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Vehicle Maintenance Bulletin V-07-98

1. 76 Fuel tank A amp B Check the fuel tank mountings Check all bolts for tightness and torque if necessary Inspect the tank for corrosion cuts dents or bulges Damage lo tanks must not exceed the tank manufacturer s criteria Inspect the condition of the CNG tank s fiber covering The tank must not have any exposed metal surfaces Make sure that the tank is not rubbing against any components Ensure that the DOT label is on the tank and is readable and review the expiration date to see when the tank was last certified Fuel tanks must be removed every 3 years to be hydrostatically pressure tested by a certified testing facility Acoustic tank testing may be substituted for the hydrostatic pressure test This test is done with the tank mounted on the vehicle NGV 2 tanks have a 15 year life from the date of manufacture and do not require recertification Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Administrative Vehicles 77 Lines valves and regulators A amp B Check the condition of all lines Make sure they are not rubbing against any other components Ensure that the brake cable is not rubbing against the fuel tank or brackets Inspect the lines and valves for proper attachment Ensure that there are no kinks and that the lines are protected from damage Inspect the valve condition and the operation of the manual shut off valve Ensure that the shut off valve is properly labeled Inspect the regulators fo
2. 2 0 3 5 Level A Level B The B PMI and the follow up repairs satisfy the Federal Annual Vehicle Inspection as prescribed in the Federal Motor Carrier Safety Regulations Vehicle Maintenance Bulletin V 07 98 PMI Program Trailers PMI Guidelines for Trailers These tools are needed to perform the PMI Miscellaneous hand tools Spray lubricant Shop rags Flashlight Air pressure gauge Tread depth gauge Tire square Air chuck Air system light checking tool Axle alignment tools King pin tools 50 foot tape measure June 1 1998 81 Trailers PMI Program Explanation of Form 4546 F Preventive Maintenance Inspection Guidelines Trailers Fill in the vehicle number assigned location due date for PMI and the type of PMI level A or B Walk Around 1 Review vehicle jacket modification orders and repair tags A amp B Prior to each preventive maintenance inspection review the vehicle jacket to determine the nature and extent of work to be performed Reviewing the vehicle jacket provides maintenance personnel with the vehicle s history Compare the current mileage with the mileage at the last PMI Examine the file to determine when items such as brake work and tune ups were performed last Review the vehicle records for any pending Vehicle Modification Orders and for any history of repetitive repairs Review Forms 4565 Vehicle Repair Tag 2 Landing gear assembly A amp B Raise and lower the la
3. Add 0 3 hours if the vehicle is hand washed and 0 2 hours for cleaning windows and inside of vehicle 13 Lights turn signals and back up lights A amp B Examine all lenses for cracks deterioration and brightness Check all lights for proper operation 14 Floor and underdash wiring A amp B Inspect the floor mats for wear and tear Examine wiring and harnesses for chafing and for proper connection and support Ensure that the wiring is neatly taped and secured 15 Window window guides and regulator A amp B Test the windows and regulators to ensure they are working properly Inspect the window guides for cracking fraying excessive dryness and ease of movement 16 Authorized cab decals and Label 70 A amp B Ensure that only authorized decals are present and that they are positioned properly on the dashboard for visibility Remove any unauthorized decals The following decals must be displayed in each vehicle a Look Before Backing decal b Label 70 Safety Check and Vehicle Dimensions 17 General paint and body condition A amp B Inspect all painted surfaces for deterioration and condition Repaint vehicles on an as needed basis as determined by the Manager Vehicle Maintenance Do not delay any wear and tear repairs painting or accident caused body work 18 Wax vehicle B only Wax the vehicle at least once a year The estimated time to wax the vehicle is 1 hour Add this as a line item on
4. Administrative Vehicles 14 PMI Program 64 Regulator voltage A amp B Perform a regulator test using a volt amp tester Sun VAT 60 or similar equipment Record the results in the space provided on Form 4546 A 65 Emission control systems B only The vehicle emissions inspection maintenance I M program tests the emission system Follow the step by step procedure as outlined Note It is unlawful to modify or render inoperative any emission control devices or to allow a vehicle to operate if the vehicle fails this test The I M program is divided into three sections the visual inspection the emissions inspection and the functional inspection The first portion involves a thorough check of the vehicle to ensure that critical emission control components are present and operational The second procedure tests the exhaust emissions from the tailpipe The functional testing verifies that certain equipment is operating to Original Equipment Manufacturers OEM standards During the I M inspection use the vehicle s service maintenance manual Some states also require that specific emissions manuals must be available during the testing procedure for referencing the various specifications applicable to different vehicles Many electronic analyzers will prompt you automatically for answers to questions as well as the next steps to be taken in testing During the testing all the information is recorded into the analyzer When a
