor

Depending on design and principle of operation , compressors

can be divided into

1.Reciprocating compressor

2. Rotary compressor

114
 Air Compressor
Reciprocating compressor

Fig
115
10
 Air Compressor
Rotary compressor

Fig
11 116
 Air compressor

1.Reciprocating compressor :

Compression is due to reciprocating motion of piston

117
 Air compressor

Rotary compressor :

Compression is due to rotary motion of the rotor

118
 Quiz

(1) Which one of the following is not function of compressed air

( ) d
(a) To clean engine
(b) To spray paint
(c) To inflate tyre
(d) To adjust tappets

119
 Air Compressor

Uses of compressed air in Automobile service

station:

• To provide pressure to water while washing a vehicle.

• To dust out the engine and vehicle interiors .

• To spray lubricating oil

120
 Air Compressor
Uses of compressed air:

• To spray paint

• To inflate tyres

• To assist in greasing operation

• To lift the vehicle hoist

• For operating pneumatic hand tools

121
 Air Compressor

Uses of compressed air:

• spark plug cleaner

• For operating special tools

122
 Air Compressor

• Classification :
• The reciprocating compressors may be classified as below:
• Depending on operation:
a) Single Acting: Air is compressed by one side of
piston

b) Double Acting: Air is compressed by the both

sides of piston

123
 Air compressor

• Number of stages employed:

a) Single stage compressor :

Air is compressed in single cylinder.

b) Multi stage compressor

Air is compressed in more than one cylinder

• Method of cooling:
a) Air cooled compressor.
b) Water cooled compressor.

124
Air Compressor

Fig 1
125
 Fig 2
Twin cylinder compressor

126
 Air Compressor

• A compressor is a machine capable of compressing and

delivering the air at a desired pressure.

• It takes in atmospheric air, compresses it and delivers the

high pressure air to a receiver or storage tank.

127
 Air compressor

Construction :

It can be compared with the working of I.C engine

• The air compressor is coupled to electric motor.

128
 Air compressor

Construction :
Reciprocating air compressor

Fig 3 129
 Air compressor

Construction :
Reciprocating air compressor

Fig 4
130
 Air compressor
Construction : (Reciprocating type)

• It consist of a cylinder in which piston reciprocates by

means of an external source

• The cylinder cover accommodates two valves , one is intake

valve and other discharge valve

131
 Air Compressor

Construction :

Both valves open and close automatically due

to pressure difference

132
 Air Compressor

Working :
When electric motor is switched on, it drives the
crankshaft of the compressor by a belt and pulley
arrangement

133
 Air Compressor
Working :

Fig 5
134
 Air Compressor

Working :
The crank shaft inturn,causes the piston to reciprocate

135
 Air compressor
Working :

• During downward movement of piston , the inlet valve

opens due to pressure difference

• Atmospheric air enters into cylinder

136
 Air Compressor
Working :

Fig 6
137
 Air Compressor

Working :

• During upwards movement of piston inlet valve closes

• Air will be compressed there by increasing its pressure

138
 Air Compressor

Working :
• As the piston reaches T.D.C , delivery valve opens
• Compressed air is discharges to a receiver
• Receiver is a storage tank , from where air is disposed
to other applications
• The cycle repeats in this way

139
 Air Compressor
Working :

• An automatic pressure controller is provided between motor

and main current line.

• It is to break the circuit when the pressure inside the air tank
reaches a maximum value.

140
 Air Compressor
Working :

• Pressure gauge is fitted on air tank which indicates the

compressed air pressure within the tank.

141
Specifications of Air compressor (For automobile
service station )
adopted for auto servicing unit :

• 1 HP rating directly coupled

• Piston displacement - 5 cm3

142
 Air Compressor

Specifications of Air compressor (For automobile

service station )

• Maximum working pressure 8 kg/cm2 ( 14 PSI )

• Provided with intake air filter

143
 Air Compressor
Specifications of Air compressor (For automobile
service station )

• 220 volts supply

• Air receiver capacity of 45 litres with a drain plug.

144
 Quiz
1. Compressor draws air into the cylinder during which stroke
(a) Suction
(b) Compression
(c) Both a & b
(d) None ( )
a

145
 Quiz
2. Which one of the following gauge is used to check
the pressure of compressed air in the tank
a) Feeler gauge
b) Plug gauge
c) Pressure gauge
c
d) None ( )

146
 General Lubrication

• The moving points of an automobile should be periodically

lubricated.

• This reduces friction in its parts and thus prolongs its life.

