Ambulance Preventive Maintenance Manual
Contents
1. AMBULANCE PREVENTIVE MAINTENANCE MANUAL Government of Alberta FOREWORD As emergency response vehicles ambulances must be maintained in safe and reliable operating condition at all times While occasional mechanical failures are inevitable much can be done to prevent them The provincial Safety Inspection Audit Program which started in 1999 serves two purposes the safety inspections done by the operator s mechanics are audited and the operator s preventive maintenance PM program is evaluated These evaluations have revealed a wide range of PM programs Some operators had very comprehensive PM programs with regular detailed inspection of all components Other programs were limited to change oil every 5 000 km and fix it if it breaks This has led in more than instance to poor vehicle performance and premature component failure Through discussions with operators and mechanics during and after the audits we have found that a new level of awareness often leads to a safer more reliable fleet Several operators asked where they could get more information We saw this as an opportunity to provide a framework for developing solid PM programs This manual was compiled in consultation with a number of operators who have shared their PM programs with us Preventive maintenance should be an important part of every ambulance operator s written maintenance policy which is a required component of the ambulance licensing2. In severe duty applications it is very important to inspect and service the differential at regular intervals to prevent premature failure Failures can be caused by worn or loose bearings which may not be noticeable while driving B 43 Differential Backlash Measure backlash on differential with a dial indicator as per manufacturer s specifications Checking the backlash can help determine worn loose or improperly fitted parts and prevent premature failure B 44 Shock Absorbers Disconnect one end of each shock absorber Inspect for weak damaged or seized shocks This is done to ensure proper operation of vehicle for stability You may not be able to determine if a shock is working correctly without removing one end and checking operation B 45 Cables heater throttle and brake Check heater cables for proper routing and operation Check for stiff or seized cables Lubricate with appropriate lubricants Ensure cable movement is not restricted This will ensure proper operation and can prolong the life of the cables SECTION C BODY C 1 Clearance Lights Check lights for proper operation and secure mounting Check for cracked damaged or missing lenses C 2 Headlamps Check the headlamps for proper operation and proper aim Check for cracked or damaged lenses Vehicle vibrations can cause headlamps to loosen thereby causing improper aim and poor visibility If headlamps are replaced it is good practice to re aim them C 3
3. travel Refer to B 20 B 26 Springs Bushings and Shackles Check for cracked or damaged springs Check the bushings for excessive clearance Check shackles for damage Ensure spring mounts are secure Excessive wear can cause vehicle instability and poor handling B 27 U Bolts and Mounting Check for damaged cracked or loose u bolts and mounts Due to vehicle vibrations u bolts may loosen or crack Torque u bolts to manufacturer s specifications B 28 Frame and Rivets Check the frame rails for cracks bends or damage Ensure that rivets are secure and fully intact Frame rivets may loosen and frames rails may crack or bend under the high stress of ambulance operation Inspecting these components could prevent major damage to the vehicle B 29 Differential Stops Check that the differential stops are present and that they are not damaged worn or loose Differential stops help ensure vehicle stability and prevent damage to springs shackles etc while travelling over rough terrain B 30 Fuel Lines Check that routing is proper and lines are secure Check for leaking kinked corroded or damaged steel fuel lines Check for leaking cracked swollen or brittle rubber fuel lines When lines become brittle normal vehicle vibration can cause cracks which may lead to leaks B 31 Fire Extinguisher charge date Check that the fire extinguisher is fully charged and is up to date B 32 Flares Triangle Reflectors Check the traffic warni
4. Breaker Function On board Inverter Function Inverter powered Outlets Block Heater Connection amp Operation Cable Connections 12 VOLT SYSTEM D 62 D 63 12 Volt Outlets amp Plugs Check Ground All Circuits vi 15 15 15 16 19 19 MODULAR BODY D 64 D 65 D 66 D 67 D 68 D 69 D 70 Exterior Doors Door Latches amp Pins Door Hinges Latches amp Locks Entrance Doors Door Seals Exterior Compartments Door Closers amp Hold Open Devices INTERIOR OF MODULE 0 71 0 72 0 73 0 74 0 75 0 76 Sliding Cabinet Doors Latches amp Locks Interior Cabinetry Grab Rails amp Door Pulls Shelving Tri or Edge Mouldings Squad Bench amp CPR Seat Lid Latch amp Hold Open Devices MEDICAL EQUIPMENT D 77 D 78 D 79 D 80 D 81 D 82 Cot Anchor Main Cot Lubrication Main Cot Inspection Cot Mattress amp Straps Secondary Cot Portable Stretcher Scoop Stretcher SECTION E SAMPLE FORMS Schedule A Schedule B Schedule C Schedule D vii 23 26 28 DEDICATION This manual is dedicated to Mr Vern Burton 1953 2001 As a part time ambulance attendant who worked with St Paul and District Ambulance Vern understood the need for fleet safety and reliability As an emergency vehicle technician Vern was a highly trained mechanic who specialized in maintenance and repair of ambulances and fire apparatus in northeastern Alberta His vision and his passion for the safety of
5. Check Electric Oxygen Solenoid Valve Function if Applicable Check operation of the electric control to ensure that it stops and starts the flow of oxygen Check wire connections for loose wires and dirty or corroded grounds D 49 Main Tank Retainers Check main oxygen tank holder for proper fit Check for misaligned or loose parts These tanks are very heavy and can cause a lot of damage if they come loose during a collision D 50 Portable Oxygen Tank Retainers Check portable oxygen tank holders for proper fit Check for misaligned or loose parts Portable tanks can hurt patients and attendants if they come loose during a collision D 51 Main Tank Regulator Function Check main tank regulator function If the regulator is adjustable check that the pressure is set accurately Adjust the pressure downwards and then back to specified pressure 17 ON BOARD SUCTION SYSTEM D 52 Provincial Standard for On Board Suction The suction unit must develop a minimum vacuum of 300mm 30 cm Hg in 4 seconds or less Clamp off the suction hose and turn on the switch Monitor the gauge to ensure that the system meets the standard D 53 Suction Pump Filter and Motor Remove outlet filter from suction pump and check for dirt and contamination Clean or replace as required Regular servicing is important in order to get full capacity out of the suction unit Check motor and wiring for signs of overheating Check for loose or corroded wire terminals