5. If the vehicle fails any part of the testing it must be repaired and then retested After the test is complete print one copy of the vehicle inspection report VIR Sign it and staple it to the work order and Form 4546 A The I M test procedures must be followed for all administrative vehicles including those powered by compressed natural gas CNG Procedures may vary depending on the type of vehicle being tested Persons performing emissions tests should refer to that vehicle s service manual In some states vehicles may be subjected to further testing at a centralized state test facility Local management must ensure that all state required tests are performed Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Administrative Vehicles If vehicle is CNG powered go to step 68 66 List all repair actions on Form 4541 or 4543 A amp B List all repair actions on Form 4541 Order Invoice for Vehicle Repair or Form 4543 Vehicle Maintenance Work Order Schedule work generated by the PMI 67 Quality assurance road test A amp B After the required repairs have been completed drive the vehicle and check engine for acceleration smoothness and power Check transmission shift pattern Check steering for ease of operation wander pulling etc Listen for any unusual noises Check brake stopping ability and parking brake holding ability Before the vehicle is released for service ensure that seat seatbelt steer
6. This check has many variables Refer to the vehicle s emissions or service manual for the proper procedure Begin by determining which EGR system is being used There are three types of EGR valves standard positive back pressure and negative back pressure Knowing the type of valve is very important since the testing procedures are different for each valve To find out which valve is on the vehicle being tested use the shop manual identification code then visually check the number on the valve itself 3 Park Neutral Switch On vehicles equipped with automatic transmissions test the park neutral switch using a hand held Scan tool D Ignition Timing Because of the many types of vehicles in the administration fleet follow the procedure on the underhood emissions label to check timing Before checking timing start the engine and verify that the check engine light is not on If the light is on a code is stored in the Electronic Control Module ECM memory and the emission system needs to be serviced E Check Engine Light Test The final function test is on the emission control check engine or system malfunction light indicator Turn the ignition Key to the on position the check engine light should come on Turn the ignition key to the off position the light should go off start the engine The check engine light should be off when the engine is started and running The I M testing procedure is now complete
7. computer and vehicle computer 71 CNG labels A amp B Inspect the vehicle to ensure that the CNG labels blue diamond are properly positioned on the vehicle Refer to Publication 500 G Vehicle Guidelines for proper location of decals Inspect the manual shut off label which is located near the shut off valve AT Intermediate Delivery Vehicles PMI Program 43 Engine Compartment 72 CNG labels A amp B Check the condition of the CNG label which must be located in the engine compartment area Verify that the label identifies the system manufacturer operating pressure installation date and tank expiration date or recertification date Vehicles operated in California must also have a Bureau of Automotive Repair BAR emission label 73 CNG components A amp B Check all CNG components Check for proper operation of the system Refer to the vehicle s service manual 74 Emission control systems B only With the vehicle running on CNG recheck the tail pipe gases according to the procedures outlined in item 65 Record the emission control systems results in the spaces provided on Form 4546 C Compare the gasoline and CNG emissions readings If the two sets of readings differ a great deal recheck the engine operation Underneath Inspection 75 Leak checks A amp B Check all components and connections for leaks using a non ammonia soap solution or a methane detector It is important that all connections
8. 32 Belts and pulleys 59 Alternator and power steering Fuel lines fuel system and linkage PS Form 4546 E March 1998 PREVENTIVE MAINTENANCE INSPECTION GUIDELINES continued HET ee ie 70 Regulator voltage volts 71 Engine 72 Emissions 63 Air filter restriction inches ial E 73 List all repair actions on Form 4541 or 4543 64 Clean battery post and cables 65 Battery box and hold downs 66 Wiring and hoses 67 Battery load test volts 74 Quality assurance road test e uw 68 Starter cranking test i E Ne 69 Alternator output test volts amps Note If damage is more than normal wear and tear a separate work order must be written and coded as an accident ERT to perform an A PMI on a tractor is 2 0 hours ERT to perform a B PMI on a tractor is 3 5 hours noc LE Tu ak PS Form 4546 E March 1998 UNITED STATES POSTAL SERVICE PREVENTIVE MAINTENANCE INSPECTION GUIDELINES Bzd TRAILERS UNITED STATES POSTAL SERVICE Vehicle No Assigned Location In box before each item indicate condition as follows N tem is OK 0 Adjustment Made LF 32 RF Landing gear ET 32 LRI 32 RRI 32 RRO 32 Glad hands and connectors ive 32RRI 32 RRO m Road test 5 Test brakes for proper operation j Emergency brake valve operation Perform air system leak checks and drain air tanks 8 Lights and turn sig
9. 50 antifreeze and 50 water Record the protection level in the space provided on Form 4546 A 51 Alkalinity protection A amp B Test corrosion resistant properties of the coolant with a coolant test strip If test results are unsatisfactory drain flush and refill cooling system with a solution of 50 antifreeze and 50 water 52 Replace or recycle coolant as required A amp B Replace or recycle coolant as required by the type of coolant used The service requirement might differ between coolant manufacturers Refer to the coolant manufacturer s recommendations concerning the change or recycle interval 53 Radiator hoses and leaks A amp B Pressure test complete cooling system Examine all hoses and connections for leaks or wear Inspect water pump Replace hoses as needed Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Administrative Vehicles 54 Belts and pulleys A amp B Check all belts for condition alignment and proper tension When adjusting belts use a belt tension gauge Inspect all pulleys for alignment and condition 55 Alternator and power steering A amp B Check alternator terminal connections and mounting Check the fluid level of the power steering pump Ensure there are no leaks 56 Fuel lines fuel system and linkage A amp B Inspect fuel lines for routing and leaks Inspect carburetor or fuel injection system linkage and lubricate as needed 57 Fuel