147
Lubricating points of a vehicle are :

• Engine

• Clutch

• Propeller shaft

• Gear box

• Rear axle

148
 Points of Lubrication

• Steering system

• Suspension system

• Braking system

• Miscellaneous

149
 Points of Lubrication

Engine :

• Interior parts of an engine

• Moving mechanism in the engine

150
 Points of Lubrication

• Parts moving outside the engine

Ex: fan bearing, dynamo or alternator bearing,

starter motor bendix mechanism,
Operating linkages of carburetor or
fuel injection pump

151
 Points of Lubrication

Clutch :

• Various linkages of clutch

152
 Points of Lubrication

Gear box :

• Internal moving parts of the gear box

• Joints of the forks which move or shift the gears

153
 Points of Lubrication

Propeller shaft :

• At universal joints

154
 Points of Lubrication
Rear axle :

• Interior portion of the rear axle and final drive

155
 Points of Lubrication

Steering system :

• Interior parts of the steering gear box

• Bearings of the steering column

• Joints of the steering system

156
 Points of Lubrication

Suspension system :

• Leaf springs and bushes in the shackles

• Joints of the levers in the front suspension

157
 Points of Lubrication

Braking system :

• Joints in the brake pedal

• Mechanical hand brake linkages

158
 Points of Lubrication

Wheels :

• Front and rear wheel hubs

159
 Points of Lubrication

Miscellaneous parts :

• Hinges of doors

• Hinges of bonnet

• Hinges of luggage boot and lock

• Seats, etc.,
160
 Quiz

1) Which one of the following will not cover under lubricating

points of an engine ( ) a

(a) Interior parts

(b) Fan bearing
(c) Carburetor linkages
(d) Leaf springs

161
 Time of lubrication

• Every part does a certain amount of work.

• The lubrication time varies depending upon the amount of

work a part does and the time it will take to wear out.

162
 Time of lubrication

Example: In case of engine

• The internal parts of the engine operate at high speeds

and temperatures

• Therefore these parts need to be lubricated continuously.

163
 Time of lubrication

• For this an oil pump is installed inside the engine.

• It supplies oil to various parts continuously.

• The driver should check daily, whether the oil in the engine
sump is at the correct level.

164
 Time of lubrication

• Once the engine has covered 5000km / as per manufacturer

specifications , the engine oil should be replaced along with
filter.

• Vehicle manufacturers provide instructions about when

various parts need lubrication.

• These are calculated on the basis of the work done by various

parts.
165
 Type of lubricant

• The lubricant to be used, depends upon the pressure between the

parts, friction and the speed of their movement.

• It also depends upon the temperature attained by the parts.

• Oil and grease are the main lubricants.

166
 Type of lubricant

• There are different types of oil lubricants, which are having

different viscosities.

• Therefore SAE (Society of Automotive Engineers) numbers

are given on the basis of grades of oil.

167
 Type of lubricant

• There are also different types of greases.

• The manufacturer indicates type of grease to be used for a

particular part.

• While lubricating with grease, the instructions of the

manufacturers should be followed.

168
 Quiz
• The lubrication time varies depending upon the amount of -----
---- a part does and --------- it will take to wear out.

(Ans: work, time)

• Generally in a four wheeler the engine oil should be replaced
for every:
(a) 2000KM
(b) 1500KM
(c) 5000KM
(d) 7000KM ( c )

169
 Methods Of Lubrication

• In a vehicle, for lubrication purpose various lubricating

points are provided.

• Various lubricating points have oil holes or nipples.

• The oil or grease is forced through these points.

170
• For this purpose an oil can or oil gun or grease gun is used .

• This depends upon the type of oil and type of points provided
in the vehicle.

171
The following diagram shows the various parts of the chassis
which need to be lubricated

172
Lubrication Points Of A Car

Fig 1
173
Different parts of a chassis which are to be lubricated are
shown in the following table:

174
 Typical Lubrication Chart
No .as Parts to be Work to be carried Type of
found in lubricated/ out lubricant to be
diagram checked used
Daily
1 Engine oil Check the oil level. SAE 20W40
sump If the level is engine oil
reduced, add fresh
oil so as to bring it
to the required level
Every 500 km run
1 Engine oil Check the oil level SAE 20W40
sump and top up if engine oil
necessary
175
Every 3000 km run
No .as Parts to be Work to be Type of
found in lubricated/check carried out lubricant to be
diagram ed used
1 Engine oil sump Check the oil SAE 20 w 40
level and top up engine oil
if necessary
2 Distributor Turn the grease Grease which
container cap can melt at
by two or three very high
rotations temperature
3 Clutch pedal Apply the Chassis
shaft grease in the grease
joints
176
 No .as Parts to be Work to be Type of
found in lubricated/ carried out lubricant to
diagram checked be used