6. and ground straps D 54 Suction Regulating Valve Check the function of the regulating valve making sure it is operational Some suction units use a threaded needle valve It may be closed such that no vacuum will be created within the suction jar As the valve is first turned open it will allow maximum vacuum Further rotation of the valve allows bypass air to enter thereby limiting the amount of vacuum that can be built up Other suction units use a slide valve and or a variable speed motor switch to regulate the amount of vacuum D 55 Leak Test Suction System Ensure that the regulating valve is set for maximum suction With the unit running pinch off the hose and build up vacuum Turn the motor off and observe the gauge If there is a drop in vacuum check for leaks at all connections seals and at the collection jar 110 VOLT SYSTEM D 56 Shoreline Connector on Exterior of Body Check the shoreline plug connection for loose or corroded terminals Remove mounting screws remove plug from wall and check connection of cable to the plug It is important that the connections are sound to prevent arcing and poor power flow Components powered by a faulty shoreline may not function properly Some components usually motors may leak power and burn out D 57 GFI Breaker Function if Equipped Push the Test button on the ground fault interrupt breaker to make sure it trips Press the Reset button and ensure that it resets and holds D 58 On
7. board Inverter Function Check on board inverter operation With the ambulance s engine running turn the inverter on Check the power output with an AC meter and compare the output to the specification sheet on the inverter 18 D 59 Inverter powered Outlets With an AC voltmeter check the function of each 110 volt outlet supplied by the inverter If the voltage varies check all connections before removing inverter for repairs Sometimes loose or corroded connectors can cause voltage fluctuations D 60 Block Heater Connection and Operation Check condition of underhood wiring and block heater operation This can be done with an AC voltmeter You should be able to hear the block heater sizzling when it is plugged in and the engine is cold Check that it cuts out when it reaches the cutout temperature set out in the manufacturer s specifications D 61 Cable Connections Check to see that connections on cables to batteries isolators and inverter are tight With a DC voltmeter check that the proper current goes to them 12 VOLT SYSTEM D 62 12 Volt Outlets and Plugs Check that each outlet is functioning Check that all appliance plugs are making and maintaining good contact D 63 Check for Ground in All Circuits Using a DC voltmeter check for voltage drop on each circuit Determine reason for drop e g inadequate power feed poor connection poor ground etc MODULAR BODY D 64 Exterior Doors Open every door on the ambulanc
8. if there is any potential for failure If there is excessive clearance the cause should be determined immediately B 10 Tire Pressure Check all tire pressures and adjust to manufacturer s recommended pressures If any tire has excessive air pressure loss check that tire for leaks Record tire pressures on the inspection form Checking tire pressure regularly will help ensure vehicle stability and maximize fuel efficiency B 11 Tire Condition Check tires for cracks belt separation cupping and other abnormal wear Measure the tread depth of each tire and record on the inspection form B 12 Rotate Tires and Balance Wheels if Required Rotate tires to even out wear and extend the tire life Balance tires if vehicle has any vibration on road test Use this interval or see your operator s manual for suggested rotation intervals B 13 Brake Cylinder Seals Wheel Bearings and Axle Seals Remove the wheels Inspect for worn cracked leaking or brittle brake cylinder seals and axle seals Inspect for pitted worn or discolored bearings B 14 Front Brakes Check front brake pads for condition and thickness Refer to the Alberta Ambulance Safety Inspection Manual for minimum thickness Inspect caliper slides and calipers to ensure they move freely and are not seized Due to moisture and dirt caliper slides may seize or partially seize resulting in premature failure of brakes Record measurements on inspection form B 15 Rear Brakes Check t
9. process However use of this manual is not mandatory It is not a legislated part of the Alberta ambulance program Operators are encouraged to choose which parts of the manual will be implemented Please feel free to adopt or adapt the manual to meet local needs The following recommended service intervals will work well for most fleets but can be adjusted to meet local operations Schedule A every 5 000 km or 6 months or 250 hours Schedule B every 25 000 12 months or 1 250 hours Schedule every 50 000 24 months 2 500 hours Schedule D every 6 to 12 months Operator and service tech should decide frequency of Schedule D based on vehicle usage For additional copies of this manual write to Emergency Health Services Alberta Health and Wellness 10025 Jasper Ave Edmonton AB 5 156 TABLE OF CONTENTS Foreword Table of Contents Dedication SECTION A ENGINE COMPARTMENT 1 Change Engine Oil A 2 Change Oil Filter A 3 Service Air Cleaner A 4 Air Intake Ducts A 5 Belts A 6 Hoses A 7 Brake Fluid Level amp Condition A 8 Engine Leaks 9 Transmission Fluid Level amp Condition A 10 Washer Fluid Level A 11 Coolant Level amp Condition A 12 Coolant Strength A 13 Battery Water Levels amp Terminals A 14 Starter Draw A 15 Alternator amp Starter Wiring A 16 Alternator Output A 17 Load Test Batteries A 18 Fan End Play amp Operation A 19 Radiator Condition A 20 Pressure Test R
10. LECTRICAL CONTROL CENTRE D 21 D 22 D 23 D 24 D 25 D 26 D 27 Voltage Drop Main Power amp Auxiliary Solenoids Relays Function amp Connections Voltage Drop Relay Controlled Circuits Check for Ground on All Circuits Pin Connectors amp Terminal Blocks Looms Cables amp Connectors Electronic Flasher Terminals amp Wiring PATIENT COMPARTMENT SWITCH CONSOLE D 28 D 29 D 30 D 31 D 32 Switch amp Indicator Light Function Dome Cot Lights Fluorescent Lights Intake amp Exhaust Vents Electric Suction 11 11 11 11 D 33 Air Conditioner Patient Compartment D 34 Heater Patient Compartment D 35 Cabinet Lamps 0 36 Electric Oxygen D 37 Options D 38 Electrical Overload Poor Connections CLIMATE CONTROL 0 39 Heaters amp Air Conditioners Operational Check D 40 Air Exchange D 41 Worn Bushings Fan Obstructions D 42 Thermostat Function D 43 Heater amp Air Conditioning Hoses D 44 Condensation Drain Air Conditioners OXYGEN SYSTEM D 45 D 46 D 47 D 48 D 49 D 50 D 51 Pressure Drop Test Leak Test Oxygen Flow Rate Electric Oxygen Solenoid Valve Main Tank Retainers Portable Tank Retainers Main Tank Regulator Function ON BOARD SUCTION SYSTEM D 52 D 53 D 54 D 55 Provincial Standard for On Board Suction Suction Pump Filter amp Motor Suction Regulating Valve Leak Test 110 VOLT SYSTEM D 56 D 57 D 58 D 59 D 60 D 61 Shoreline Connector Exterior of Body GFI