10. B only Test air filter restriction Record reading on Form 4546 D Replace air filter when restriction exceeds 25 inches water Examine mounting brackets on air cleaner and compressor aftercooler Check hoses clamps and piping for leaks or loose connections 61 Carge Vans 62 PMI Program 64 Clean battery post and cables A amp B Clean battery posts and cables Clean the terminals with a wire brush If very corroded clean the area with a solution of baking soda and water Apply protective spray to the cleaned terminals Make sure the battery posts bolts are properly tightened 65 Battery box and hold downs A amp B Examine battery box for signs of corrosion Clean and paint box if needed Check hold downs for looseness and tighten if needed 66 Wiring and hoses A amp B Check for proper routing of all wiring and hoses including electrical wiring and fuel hoses Ensure that these components are not rubbing against each other or any other metal surface 67 Battery load test A amp B Perform a battery load test using a volt amp tester Sun VAT 60 or equal equipment Record the results in the space provided on Form 4546 D 68 Starter cranking test A amp B On cargo vans equipped with electric starters perform a starter cranking test using a volt amp tester Sun VAT 60 or equal equipment Record the results in the space provided on Form 4546 D On cargo vans equipped with air starters check for p
11. Drain air tanks Inspect the air springs for proper clearance Do not mount any optional or auxiliary equipment too close to the air springs After system stabilizes check ride height It takes 2 seconds to 8 seconds after movement of the control before air starts to flow into or out of the air springs If all air springs are inflated equally the vehicle should be at the required r de height If it is not refer to the vehicle s service manual for proper repair procedure Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Tractors Engine Compartment Area 53 Engine compartment and cab lifting system A amp B Examine cab lock lever and safety catches for broken springs Check cab tilt latches for proper adjustment Check springs in tilt assist torsion unit Examine tilt trunnions Inspect the cab lifting system for proper operation Fill windshield washer reservoir 54 Antifreeze protection level A amp B Before removing the radiator overflow tank cap squeeze the hoses to see if the system is pressurized or hot Carefully remove the radiator cap and check the seal Inspect the fluid level Test coolant mixture for freeze protection with a refractometer or test strip Add quantities as necessary to maintain a solution of 50 antifreeze and 50 water Record the protection level in the space provided on Form 4546 E 55 Alkalinity protection and water filter A amp B Test corrosion resistant properties of t
12. Refer to the vehicle s service manual 74 Emission control systems B only With the vehicle running on CNG recheck the tail pipe gases according to the procedures outlined in item 65 Record Ihe emission control systems results in the spaces provided on Form 4546 B Compare the gasoline and CNG emissions readings If the two sets of readings differ a great deal recheck the engine operation Underneath Inspection 75 Leak checks A amp B Check all components and connections for leaks using non ammonia soap solution or a methane detector It is important that all connections be checked for leaks during the PMI Repair all leaks 35 Light Delivery Vehicles 36 PMI Program 76 Fuel tank A amp B Check the fuel tank mountings Check all bolts for tightness and torque if necessary Inspect the tank for corrosion cuts dents or bulges Damage to tanks must not exceed the tank manufacturer s criteria Inspect the condition of the CNG tank s fiber covering The tank must not have any exposed metal surfaces Make sure that the tank is not rubbing against any components Ensure that the DOT label is on the tank and is readable and review the expiration date to see when the tank was last certified Fuel tanks must be removed every 3 years to be hydrostatically pressure tested by a certified testing facility Acoustic tank testing may be substituted for the hydrostatic pressure test This test is done with the tank mounted on
13. Tractors 68 PMI Program 13 Floor and underdash wiring A amp B Inspect the floor mats for wear and tear Examine wiring and harnesses for chafing and for proper connection and support Ensure that the wiring is neatly taped and secured 14 Clutch operation pedal and pads A amp B On vehicles with manual transmission test the clutch for slippage pedal free play and proper clutch brake operation Pedal free travel should be 1 1 2 inches to 2 inches and clutch brake application should be 1 inch above the floor board Listen for abnormal noise from release bearing Adjust if needed Inspect all pedals for wear On vehicles with automatic transmission inspect all pedals for wear 15 Window regulator and door hinges A amp B Test the windows regulators and door hinges to ensure they are working properly Inspect the window guides for proper condition 16 Safety equipment fire extinguisher and accident kit A amp B Check the vehicle s fire extinguisher and emergency warning kits per Section 243 of Handbook PO 701 Check the seal on the fire extinguisher Inspect the contents of the warning kits Replace the fire extinguisher and contents of the warning kits as necessary Ensure that the forms compartment contains Item 087 H Accident Report Kit and the vehicle s operator s manual Remove all other debris from the forms compartment 17 Authorized cab decals and Label 70 A amp B Ensure that only auth