4 Arms of the Apply the Chassis

front grease in the grease
suspension joints
5 Steering rods Apply the Chassis
grease in the grease
joints
Bushes of the Apply the Chassis
6 cross shaft of grease in the grease
the steering joints
fear box
177
Every 5000 km run
No .as Parts to be Work to be carried Type of
found in lubricated/ out lubricant to be
diagram checked used
1 Engine oil Remove the oil and SAE 20W40
sump replace with fresh oil
2 Distributor Apply the grease in Grease which
the grease cap of the can resist high
distributor and turn temperature
the cap. Smear
grease on the cam of
the contact breaker

178
 No .as Parts to Work to be carried out Type of
found in be lubricant to
diagram lubricate be used
d/
checked
7 Gear Check the oil level in SAE 90 oil
box the gear box. If the
level of oil is reduced,
add fresh oil so as to
bring it to the required
level

179
No .as Parts to be Work to be carried Type of
found in lubricated/ out lubricant to
diagram checked be used

8 Propeller Apply grease on the Chassis

shaft nipples. grease
9 Rear axle Check the oil level. If SAE 90 oil
the oil level is not at
the correct level pour
fresh oil till it reaches
full level of the plug

180
No .as Parts to be Work to be carried Type of
found in lubricated/ out lubricant to be
diagram checked used

10 Steering Check the oil level. SAE 90 oil

box If the oil level is not
correct, pour fresh
oil till it reaches the
correct level

181
Every 12000 km run

No .as Parts to be Work to be Type of

found in lubricated/ carried out lubricant to
diagram checked be used
Rear leaf Wash the leaf Graphitized
11 springs springs with oil
kerosene. Then
apply carbon
graphite oil in
between the
levels

182
No .as found in Parts to Work to be Type of
diagram be carried out lubricant to be
lubricated/ used
checked
Front Lubricate the Wheel bearing
12 wheel wheel grease
bearing bearings
using grease
13 Generator Use a few SAE 30 engine
/ drops of oil oil
Alternator

183
Every 24000 km run
No .as Parts to be Work to be carried Type of
found in lubricated/ out lubricant to be
diagram checked used
7 Gear box Remove the oil and SAE 90 oil
flush it with
9 Rear axle kerosene, when the
kerosene is also
emptied, fill up with
fresh oil
14 Starter Apply motor grease Special starter
motor on the motor motor grease
bearing parts

184
• Along with lubrication, the water level in the radiator should
be checked.
• Tyres should be checked for proper inflation.
• If all this is done, the vehicle will run properly and last long.

185
 Quiz

1) Distributor should be lubricated at every:

(a) 2000KM ( )b
(b) 5000KM
(c) 6000KM
(d) 8000KM

186
2) Gear box oil should be replaced at every:

a) 6000KM ( ) d

b) 8000KM

c) 12000KM

d) 24000KM

187
 Methods Of Lubrications

• In a vehicle for lubrication purpose various lubricating

points are provided.

• Various lubricating points have oil holes or nipples.

• The oil or grease is forced through these points.

188
• For this purpose an oil can or oil gun or grease gun is used .

• This depends upon the type of oil and type of points provided
in the vehicle.

189
 Lubrication Equipments

• Lubrication is the most important factor in the maintenance of

the vehicle.

• If this is neglected in any way, the mechanism wears more

rapidly and occurrence of troubles increase.

190
 Lubrication Equipments

• On the other hand liberal lubrication means long life and

efficient running with freedom from trouble.

191
 Lubrication Equipments

• To lubricate certain components beneath the chassis ,

grease guns and high pressure lubrication equipments are

used.

192
 Grease Guns

• Grease guns are used to lubricate the chassis components with

grease.

193
• Several types of hand operated grease guns are available

They are :

• Push type
• Handle type
• Bucket type

194
 Push Type Grease Gun

2 Push rod
2
nozzle spring
cylinde piston
r

Fig 1
195
 Push Type Grease Gun

• It consists of casing.

• To one end of the grease gun,nozzle is provided.

• Inside the casing piston is connected to the push rod.

• In between the pushrod and piston a spring is provided.

196
 Push Type Grease Gun

Working :

• casing is filled with grease by removing push rod assembly

with piston.

• After filling the grease push rod assembly with piston is fitted.