11. Operation of Heaters and Air Conditioners With vehicle in an ambient atmosphere of at least 10 C run the engine Remember exhaust precautions Set the patient compartment air conditioning to maximum cooling Check temperature with a thermometer Turn the cab heater onto maximum heating and check for change in temperature of patient compartment air conditioner Set the patient compartment heater to maximum heat Check temperature with a thermometer If the ambulance has a combination heater air conditioner set the dash air conditioning to maximum cooling and the rear heater to maximum heat Note any change in the heater s output temperature Each unit is to be independent of each other Changes in one unit should not affect the other Check shut off valves if equipped Some units have shut off valves on the hoses going to heater core Some older units have a push pull control at the rear panel or under the dash near the driver Check cable operation make sure it is freely moving on both ends If not disconnect cable and determine if the cable or shut off valve is defective Repair or replace as necessary D 40 Air Exchange Check for sufficient air exchange in and out D 41 Worn or Dry Bushings Fan Obstructions Check fan for noises that may indicate dry or worn bushings Check fan intakes for debris that may restrict airflow or hit against squirrel cage D 42 Thermostat Function With a thermometer verify the hot and cold readings of
12. Signal Lights Check the signal lights for proper operation or damage C 4 Backup Lamps Check operation of backup lamps C 5 Brake Lamps Check operation of brake lamps C 6 Hazard Warning Lights Check operation of hazard warning lights C 7 Horn Operation Check the horn operation for proper tone and volume Check horn pad for ease of operation C 8 Siren Operation Ensure all siren modes are fully functional and speakers are clear of any obstructions If two siren amplifiers are installed check each separately See D 19 for preventive maintenance of the siren amplifier C 9 Hinges Pins and Bushings Lube all door hinges and latches Check for loose pins and bushings Compartment latches may have to be adjusted for proper operation of doors Ensure all doors work with ease 10 10 Air Conditioner Operation Record Temperature With a thermometer check temperature of cool air at duct outlets for front and rear air conditioners Ensure that they are within the manufacturer s specifications Record temperatures on inspection form C 11 Heater Operation Record Temperature With a thermometer check temperature of hot air at duct outlets for defroster and front and rear heaters Ensure that the temperatures are within the manufacturer s specifications Record temperatures on inspection form Check that there is adequate airflow from defrost vents to keep windows defrosted Check that there is proper airflow from heater
13. adiator amp Cap A 21 Air Conditioner Condenser A 22 Airflow Through Radiator A 23 Coolant Additive Level A 24 Glow Plug Operation A 25 Fuel Filters amp Water Separator A 26 Block Heater Operation A 27 Belts A 28 Accessory Brackets A 29 Cooling System A 30 Thermostat A 31 Power Steering Fluid 32 Turbocharger A 33 Water Pump Endplay SECTION B UNDER VEHICLE B 1 Lube Chassis B 2 Driveshaft amp U Joints B 3 Exhaust B 4 Heat Shield Condition B 5 Shock Absorbers B 6 Suspension Components vii RRARARARWWWWWWWWNNANNNNNDAAABABAaAaan ania O1 OF O1 15 16 17 18 19 B 20 B 21 B 22 B 23 B 24 B 25 B 26 B 27 B 28 B 29 B 30 31 32 B 33 B 34 B 35 B 36 B 37 B 38 B 39 B 40 41 42 43 44 45 Differential Oil Level amp Condition Differential Leaks Crown amp Pinion Tire Pressure Tire Condition Rotate Tires amp Balance Wheels Brake Cylinder Seals Wheel Bearings amp Axle Seals Front Brakes Rear Brakes Rotor Thickness Front amp Rear Brake Drum Thickness amp Condition Brake Lines amp Hoses Parking Brake Operation Ball Joints King Pins Tie Rod Ends Idler Arm Pitman Arm Steering Gear Box Control Arms amp Bushings Springs Bushings amp Shackles U Bolts amp Mounting Frame amp Rivets Differential Stops Fuel Lines Fire Extinguisher Flares Triangle Reflectors Torque All Wheel Nuts amp Record Road Tes
14. aintenance of the suction unit D 33 Air Conditioner Patient Compartment Check the fan functions on all settings See D 39 D 44 for preventive maintenance of the climate control system D 34 Heater Patient Compartment Check the fan function on all settings See D 39 D 44 for preventive maintenance of the climate control system D 35 Cabinet Lamps Check cabinet lamps for operation Remove lenses and check for dirt and moisture Check bulbs for discoloration and lubrication on contacting surface Check electrical contacts for proper connections D 36 Electric Oxygen if Equipped Check function of the electric oxygen switch See D 48 for preventive maintenance of the electric oxygen system D 37 Options Check as per Manufacturers Specifications Check any optional components not specifically noted in this manual Assess them according to any specifications supplied with the component at the time of purchase 15 D 38 Electrical Overload Poor Connections Check wire connections wiring and ground straps for discoloration corrosion and dirty terminals which can all cause poor connections Discoloration is also a sign of overloading causing too much heat Ensure that the wires are the proper size for the loads they are carrying and that connectors are the proper size for the wire used Check for dry bushings if a motor seems to drag A draw test may indicate that it needs to be serviced or replaced CLIMATE CONTROL D 39 Check
15. all moving parts with lithium grease Test the anchor by pulling sideways on the cot If the anchor releases with a sharp sideways pull it is not locking properly Adjust according to manufacturer s specifications 20 D 78 Main Cot Clean and Lubricate Clean the main cot as per manufacturer s specifications Lubricate all moving parts using light white grease Check and lubricate the wheel bearings and the pivots on the wheels D 79 Main Cot Inspection Check the cot very closely for damaged worn or fatigued parts If there are cracks in any of the cast aluminum fittings take the cot out of service until the broken parts are replaced A crack in cast aluminum may cause the fitting to fail at any time weight is put on the cot D 80 Cot Mattress and Straps Check the mattress cover for holes cuts tears etc Check for abraded cut or damaged restraint straps Check for damaged or nonfunctioning buckles D 81 Secondary Cot Portable Stretcher Check secondary cot or portable stretcher for bent broken or fatigued parts Clean up and lubricate moving parts with light grease Replace any parts showing signs of wear D 82 Scoop Stretcher Check scoop stretcher for broken bent or fatigued parts Clean and lubricate moving parts with light grease Check pins and latches for wear and replace if needed 21 SAMPLE FORMS 22