14. amp B Inspect the condition of the undercoating Touch up the undercoating annually to ensure the long life cycle for postal vehicles After accident repairs are made reapply rustproofing Check for corrosion of all chassis components 51 Automatic lubrication system A amp B If the vehicle is equipped with an automatic lubrication system check for proper lubrication of the chassis by setting the timer to the test cycle Grease should appear at each lube point If no grease is found make necessary repairs Refill system as needed 52 Air suspension system B only For vehicles equipped with an air suspension system operation of the air suspension ride height is controlled by an air leveling valve that increases or decreases the amount of air pressure in the air spring for a given load The air leveling valve senses the weight of the load and inflates or deflates the air springs to maintain the required ride height The vehicle ride height remains the same whether the vehicle has a loaded or unloaded trailer hookup The driver controls the air suspension system with a control valve located in the cab of the vehicle For operation the valve must be in the Ride position For hooking or unhooking to trailers the valve must be in the Lower position Failure to follow these directions may cause damage to the tractor On each PMI check nuts for proper torque Inspect the condition of springs radius rod and torque rod bushing
15. an electronic leak detector It is important that all connections be checked for leaks during the PMI Repair all leaks Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Light Delivery Vehicles 69 Warning lights and engine operation A amp B Start the engine With the engine running on CNG check the operation of the engine All CNG vehicles have a light on the dash to inform the driver what fuel the engine is operating on Check the operation of this light Check the operation of the engine hour meters for both CNG and gasoline 70 Wiring A amp B Examine all wiring for chafing and for proper connection to the CNG computer and vehicle computer 71 CNG labels A amp B Inspect the vehicle to ensure that the CNG labels blue diamond are properly positioned on the vehicle Refer to Publication 500 G Vehicle Guidelines for proper location of decals Inspect the manual shut off label which is located near the shut off valve Engine Compartment 72 CNG labels A amp B Check the condition of the CNG label which must be located in the engine compartment area Verify that the label identifies the system manufacturer operating pressure installation date and tank expiration date or recertification date Vehicles operated in California must also have a Bureau of Automotive Repair BAR emission label 73 CNG components A amp B Check all CNG components Check for proper operation of the system
16. and door key assembly A amp B Check the keys for cracks and signs of wear Inspect the lock assemblies for signs of wear Lubricate all lock assemblies with spray lubricant 6 Buzzer and warning devices A amp B Ensure that all warning lights located on the dash temporarily light when the ignition key is in the on position After the engine starts ensure the lights go Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Tractors out If the lights and warning devices are not working correctly refer to the manufacturer s service manual T Cold weather starting aids A amp B Check operation of the cold weather starting system usually a glow plug or ether system See manufacturer s shop manual for proper operation This vehicle is also equipped with a block heater Inspect the electrical cord and plug for damage 8 Starter action unusual sounds and neutral switch A amp B For vehicles equipped with automatic transmission ensure that the engine will not crank except in neutral or park Note the sound of the starter operalion there should be no unusual noises 9 Gauges horn heater oil pressure and mirrors A amp B With the car on check the operation of all gauges Check the horn for operation and loudness Turn on the heater defroster and all other cab systems Check the oil pressure gauge when the engine starts If the engine is warm note this pressure Refer to the manufacture
17. and mounting Check the fluid level of the power steering pump Ensure there are no leaks Examine pump and mounting bracket for condition and check for loose or broken bolts 60 Fuel lines fuel system and linkage A amp B Inspect fuel lines for routing and leaks Inspect fuel injection system linkage and lubricate as needed Examine linkage levers connectors and return springs for wear or interference 61 Fuel filter s B only Replace all fuel filters annually or more frequently as necessary 62 Emission control devices A amp B Inspect the engine for all related emission control components Ensure their correct operation Examine crankcase emission system regulator Examine all hoses connections and grommets for deterioration 63 Air filter restriction B only Test air filter restriction Record reading on Form 4546 E Replace air filter when restriction exceeds 25 inches water Examine mounting brackets on air cleaner and compressor aftercooler Check hoses clamps and piping for leaks or loose connections 64 Clean battery post and cables A amp B Clean battery posts and cables Clean the terminals with a wire brush If very corroded clean the area with a solution of baking soda and water Apply protective spray to the cleaned terminals Make sure the battery posts bolts are properly tightened 65 Battery box and hold downs A amp B Examine battery box for signs of corrosion Clean and paint box