197
 Push Type Grease Gun
Working :

• Now the grease gun is positioned to the part which is to be

lubricated.

• Press the push rod in the forward direction.

• Due to which the piston moves forwards by creating pressure

inside the casing , compressing the grease.

198
 Push Type Grease Gun

• Further movement of the push rod causes the compressed grease to

exit out of the casing and penetrates into the vehicle component
through nozzle and grease nipple.

199
 Push Type Grease Gun

Limitations :

• This type of grease gun is very tiresome to the operator

200
 Quiz

• In a push type grease gun the compressed grease will exit out
through ---------

(Ans: nozzle)

201
Hand Operated Grease Gun

202
 Filling
cap Pressing
handle

spring
Flexible
hose

casing

Greasing
end Push rod
Fig
203
1
 Hand Operated Grease Gun

Construction:
• It is a portable type of grease gun.

• It consists of a casing, in which grease is filled by

pulling back the push rod.

• The push rod is placed against a spring pressure inside

the casing.

204
 Hand operated grease gun

Construction:

• After filling the grease in the casing the filling cap is

tightened.

• One end of the filling cap is provided with spring loaded

pressing handle.

205
 Hand Operated Grease Gun

Construction:

• Due to spring force , the handle will come to original

position after every operation.
• To the other end of the filling cap, flexible hose is
provided to deliver the grease.

206
 Hand Operated Grease Gun

Construction:

• At the end of the flexible hose, adapter is provided.

• In this adapter the greasing nozzle is seated.

207
Hand Operated Grease Gun Operation

Fig 2
208
 Hand Operated Grease Gun

Operation:

• The portable hand operated grease gun is placed against

the lubricating part of the chassis.

• The flexible adapter is pressed against the greasing

nipple of the part to be lubricated.

209
 Hand Operated Grease Gun

Operation:
• Now press the handle of the gun, so that the grease from
the casing will be emerge out.

• This emerged grease will enter into the lubricating part

through flexible pipe, adapter and from the greasing
nozzle.

210
 Hand Operated Grease Gun

Operation:

• While the greasing operation is in progress the push rod

will move forward in the casing due to spring pressure.

211
 Hand Operated Grease Gun

Operation:

• Due to which the grease is forcibly exited out of the

casing.

• Continue the greasing operation, till the fresh grease

appears at the opposite end of the greasing component.

212
Types of greasing nipples:

• Straight

• Inclined

213
Straight Nipple Ball loaded end
through which grease
enters

Threaded end
which in turn
connects the
greasing part
Fig 3
214
 Inclined Nipple
Inclined end
Ball loaded end
through which grease
enters

Threaded end
which in turn
connects the
greasing part

Fig 4
215
Types of greasing nipples:

• Straight type:

• This type of greasing nipple is used, where

accessibility is more for greasing operation.
• Ex: universal joints

216
Types of greasing nipples:

• Inclined type:

• This type of greasing nipple is used, where

accessibility is less for greasing operation.

• Ex: Steering linkages

217
 Quiz

• In a hand type grease gun the handle return back to its position
by -------------
(Ans: spring pressure)

• ------------ nipple is used where accessibility is less for

greasing operation.
(Ans: Inclined)

218
 Lever operated Grease gun

Central tube

Fig.1

219
 Lever operated Grease gun
clamps

Adaptor
Handle & lever

Nozzle pipe Nozzle

valve Flexible
pipe
cap
Steel
container

Fig.2
220
 Lever operated Grease Gun

Construction:

• It consists of a bucket type steel container.

• To the cap centre metal tube is provided.

221
 Lever operated Grease Gun

Construction:

• To the top of the central tube a valve and hand lever are

connected.

• To the other end of the valve a flexible pipe connection is

given.

222
 Lever operated Grease Gun

Construction:
• At the end of the flexible pipe an adaptor and nozzle are
connected.

223
 Lever operated Grease Gun

Operation:
• Initially, the clamps of the cap are loosened.

• The cap along with central tube is removed.

224
 Lever operated Grease Gun

Operation:
• Fill suitable grease in the container.

• Now fix the cap and tight the clamps.

225
 Lever operated Grease Gun
Operation:
• press the handle for few strokes.

• As soon as we press the handle, the grease from container will

be sucked into central tube.

226
 Lever operated Grease gun

Operation:

• Further operation of handle, the grease will enter into the valve

(at the top of the cap) of the central tube.

• From the valve the grease will reach the nozzle through

flexible pipe.

227
 Lever operated Grease Gun
Operation:

• Now, connect the nozzle to the greasing nipple of the vehicle

component.