16. all power draws in vehicle On many ambulances power for the on board computers including the transmission controller may be hooked up to bypass the battery switch This is to keep the computer chips programmed and in a constant state of readiness When testing identify whether it is hooked up this way or not Check to see that the switch is mounted securely Check continuity on both sides of the switch to be sure it is making full contact and complete disconnection Check operation of isolator module for battery making sure each circuit is connecting correctly D 4 Master Power Switch a k a AMB connect or MODULE connect Check operation of master power switch Test both sides of the switch to be sure full contact is being made within the switch The meter should read the same on both sides of the connection D 5 Emergency Boost Sure Start if equipped Check operation of the emergency boost system Also check connections at solenoid and batteries Checking the draw on the circuit through the solenoid can also tell you if solenoid is breaking down Some older units had a separate battery dedicated to the emergency boost circuit This battery tends to not last as long due to limited amount of use On newer units emergency boost power is taken from the coach batteries which may be RV deep cycle batteries D 6 Light Bar Check operation of light bar Make sure all bulbs are illuminated and rotators are turning freely Listen for noisy rot
17. are intended to only work on low beam headlamps When high beams are activated the wig wag control module should not flash Check wiring and connections to headlamps from wig wag control If the control module is mounted where it is exposed to the outside atmosphere check it for moisture rusting or corrosion D 10 Strobe Flashers if Equipped Check operation and quality of light of strobe lamps Remove lenses and check for moisture dirt etc To prevent shock to the service person strobe lights must be shut off for approximately 20 to 30 minutes before servicing Replace bulbs or sockets if rusted or corroded Clean and replace lens Install new seals if required D 11 Auxiliary Lamps fog driving Check operation of fog and driving lamps Check for dirt and moisture in lens Check wiring and connections for corrosion Set the aim for best coverage of the roadway ahead D 12 Scene Lamps Check operation of scene lamps Remove lenses and check for moisture and dirt Remove and check bulbs reinstall with dielectric grease on contacting surfaces Check lens seals and replace if necessary Check door switch operation Some units have 2 way plunger switches on rear and side doors that will activate scene lamps Check plunger operation Clean and lubricate as necessary D 13 Dome Lamp Switch for Patient Compartment Lights If the master console is equipped with a dome lamp or cot lamp switch check that it operates the lamps in t
18. ators Check the amount of power draw with test meter to determine if it is within the manufacturer s specifications Remove lenses and check wiring making sure that the wires are not damaged and insulation is intact Check ground in the body of light bar and to each light and rotator Clean rotators and lubricate with light grease lubra plate graphite Make sure lens seals are good Clean lenses before installing Draw test again to compare difference to before and after servicing Ensure mounting brackets and main wire cable to the ambulance are secure Ensure that the grommet through the body of ambulance is good and does not leak D 7 Emergency Warning Flashers Primary and Secondary Check operation of all primary and secondary warning flashers Remove all lenses and check bulbs for deterioration due to moisture and dirt Remove bulbs and apply a small amount of dielectric grease on the contacting area and reinstall Rusted bulb sockets and connectors should be replaced Check lens gaskets for proper seal Consider replacing bulbs and seals on an annual basis as part of your preventive maintenance program D 8 Intersection Lights Check operation of intersection lights Remove lenses and check for moisture dirt etc Check bulb contacts Clean and apply a small amount of dielectric grease to contacting surface Check lens seals clean and replace if required 12 D 9 Wig wag Headlamps Check operation of wig wag headlamps Wig wags
19. ccurate reading Due to the high electrical load caused by the ambulance conversion a failing alternator will cause the system to start feeding off the batteries This will result in a lower voltage and some components will fail to operate correctly A 17 Load Test Batteries Load test batteries to determine their condition Record the beginning and ending voltages on the inspection form Replace weak or marginal batteries in sets This is recommended because a new battery will likely not operate at its full voltage if it is mated with an older one The system will cause the new battery to operate at the same voltage as the older battery This can cause insufficient power for the starting system A 18 Fan End Play and Operation Ensure there is not excessive endplay in the fan Due to severe duty application it is important to check fan endplay regularly Check that blades are not damaged and check fan operation by testing the airflow This is important to ensure that the engine does not overheat The fan shroud must be fully intact to prevent water pump failure When part of the fan shroud is damaged or missing changes in airflow may create an imbalance in the fan s operating plane causing premature fan or water pump failure A 19 Radiator Condition Check condition of radiator core Check tanks for cracks leaks and overall condition Radiators are susceptible to corrosion and may spring leaks at any time Regular inspections can locate th
20. cks is important as they are required to stabilize the vehicle when cornering or travelling over rough roads Worn shocks can cause vehicle handling to become erratic and hard to control B 6 Suspension Components Visually inspect all suspension components for loose parts cracks in springs and damaged parts Any of these conditions may compromise handling of the vehicle B 7 Differential Oil Level and Condition Check level and condition of differential oil If oil needs to be added refer to manufacturer s specifications for correct type Check for contamination caused by dirt or water which can lead to failure of differential Check that the vent is open so that any pressure build up will be released Check that vent cap is in place to prevent water from entering the differential Due to severe duty application differential oil can become very hot This may cause breakdown of bearings or other differential components B 8 Differential Leaks Check rear pinion seal and differential cover for leaks Check backing plates on differential Look for oil leak at axle seals Axle seals and pinion seals are a common place for oil to leak as seals become brittle or wear on axle shafts and pinion yoke Also the differential vent could be plugged leading to increased pressure within the housing which can cause leaks B 9 Crown and Pinion Check for any abnormal clearance in pinion and crown gears by testing play on driveshaft This can help determine