18. and other steering components Lubricate the tie rods and other steering components Inspect the power steering hoses and connections to ensure the hoses are not rubbing leaking or deteriorating 37 Brake linings B only Remove all wheels to inspect brake assemblies linings and drums Record the findings in the spaces provided on Form 4546 A Check all applicable brake components for leaks Check the wear rate of the shoes and compare the shoes to new shoes For example brake linings that have 4 32 inch remaining are not worn out if the vehicle has gone three or four inspections since the brakes were new The original amount of shoe may have only been Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Administrative Vehicles 8 32 inch The inspector must balance brake safety against the risk of throwing away good lining material Brake linings with less than 2 32 inch must be replaced Inspect the parking brake cables to make Sure they are operating properly secure and not frayed The B PMI ERT includes the time for the brake inspection If the brakes need to be inspected during an A PMI the inspection time must be written as a line item on Form 4543 Vehicle Maintenance Work Order The estimated time to perform this brake inspection on an administrative vehicle is 0 5 hours which includes the time to clean inspect and adjust all brakes 38 Bearing play and condition A amp B Check the wheel bearing for
19. and weather seals Inspect the handles for proper operation and security Check the door and window seals for wear and damage Check the condition of steps and step wells 4 Seat belt and interior A amp B Examine seat mounts seat coverings adjusting mechanisms seat belts retractors and anchors Check the sun visors and other inside cab components for operation and condition 5 Key ignition and door key assembly A amp B Check the keys for cracks and signs of wear Inspect the lock assemblies for signs of wear Lubricate all lock assemblies with spray lubricant 6 Buzzer and warning devices A amp B Ensure that all warning lights located on the dash temporarily light when the ignition key is in the on position After the engine starts ensure the lights go Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Intermediate Delivery Vehicles out If the lights and warning devices are not working correctly refer to the manufacturer s service manual 7 Starter action unusual sounds and neutral switch A amp B Ensure that the engine will not crank except in neutral or park Note the sound of the starter operation 8 Cold weather starting aids A amp B Check operation of the glow plug system if equipped See manufacturer s service manual for proper operation Some engines may have another type of starting aid other than a glow plug system See manufacturer s service manual for inform
20. condition of the stabilizer bar Check tightness of spring U bolts Examine shock absorbers for leaks damage or worn grommets 43 Intermediate Delivery Vehicles PMI Program 44 40 Transmission and mountings A amp B Check transmission fluid level and condition Inspect the speedometer cable and attachment Ensure there are no kinks or leaks and that the cable bends smoothly and is protected from damage Examine transmission mounts for deterioration Check the transmission cooler lines for leaks and chaffing Drain and refill automatic transmission fluid every 50 000 miles or every 2 years whichever comes first Some vehicles with automatic transmission have both internal and external filters Change both of these filters when changing transmission fluid 41 Exhaust systems converter and muffler A amp B Examine complete exhaust system for leaks damage or loose hangers 42 Driveline alignment and condition A amp B Examine propeller shaft universal joints carrier bearing and slip joint for wear and damage and for proper alignment 43 Body hold downs hoses and wires A amp B Inspect the vehicle body hold downs to make sure they are intact and tight Ensure that all hoses and wires are properly secured to the chassis 44 Differential and breather A amp B Check the differential fluid level and check for leaks Fill as necessary Check the breather hose for proper operation 45 Undercoating conditio
21. coolant as required A amp B Replace or recycle coolant as required by the type of coolant used The service requirement might differ between coolant manufacturers Refer to the coolant manufacturer s recommendations concerning the change or recycle interval 53 Radiator hoses and leaks A amp B Pressure test complete cooling system Examine all hoses and connections for leaks or wear Inspect water pump Replace hoses as needed 54 Belts and pulleys A amp B Check all belts for condition alignment and proper tension When adjusting belts use a belt tension gauge Inspect all pulleys for alignment and condition 55 Alternator and power steering A amp B Check alternator terminal connections and mounting Check the fluid level of the power steering pump Ensure there are no leaks 56 Fuel lines fuel system and linkage A amp B Inspect fuel lines for routing and leaks Inspect carburetor or fuel injection system linkage and lubricate as needed 57 Fuel filter air filter and PCV filter A amp B Replace fuel filter air filter charcoal canister filter if applicable and PCV fillers as necessary or when indicated by mileage age or condition 58 Clean battery post and cables A amp B Clean battery posts and cables Clean the terminals with a wire brush If very corroded clean the area with a solution of baking soda and water Apply protective spray to the cleaned terminals Make sure the battery
22. device or to allow a vehicle to operate if the vehicle fails this test The I M program is divided into three sections the visual inspection the emissions inspection and the functional inspection The first portion involves a thorough check of the vehicle to ensure that critical emission control components are present and operational The second procedure tests the exhaust emissions from the tailpipe The functional testing verifies that certain equipment is operating to Original Equipment Manufacturers OEM standards During the I M inspection use the vehicle s service maintenance manual Some states also require that specific emissions manuals must be available during the testing procedure for referencing the various specifications applicable to different vehicles Many electronic analyzers will prompt you automatically for answers to questions as well as the next steps to be taken in testing During the testing all the information is recorded into the analyzer When all the procedures Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Light Delivery Vehicles have been completed print the results from the analyzer and staple the printout to the work order as part of the permanent record A Visual Inspection 1 Positive crankcase ventilation PCV system Examine all the PCV hoses connections and grommets for deterioration Replace valve if necessary 2 The thermostatic air cleaner Inspect system to ens