• Further moving the handle up and down the grease will

emerge out of the nozzle and enter into the component to be

lubricated.

228
 Lever operated Grease Gun
Operation:

• Continue this operation till the fresh grease appears at the

opposite end of the vehicle component.

229
Compressed air operated grease gun

230
Handle with trigger

valve cap

Connection to
compressed air
Nozzle pipe
Nozzle

Flexible pipe Steel

container

Fig.3
Rollers 231
 Compressed Air operating Grease Gun

Construction:

• It is similar to the hand operated bucket type grease gun.

• This type of grease gun is used where more pressure is

required for greasing

232
 Compressed Air operating Grease Gun

Construction:

• This type of grease gun is used where the more pressure is

require for greasing certain vehicle components

• Ex: Heavy vehicle – leaf spring

– universal joints

233
 Compressed Air operated Grease Gun
Construction:
• It consists of steel container.

• To its cap a central tube is connected.

234
 Compressed Air operated Grease gun
Construction:
• On the top of the central tube a two way non return valve is
fitted

• To one end of the valve a flexible pipe is connected.

235
 Compressed Air operated Grease Gun
Construction:

• At the end of the flexible pipe a grease gun with a nozzle is

provided.

• To the another opening of the valve, a passage is provided.

236
 Compressed Air operated Grease Gun
Construction:

• Through which, a flexible pipe should be connected.

• The other end of this flexible pipe is connected to air

compressor.

237
 Compressed Air operated Grease Gun
Operation:

• The pneumatic grease gun is positioned near to the vehicle.

• Allow compressed air supply from the air compressor.

238
 Compressed Air operated Grease Gun
Operation:

• The compressed air now reaches the grease container and

pressurize the grease.

• This pressurized grease will be lifted up and reaches the nozzle

end through central hub and flexible pipe.

239
 Compressed Air operated Grease Gun

Operation:

• Now connect the greasing nozzle to the nipple of the vehicle

component.

• Press the trigger handle, so that the pressurized grease which is

to emerge out, will enter into the component through nozzle

end and greasing nipples.

240
 Compressed Air Operated Grease Gun
Operation:
• Press the trigger until the fresh grease appears at other end of
the vehicle component.

241
 Quiz
1. In lever operated grease gun the grease from central tube

Flexible pipe
goes to nozzle through________________

2. In compressed air type grease gun, the grease will emerged

trigger
out by pressing _________of the grease gun

242
High pressure lubrication equipment

243
 Air regulator
valve

Electric
motor

Figure 1
244
 High pressure lubrication equipment
Construction :

• The purpose of this lubrication equipment is to provide

greasing to the vehicle components which requires high

pressure.

• Ex: Heavy vehicles – King pins, Universal joints etc.

245
 High pressure lubrication equipment

Construction :

• In this type, grease tin is directly mounted on the reservoir

of air compressor.

• This greasing equipment consists an air compressor which

is operated by electric motor through belt drive.

246
 High pressure lubrication equipment
Construction :

• To the extreme right top of the air reservoir an outlet pipe is

provided with a pressure gauge which in turn is connected

to the air regulator valve.

247
 High pressure lubrication equipment

Construction :

• The function of the air regulator valve is to send air at

suitable pressure to the grease tin.

• The air pressure can be varied by adjusting the nut

provided on this valve.

248
 High pressure lubrication equipment
Construction :

• One end of flexible hose is coupled to air regulator valve

outlet and the other end is connected to grease gun.

249
 High pressure lubrication equipment
Operation :
• Compressor sucks air from atmosphere, compresses it.

• This air at high pressure is stored in reservoir

250
 High pressure lubrication equipment

Operation :
Note:

• Drain the air reservoir once in a week to remove

watervapour by unscrewing the drain plug .

• After draining ensure that the drain plug is fully

tightened.

251
 High pressure lubrication equipment
Operation :
• If air under pressure is supplied to grease tin.

• The grease in the grease tin gets pressurized due to the

compressed air.

252
 High pressure lubrication equipment

Operation :
• Connect the nozzle of the grease gun to the nipple of the
component to be greased

• Press the trigger of the grease gun, which allows

pressurized grease to be enter into the component.

253
 High pressure lubrication equipment

Operation :
• Continue this process till fresh grease appears at opposite
end of the component.

254
 Quiz

1. The grease tin of high pressure lubrication equipment is

On top
positioned ______________ of the air reservoir.

2. The compressed air in the reservoir is controlled by

Cut-off
_____________ switch.

255