21. d contracting of the hoses A 7 Brake Fluid Level and Condition Inspect brake fluid level and top up as necessary Check fluid in brake reservoir for contamination and condition If any contamination is found in the brake fluid it should be flushed and refilled The brake lines must be bled as per manufacturer s specifications A 8 Engine Leaks Run the engine and check oil filter and drain plug for any leaks Check the engine for any other leaks This is important after an oil change as occasionally the filter o ring or drain plug gasket may leak Replace as required A 9 Transmission Fluid Level and Condition Check transmission oil This should be done with transmission at operating temperature to ensure an accurate reading It is important not to overfill the transmission Check the oil for discoloration burnt smell or metal filings built up on dipstick This could prevent premature transmission failure IF INDOUBT SEND AN OIL SAMPLE FOR ANALYSIS A 10 Washer Fluid Level Check and add washer fluid as needed Check washer operation 11 Coolant Level and Condition Check coolant level if equipped with an overflow reservoir ensure that it is full Check for any leaks in the cooling system Check coolant condition to ensure there is proper lubrication for moving parts If there is any discoloration the coolant should be flushed and replaced A 12 Coolant Strength Test the coolant strength If necessary adjust to meet manufacturer
22. e and check the function of the doors Check the seals to make sure they are intact all the way around This prevents dust and exhaust from entering the vehicle D 65 Door Latches and Pins All latches should be cleaned and lubricated as necessary Adjust latches and pins so doors close snugly on second latch Check that the seals are making good contact and the latches are locking on both safety latch and second latch D 66 Door Hinges Adjust and lubricate hinges on all doors If piano hinges sound gritty when operated they should be cleaned before being lubricated D 67 Latches and Locks Entrance Doors Check that both interior and exterior latches on all entrance doors operate properly Using a key check the function of all key locks on the doors If any locks are equipped with interior Knobs check that they operate easily If a lock is sticking you may have to replace it For safety reasons all entrance door latches must lock and unlock properly D 68 Check Door Seals Replace As Necessary 19 D 69 Exterior Compartments Check seals on all exterior compartment doors Check floor and corners for rust or corrosion Check for leaks in compartment Replace seals if needed and repair any holes in the body of the compartment D 70 Door Closers Hold Open Devices Inspect all door closers and hold open devices Lubricate as necessary with a light oil or grease Replace worn parts as required INTERIOR OF MODULE D 71 Sliding Cabine
23. en position Check for loose damaged or corroded wiring D 20 Siren Speaker Resistance Disconnect wires at siren speakers Use an ohmmeter to test the resistance through each speaker driver Check manufacturer s specifications for proper readings MAIN ELECTRICAL CONTROL CENTRE D 21 Voltage Drop Main Power and Auxiliary Solenoids Check solenoids by creating a draw and measuring the current on each side of the solenoid If the voltage is not the same check the manufacturer s specifications for variation D 22 Relays Function and Connections Check relays for function Visually check for loose connections and discoloration Check for loose or corroded ground strap D 23 Voltage Drop Relay Controlled Circuits Relays may become weak in time and arcing on contacts may affect voltage output Check voltage on output side of relays to ensure appliances are receiving proper voltage D 24 Check for Ground on All Circuits Using a DC voltmeter check for voltage drop on each circuit Determine reason for drop e g inadequate power feed weak relay poor ground D 25 Pin Connectors and Terminal Blocks Check for loose or discolored pin connectors indicating possible poor connection or overload Re grease pin connectors if insufficient signs of grease in connectors Use dielectric grease D 26 Looms Cables and Connectors Check for broken chaffed or damaged looms Check damaged spots for any wire damage Tie up loose or dangling cables
24. ese leaks before a major failure of the cooling system results A 20 Pressure Test Radiator and Cap Install a pressure tester and pressure test the radiator to the manufacturer s specifications Check for any drop in pressure If pressure drop is seen check cooling system including patient compartment heaters for leaks Check cap for leaks and opening pressure as per manufacturer s specifications Record pressures on inspection form It is important to check the radiator and its cap as the pressure that they are both holding is necessary to prevent overheating of the engine A 21 Air Conditioner Condenser Check AC condenser for bent fins or obstructions Check mounting brackets to ensure the condenser is not loose It is very common for the condenser to become loose from the vibrations of the vehicle A loose condenser may rub on something causing a leak which will result in failure of the air conditioning Bent fins or obstruction may not allow enough air to pass through the condenser which will result in poor cooling A 22 Airflow Through Radiator Inspect the space between the condenser and radiator for debris that could restrict airflow Clean as necessary Debris in this area is very common even with bug screens If not removed it may cause both poor operation of the air conditioner and engine overheating A 23 Coolant Additive Level Check coolant additive level as per manufacturer s specifications Lack of additive lubrican