23. door and filler neck 5 Fuel lines fuel system and linkage 1 y 2B Accident kit aac 57 Fuel filter air filter and PCV filter BE 9 Accident damage list on diagram Clean battery post and cables Se 5 Battery box and hold dows PS Form 4346 4 March 1998 PREVENTIVE MAINTENANCE INSPECTION GUIDELINES continued aje Engine Compartment Area con t Afe CNG Vehicles con t TEL Sc Ci AGMEN EL ee a C Starter cranking test amps Engine Compartment T Tas 73 CNG components 74 Emission control systems Alternator output test volts Regulator voltage 65 Emission control systems HC J ppm CO atidle HC ppm CO ___ at idle HC ppm COQ ____ 96 at 2500 RPM HC ppm CO 96 at 2500 RPM Qi e COz __ at idle ees CO _ atidle at2500 RPM Oz m y 66 List all repair actions on Form 4541 or 4543 TRE Quality assurance road test n A Bn cNevedes 0 0 m La a 75 Leak checks 77 Lines valves and regulators T9 pus CO at 2900 RPM BELT EK 68 Fill valve and starter interrupt switch UE 69 Warning lights and engine operation Note If damage is more than normal wear and tear a separate work order must be written and coded as an accident ERT to perform an A PMI on an administrative vehicle is 1 5 hours ERT to perform an A PMI on an administrative vehicle equipped wit
24. each vehicle s mileage and operating history The two levels of inspection do not impact the PMI schedule Vehicles still must be inspected according to the current 6 13 17 and 26 week cycles V Scheduling VMF managers must schedule their fleet s PMIs to reflect a constant and balanced workload over a 52 week period A and B inspections must be scheduled to balance the workload As always needed repairs must be made at the time of inspection Repairs should not be postponed VI Parts Replacement Parts should be replaced on an as needed basis and only if warranted by the results of a PMI Repairs must be performed immediately they must not be put off until the next scheduled A or B service VII Emission and Brake Tests VMFs must perform emission tests on all vehicles in accordance with all state and local regulations At a minimum brakes must be inspected annually Vehicle history will indicate if more frequent inspections are required VIII PMI Frequency Each VMF manager must ensure that every vehicle s scheduled PMI frequency is set according to the following requirements n 900 or fewer miles per accounting period 6 500 or fewer miles per year 26 weeks m 501 1 000 miles per accounting period 6 501 13 000 miles per year 17 weeks T 1 001 1 500 miles per accounting period 13 001 19 500 miles per year 13 weeks 2 Vehicle Maintenance Bulletin V 07 98 PMI Program Introduction In addition pl
25. filter air filter and PCV filter A amp B Replace fuel filter air filter charcoal canister filter if applicable and PCV filters as necessary or when indicated by mileage age or condition 58 Clean battery post and cables A amp B Clean battery posts and cables Clean the terminals with a wire brush If very corroded clean the area with a solution of baking soda and water Apply protective spray to the cleaned terminals Make sure the battery posts bolts are properly tightened 59 Battery box and hold downs A amp B Examine battery box for signs of corrosion Clean and paint box if needed Check hold downs for looseness and tighten if needed 60 Wiring and hoses A amp B Check for proper routing of all wiring and hoses including electrical wiring and fuel hoses Make sure that these components are not rubbing against each other or any other metal surface 61 Battery load test A amp B Perform a battery load test using a volt amp tester Sun VAT 60 or similar equipment Record the results in the space provided on Form 4546 A 62 Starter cranking test A amp B Perform a starter cranking test using a volt amp tester Sun VAT 60 or similar equipment Record the results in the space provided on Form 4546 A 63 Alternator output test A amp B Perform an alternator output test using a volt amp tester Sun VAT 60 or similar equipment Record the results in the space provided on Form 4546 A 13
26. find out which valve is on the vehicle being tested use the shop manual identification code Then visually check the number on the valve itself The LLV uses a negative EGR valve b Check the vacuum source to the EGR system Find the vacuum line leading to the Throttle Body Injection assembly and disconnect it from the EGR solenoid Install a vacuum gauge to the end of the hose Start the engine and run at approximately 2000 RPM Vacuum should be present at the gauge If there is no vacuum present repair the system c Turn the engine off Remove the gauge from the hose and connect to the manifold side of the EGR solenoid Apply at least 10 inches of vacuum to the solenoid The solenoid must hold the vacuum If the solenoid loses vacuum replace the solenoid Next turn the ignition switch to on The vacuum should Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Light Delivery Vehicles still hold If not check for the proper operation of circuits Refer to the EGR systems Check in the service manual d Ground the diagnostic test terminals Once the test terminal has been grounded the vacuum should fall to zero If the vacuum does not drop check for faulty circuits EGR solenoid or Electronic Control Module ECM Again refer to the manual Remove the ground from the diagnostic test terminal and turn the ignition to off e Check the EGR valve and hose While performing this portion of the test the shop exh
27. if needed Check hold downs for looseness and tighten if needed 66 Wiring and hoses A amp B Check for proper routing of all wiring and hoses including electrical wiring and fuel hoses Ensure that these components are not rubbing against each other or any other metal surface 67 Battery load test A amp B Perform a battery load test using a volt amp tester Sun VAT 60 or equal equipment Record the results in the space provided on Form 4546 E Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Tractors 68 Starter cranking test A amp B On vehicles equipped with electric starters perform a starter cranking test using a volt amp tester Sun VAT 60 or equal equipment Record the results in the space provided on Form 4546 E On tractors equipped with air starters check for proper lubrication of the system by cranking the engine several times A light mist of diesel fuel should come from the exhaust of the starter On later model tractors the starters are self lubricated Inspect the air starter air system for leaks Drain the moisture from the air starter air tank 69 Alternator output test A amp B Perform an alternator output test using a volt amp tester Sun VAT 60 or equal equipment Record the results in the space provided on Form 4546 E 70 Regulator voltage A amp B Perform a regulator test using a volt amp tester Sun VAT 60 or equal equipment Record the results in the space
28. intermediate delivery vehicle is 3 0 hours ERT to perform a B PMI on an intermediate delivery vehicle equipped with CNG is 3 5 hours Completed by Work Order No Odometer PS Form 4546 C March 1998 UNITED STATES POSTAL SERVICE E PREVENTIVE MAINTENANCE INSPECTION GUIDELINES BPa CARGO VANS POSTAL SERIE SERVICE D box before each Item indicate condition as follows Item is OK 0 Adjustment Made Not Applicable Rear Boor s SPCUT city and condition Interior condition cargo door Moors and root Cargo restraining devices 34 Fuel cap vent and filler neck Air tanks valves hoses pipes and air gauge Accident damage list on diagram olen action unusual sounds and neutral switch 9 Gauges horn heater oil pressure and mirrors Accessories glass windshield wipers fan and radio Steering play inches Lights turn signals and back up lights Floor and underdash wiring 2 Brake hnings LF 13 Brake chamber push rod travel and slack adjusters Bearing play and condition Suspension springs shocks and hangers Transmission and mountings Exhaust systems 21 Governor range cutout ___ t Driveline alignment and condition Differential and breather Undercoating condition Tire inflation Lug nuts wheels hubs and alignment Tire probe condition and tread depths LE A RF X 3 LRO 32 LRI 32 RRI 32 RRO 32 HAr 98 Belts and pulleys d Bumpers reflec
29. list on diagram A amp B During each PMI maintenance employees must inspect the trailer for accident damage report any damage to their supervisor and indicate damage on the diagram on Form 4546 F Do not defer repairs of accident damage to a later date Prepare a separate work order and code it as an accident 16 Interior condition floors and roof A amp B Inspect the cargo lights for proper operation With the rear door pulled down inspect the roof floors and side panels for holes signs of leaks or other damage Inspect the roof bows to ensure that the roof is attached properly 17 Cargo restraining devices A amp B Check the E tracks Ensure no bolts are loose or missing from the tracks Inspect the track slots for cracks and wear Wheels Tires and Underneath 18 Lug nuts wheels rims hubs and spacers A amp B Inspect lug nuts wheels rims and hubs for tightness Check wheels and rims for cracks straightness unseated locking rings and broken or missing lugs studs or clamps Inspect for bleeding rust stains Check for loose or damaged lug nuts and elongated mounting stud holes Use a torque wrench to retorque the lug nuts Check the oil level in the hubs On wheel designs using spacers check condition of spacers 19 Tire inflation A amp B Examine condition of all tires for damage wear and proper inflation If a tire is 10 psi or more low investigate the cause for the loss of air pre
30. or broken center bolts Inspect the condition of the stabilizer bar Check tightness of spring U bolts Examine shock absorbers for leaks damage or worn grommets 27 Light Delivery Vehicles 28 PMI Program 40 Transmission and mountings A amp B Check transmission fluid level and condition Service transmissions only to correct a deficiency or if transmission fluid smells burned or contains metal or friction material particles If fluid level is adequate and is not burned or contaminated do not service If doubtful about fluid condition drain out a sample for closer examination Examine transmission mounts for deterioration Check the transmission cooler lines to make sure they are not rubbing against any other components Inspect the speedometer cable and attachment Ensure there are no kinks or leaks and that the cable bends smoothly and is protected from damage 41 Exhaust systems converter and muffler A amp B Examine complete exhaust system for leaks damage or loose hangers Examine catalytic converter for evidence of overheating 42 Driveline alignment and condition A amp B Examine propeller shaft universal joints carrier bearing and slip joint for wear or damage 43 Body hold downs hoses and wires A amp B Inspect the vehicle body hold downs to make sure they are intact and tight Ensure that all hoses and wires are properly secured to the chassis 44 Differential and breather A amp