25. he patient compartment D 14 Rear Heater Control If the master console is equipped with a rear heater switch check that it operates the heater in the patient compartment On some ambulances the front console switch runs the heater on HIGH only This overrides the multi setting operation of the switch on the patient compartment switch console D 15 Map Light if Equipped Check the map light to ensure it is secure and operational D 16 Auto Throttle Check operation of the auto throttle Assess the control function when it is activated Check that the linkage is free and the engine goes to the proper RPM Check that the auto throttle releases and engine RPM drops immediately when stepping on the brake pedal or putting transmission in gear D 17 Electrical Overload Poor Connections Check all connections and components for signs of overload or poor contact Ground contacts may corrode or become loose which can cause intermittent functioning of components 13 D 18 Back Lighting Switch Labels Check the function of back lighting on the front switch console On newer units the back lighting comes on with the park lamps On some older units turning on the master switch or AMB Connect switch activates it D 19 Siren Amplifier Check siren operation in each mode Check Public Address mode operation If equipped with a Horn Siren switch check that the horn pad activates or changes the siren tones when the switch is in the Sir
26. he rear brake pads shoes for condition and thickness Refer to the Alberta Ambulance Safety Inspection Manual for minimum thickness Ensure all hardware moves freely and springs are not stretched Check axle seals for leaks Check wheel cylinders for leaks and free movement Wheel cylinders can seize causing poor braking and could cause brakes to remain partially applied It is also important to check self adjusters as they can become inoperative or seized resulting in poor braking B 16 Rotor Thickness Front and Rear if Equipped Check that rotor thickness is within manufacturer s specifications Record measurements on inspection form Rotor thickness is very important due to the severe duty application As the rotor becomes thinner the brakes may not cool correctly causing brake fade Check radial run out and ensure wheel bearing does not have excessive play Radial run out may cause vehicle instability while braking as vehicle will shake when the brakes are applied Check rotors for excessive grooves on wear surface B 17 Brake Drum Thickness and Condition if Equipped Check that brake drum thickness is within manufacturer s specifications This is important due to the severe duty application As the drum becomes thinner the brakes may not cool correctly causing brake fade Record measurements on inspection form Check for roundness Drum roundness is important to check as warpage may cause vehicle instability while brakes are being appl
27. his patients and coworkers led to the creation of this manual viii SECTION A ENGINE COMPARTMENT A 1 Change Engine Oil Refer to owner s manual for recommended oil viscosity Use of proper viscosity is especially important due to the severe duty application of ambulances On the inspection form record the number of litres used A 2 Change Oil Filter Refer to owner s manual for recommended oil filter Lubricate the filter seal before installing On the inspection form record filter number Refer to Ford Ambulance Package filter part FL1995 should be used on 7 3 litre diesel A 3 Service Air Cleaner Check air filter element for restriction Remove any debris from the air cleaner housing Do not use compressed air to clean air filters Compressed air may tear the filter material and allow dirt and debris to enter the engine A 4 Air Intake Ducts Inspect intake ducts for debris or blockage A 5 Belts Check for worn cracked or glazed belts Check that belt tension is set to manufacturer s specifications Check for worn bearings on idlers It is common for belts to glaze and slip due to the high load that is demanded from the alternator and accessories Suggested belt lifetime is 50 000 km A 6 Hoses Inspect for cracked deteriorated or brittle hoses Check for proper and secure routing Check for loose or deteriorated clamps It is important to check for loose hose clamps regularly as they may loosen due to expanding an
28. icle A 29 Cooling System Flush the cooling system including radiator and heater core Remove drain plugs in engine block to ensure engine is thoroughly flushed Contaminants which can remain in the engine block if it is not flushed correctly may cause premature failure Refill the radiator with the correct coolant water mixture Ensure all water is removed from cooling system so that the proper strength is maintained After running engine to normal operating temperature recheck coolant level and strength A 30 Thermostat Replace thermostat Run vehicle to ensure proper operation and temperature The thermostat is replaced at this time due to the severe duty application in order to maintain vehicle efficiency and passenger comfort A 31 Power Steering Fluid Flush the power steering system until fluid comes out clean Ensure all air is purged from the system Use oil meeting the manufacturer s specifications Flushing the fluid is important as contaminants collect in the reservoir and fluid viscosity will break down over time This may cause power steering system failure A 32 Turbocharger Check for loose or broken connecting bolts and leaking gaskets on the turbocharger Inspect for damaged turbo vanes and loose bushings High heat within the turbo can cause gaskets to leak or bushings to wear These can cause immediate failure A 33 Water Pump Endplay Check water pump front hub for endplay Check that bearings operate smoothly Bel
29. ied Check for excessive grooves on shoe surface B 18 Brake Lines and Hoses Check for kinked damaged leaking or corroded brake lines Check for cracked or leaking hoses Check for proper and secure routing B 19 Parking Brake Operation Check that parking brake cables move freely and return correctly Apply parking brake and check that it holds firmly As the rear brakes wear parking brake operation becomes diminished and should be adjusted as needed Due to severe duty application especially when cornering quickly a lot of stress is put on front suspension and steering components This results in more wear so the following components need to be checked frequently B 20 Ball Joints King Pins Lift vehicle and support as per manufacturer s specifications Check ball joints or king pins for excessive play and seizing B 21 Tie Rod Ends Check tie rods for damage or play Ensure tie rods move freely Refer to manufacturer s specifications B 22 Idler Arm Check idler arm for excessive play Ensure idler moves freely Refer to manufacturer s specifications B 23 Pitman Arm Check pitman arm for excessive clearance or damage Ensure arm moves freely Refer to manufacturer s specifications B 24 Steering Gear Box Check for loose cracked or damaged mounts on the steering gear box Check the gear box for any leaks 25 Control Arms and Bushings Check for damaged or loose control arms and bushings Check control arms for proper
30. ng triangles Ensure that triangles are clean and functional base supports the device so as to provide proper warning B 33 Torque All Wheel Nuts and Record Torque all wheel nuts to manufacturer s specifications Record the torque setting on inspection form Proper torque will ensure nuts are not overtightened and they will be able to be removed in the field if necessary It will also prevent stud or nut damage B 34 Road Test Road test the vehicle for 5 km or more to ensure vehicle gets to operating temperature This will determine that the repairs made are working properly Vehicle may need to be road tested again if more repairs are required after initial road test B 35 Retorque Wheels After Road Test Retorque all the wheels to ensure they did not loosen up while being driven B 36 Wheel Alignment if Required Do a wheel alignment if there is any abnormal tire wear or if the vehicle pulls to left or right Rule out faulty steering and suspension components Wheel alignment should be done whenever any front end components are replaced as this can cause the alignment to be out of specifications B 37 Lug Nuts and Rim Condition Check for damaged bent or cracked rims Ensure lug nuts thread onto studs freely B 38 Transmission Service and Adjustment Remove transmission pan Replace filter and adjust the bands if applicable Transmission pan should be thoroughly cleaned and dried before installation Use a new gasket meeting manufactu
31. rer s specifications Some vehicles have a drain plug in the torque converter and will require more oil Transmission should be filled with oil meeting manufacturer s specifications Do not overfill Vehicle should be road tested to bring transmission to operating temperature to ensure accurate reading on the dipstick In severe duty applications it is important to service transmission at regular intervals to prevent premature failure B 39 Transmission Oil Cooler Lines and Fittings Inspect transmission oil cooler lines and fittings for leaks secure routing or damage Due to vehicle vibrations fittings may loosen and lines could rub on other components causing leaks or damage B 40 Transmission Internal Wiring Inspect the transmission internal wiring while servicing to ensure wiring is not broken brittle or cracked and that terminals are in good condition Heat from the transmission can cause wiring to become very brittle This may cause broken wires or internal shorts which will affect the transmission s performance B 41 Transmission Linkage Check for damaged or loose transmission linkage Lubricate the linkage B 42 Service Rear Differential Remove the differential cover drain oil and inspect teeth on pinion and crown gear for wear damage and adjustment Check for filings from bearings and other internal parts Clean differential components with approved cleaner and reassemble Refill with oil meeting manufacturer s specifications
32. s specifications This will help prevent freezing and overheating conditions Record the coolant strength on the inspection form A 13 Battery Water Levels and Terminals Check the battery water levels and add distilled water as required Remove battery ends and clean terminals Check for cracked or corroded cables Tighten cables onto battery posts and grease lightly A 14 Starter Draw Check starter draw with an automatic voltage regulator AVR to ensure it is within manufacturer s specifications Listen for abnormal noise during cranking On the inspection form record the number of amps drawn It is important to use an AVR to test the starter as excessive draw may not be readily noticeable This test could prevent a sudden failure A 15 Alternator and Starter Wiring Ensure alternator and starter wiring is routed correctly Check terminals for corrosion and damage Check for cracked or loose wiring Loose or corroded connections may cause improper charging or hard starting They may also cause excessive heat within a wire harness which may lead to extensive damage A 16 Alternator Output Check alternator output with an AVR to ensure that it is capable of sufficient output to power the ambulance Record the amperes output on the inspection form The minimum output required by provincial regulations is 60 of cold temp rating or 97 amps whichever is greater It is very important to test the alternator with an AVR so that you have an a
33. t Retorque Wheels After Road Test Wheel Alignment Lug Nuts amp Rim Condition Transmission Service amp Adjustment Transmission Oil Cooler Lines amp Fittings Transmission Internal Wiring Transmission Linkage Service Rear Differential Differential Backlash Shock Absorbers Cables heater throttle brake SECTION BODY Clearance Lights Headlamps Signal Lights Backup Lamps Brake Lamps Hazard Warning Lights Horn Operation Siren Operation Hinges Pins amp Bushings WOON C 10 11 12 13 C 14 C 15 Air Conditioner Operation Heater Operation Armrests amp Inner Door Panels Running Boards Steps amp Attachments Mud Flaps Attach Oil Change Sticker SECTION D AMBULANCE CONVERSION FRONT SWITCH CONSOLE D 1 D 2 D 20 Voltmeter amp Ammeter Accuracy Switches amp Indicator Lights Main Power or Battery Switch Master Power Switch AMB Connect MODULE Connect Emergency Boost Sure Start Light Bar Emergency Warning Flashers Intersection Lights Wig wag Headlamps Strobe Flashers Auxiliary Lamps Scene Lamps Dome Lamp Switch for Patient Compartment Lights Rear Heater Control Map Light Auto Throttle Electrical Overload Poor Connections Back Lighting Switch Labels Siren Amplifier Siren Speaker Resistance MAIN E
34. t can cause failure to cooling system components Coolant additive in diesel engines is important as it will lubricate the water pump bearings thereby increasing the life of the pump A 24 Glow Plug Operation Check wires for cracks and loose connections Check for proper and secure routing Test glow plugs as per manufacturer s specifications Cracks in glow plug wiring are common as the wires run close to exhaust components The resulting corrosion can cause shorts in the wiring To prevent hard starting it is very important to test each glow plug separately to ensure that they are all working A 25 Fuel Filters and Water Separator Replace fuel filters Lubricate seal on new filter before installing Drain water separator until only fuel runs out A 26 Block Heater Operation Check block heater cord for cracks corrosion damage and plug condition Test block heater operation A 27 Belts All belts should be replaced at 50 000 km due to the severe duty application Inspect condition of all pulleys Tighten new belts to manufacturer s specification Recheck the belt tension following the test drive as they may stretch after engine has been run The heavy load demand on the alternator causes high load to the belt Change them before they break A 28 Accessory Brackets alternator power steering pump Inspect all accessory brackets for cracks tightness and correct mounting as brackets may loosen or crack due to the vibrations of the veh
35. t Doors Check sliding door tracks for worn liners to ensure doors stay shut and sealed properly This will keep supplies contained within the cupboards and keep contamination out D 72 Latches and Locks Interior Cabinetry Check that latches and locks on interior cabinets work properly This is to ensure that they remain closed on rough roads or in case of a collision If the doors are not secured properly the contents may be thrown about and cause injury to the patient or attendant D 73 Grab Rails and Door Pulls Make sure all mounting screws bolts etc are secured and tightened on grab rails and door pulls Insecure hardware may break loose causing a person to lose balance and fall D 74 Shelving Check that the mounting strips for adjustable shelves are secure Check all supports to ensure that they are attached to the mounts securely D 75 Tri Or Edge Mouldings Check for loose or damaged moulding at joints between wall panels and at corners of cabinets D 76 Squad Bench and CPR Seat Lid Latch and Hold Open Device s Check lid latches to ensure that they lock properly Check that hinges are securely attached to the lid and to the bench structure These checks will ensure nothing can fall out in case of a collision or upset Check lid hold open device s to be sure the mounts are secure Check for proper function MEDICAL EQUIPMENT D 77 Cot Anchor Check the cot anchor to ensure that the mechanism latches completely Lubricate
36. t must be removed to check water pump end play to ensure accurate reading SECTION UNDER VEHICLE B 1 Lube Chassis Grease ball joints tie rod ends idler arm pitman arm u joints and other grease zerks Use grease as per manufacturer s specifications Inspect all boots for cracks and ensure all grease zerks take grease B 2 Driveshaft and U joints On units with a one piece driveshaft remove the rear u joint from the differential Rotate the rear joint in both directions Inspect for loose worn or seized joints Move the shaft so as to check the front u joint for the same faults On units with a two piece driveshaft remove the rear u joint from the differential and remove the steady bearing bolts Lower the shaft and steady bearing Check for seized u joints as described above It is important to be able to move the u joints freely because a seized joint might not be readily noticeable and will fail if not repaired B 3 Exhaust Check for corroded cracked or leaking exhaust components Inspect all exhaust hangers This is critical to prevent exhaust gases from entering the interior of the vehicle B 4 Heat Shield Condition Check that all heat shields are in place Inspect for damaged or loose shields This can prevent excessive heat from damaging the floor or causing a fire B 5 Shock Absorbers Inspect for damaged leaking or loose shock absorbers Ensure shocks stabilize the vehicle when each corner is bounced Checking sho
37. the wall mount thermostat if equipped D 43 Heater and Air Conditioner Hoses Check all heater hoses Some Type II raised roof van units have steel line partway to the back heater Check the rubber hose that runs from the end of the steel line to the heater This section of hose may be overlooked if you are not aware of its existence or are not looking in the proper places Visually check the A C hoses that run alongside the heater hoses If a hose has any damage or is getting mushy it should be replaced D 44 Condensation Drain Air Conditioners Check that condensation drains are not plugged Sometimes dirt builds up and eventually plugs them 16 OXYGEN SYSTEM D 45 Pressure Drop Test Turn on the tank valve to pressurize the system Note the pressure shown on the gauge Turn off the valve and monitor the gauge for 30 minutes to see if there is any loss of pressure In some systems the oxygen flow is controlled by a remotely switched electric solenoid Be sure the solenoid is turned ON so that the whole system is pressurized D 46 Leak Test If a pressure drop is noted D 45 above test for leaks by spraying connections with a mild soap solution Repeat procedure at each connection until the leak is found repaired and the system maintains pressure Be sure to clean all fittings after spraying them Never use oil on oxygen fittings D 47 Check for Correct Flow Rate at Each Outlet Check oxygen flow through flow meters D 48
38. vents C 12 Armrests and Inner Door Panels Check for loose deteriorated or damaged armrests and inner panels Repair replace and or tighten as necessary Due to the vibrations of the vehicle inner door panels and armrests may loosen frequently C 13 Running Boards Steps and Attachments Check for loose or damaged running boards steps and attachments Ensure all bolts are tight on these components and their support braces C 14 Mud Flaps Check mud flaps for missing bolts cracks and damage C 15 Attach Oil Change Sticker Record Date and Odometer Reading Attach a sticker with date and odometer reading as a reminder of the last and next scheduled service SECTION D AMBULANCE CONVERSION FRONT SWITCH CONSOLE D 1 Voltmeter and Ammeter Accuracy When checking the voltmeter and ammeter use AVR test equipment to compare operation of the meters The ambulance meters should be within 1 of the AVR meters Check several ways to make sure the meters work at both the top and bottom end of the scale Also check draws to confirm they work on the discharge side D 2 Switches and Indicator Lights Check the function of each switch ensuring that it works in all positions Ensure that the indicator light circuit on each switch is working With an ohmmeter check the continuity of the circuit through every switch to confirm a good contact 11 D 3 Main Power or Battery Switch if Equipped The function of the battery switch is to disconnect
39. with plastic ties Check for loose connections and poor contact at each end terminal as well as any intermediate junctions The best sign of a loose connection is arcing or discoloration D 27 Electronic Flasher Terminals and Wiring Check for loose corroded or discolored connections Check for damaged wires Test for ground faults Ensure that wires are protected in loom and looms are secured at regular intervals 14 PATIENT COMPARTMENT SWITCH CONSOLE D 28 Switch and Indicator Light Function See procedures in D 2 D 29 Dome Cot Lights Check operation on high and low settings Remove lenses and check bulbs for discoloration from heat and dust Check lens seals clean lenses if required Check door switch operation Some units have 2 way plunger switches on rear and side doors that will activate dome lamps Check plunger operation Clean and lubricate as necessary D 30 Fluorescent Lights if Equipped Check operation of fluorescent lights Check for dim flickering or burnt out bulbs If the light is not working at all verify power supply and check ballast D 31 Intake and Exhaust Vents Check for airflow from intake and exhaust vents Check intake screens to ensure that debris is not restricting airflow Check motors for overheating Check control wiring and connectors for proper contact Check that ground straps are secure and clean D 32 Electric Suction Check the function of the electric suction switch See D 53 for complete m
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