31. other than the person doing the PMI subtract 0 7 hours from PMI ERT 41 Steering tie rods and arms and slack adjusters A amp B Check steering column shaft assembly and steering gear for any deficiency or looseness Examine all steering linkage and arms for wear looseness or damage Check for proper mounting and operation of steering damper Rotate components and check for end play Examine kingpins for excessive wear Lubricate the tie rods and other steering components Inspect the power steering hoses and connections to ensure the hoses are not rubbing leaking or deteriorating 42 Brake linings B only Itis not necessary to remove the wheels on every inspection to examine the condition of the brake linings However on every service make a visual inspection of the brake drum and lining This may be done by viewing the lining through the inspection hole in the dust shields or by removing the dust shields After brake inspection reinstall the dust shields Local management must ensure that all brakes are properly maintained Once a year remove all wheels to inspect brake assemblies linings and drums Check for missing non functioning loose contaminated or cracked parts such as brake drum shoes rotors pads linings brake chamber chamber mounting push rods or slack adjusters Check for S cam roll over Check for audible air leaks around brake components and lines Check hoses brake lines and chambers for leak
32. released for service ensure that seat seatbelt steering wheel and shift lever are clean When the quality assurance road test is satisfactorily completed enter the work order number and odometer reading in the spaces provided at the bottom of Form 4546 C Sign and date the form Return the vehicle to service Compressed Natural Gas CNG Vehicles Cab Area 68 Fill valve and starter interrupt switch A amp B Check the condition of the fill valve and dust cover On some CNG systems the dust cap must be in place to engage the starter Ensure that the interrupt switch is operating properly Some models of CING systems have a filter located in the fill line If the vehicle is equipped with this filter service the filter during each PMI See the vehicle s service manual for proper servicing procedures Check all components and connections for leaks using a non ammonia soap solution and an electronic leak detector It is important that all connections be checked for leaks during the PMI Repair all leaks 69 Warning lights and engine operation A amp B Start the engine With the engine running on CNG check the operation of the engine All CNG vehicles have a light on the dash to inform the driver what fuel the engine is operating on Check the operation of this light Check the operation of the engine hour meters for both CNG and gasoline 70 Wiring A amp B Examine all wiring for chafing and for proper connection to the CNG
33. spring leaves or broken center bolts Check the tightness of spring U bolts and check for indications of misaligned or shifted springs 23 Radius rods and bushings A amp B Check all radius rods bolts and bushings for tightness and condition 24 Coupler plate and king pin condition A amp B Use a flatness gauge to check the flatness of the coupler plate If flatness exceeds 1 4 inch or if the pin fails to meet the specification replace king pin coupler plate Using a king pin gauge and square inspect the mounting height squareness and diameter of the king pin Inspect the pin s mounting for cracks 25 Brake linings B only Remove all wheels to inspect brake assemblies linings and drums Check for missing non functioning loose contaminated or cracked parts such as brake drums shoes rotors pads linings brake chamber chamber mounting push rods or slack adjusters Check for S cam roll over Check for audible air leaks around brake components and lines Check hoses brake lines and chambers for leaks Ensure that these items do no rub against any components Replace brake linings that have 8 32 inch or less of lining material remaining Record the findings on Form 4546 F The estimated time to perform this brake inspection on a trailer is 1 hour per axel This time includes adjustment of the wheel bearings and replacement of the seals 85 Trailers B6 PMI Program 26 Brake chamber push rod travel an
34. steering conditions 23 Tire probe condition and tread depths A amp B Probe tires and remove foreign objects such as nails or glass Check all tire tread depths Replace a tire if the tread is less than 2 32 inch or if winter conditions are a factor Record tread depth for each tire in the spaces provided on Form 4546 B 24 Bumpers reflectors lenses and mud flaps A amp B Examine bumpers reflectors and lenses for damage or environmental deterioration Examine condition of mud flaps and mounting for damage 25 Logos markings posters and beltline A amp B Check exterior markings and decals to ensure they are not faded scratched torn or missing and that they are positioned properly Update decals as needed Check the beltline and vehicle numbers in the same manner Review Fleet Management Bulletin V 18 94 for more information on vehicle markings 26 Rear door security and condition A amp B Check the rear door lock for proper operation and security Inspect the overhead door pull down strap and door seals 25 Light Delivery Vehicles 26 PMI Program 27 Interior condition cargo door floors and roof A amp B Inspect the cargo light With the rear door pulled down inspect the roof and side panels for holes signs of leaks or other damage Inspect and lube rear door spring assembly cable rollers door hinges and other moving parts Operate and lube the cargo vent hardware Check the parti
35. the air pressure build up time test make sure that the air starter air reservoir contains at least 100 PSI Continue running the engine at high idle Start timing when the air pressure gauge reaches 85 PSI and stop timing when the air pressure gauge reaches 100 PSI The air pressure should build up from 85 PSI to 100 PSI within 40 seconds Note The average build up time is approximately 15 seconds Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Cargo Vans 21 Governor range A amp B Reduce service air pressure to governor cut in pressure by fanning the brake pedal Continue running the engine at high idle The air pressure gauge will start to increase at approximately 100 PSI Note the cut in pressure The governor will allow the air pressure to increase to approximately 120 PSI Note the cut out pressure When the governor reaches cut out pressure the air dryer will cycle If the air dryer does not cycle perform service on the air dryer Refer to the vehicle s service manual for proper serving procedures Enter the cut in and cut out pressures on Form 4546 D The difference between cut in and cut out pressure must not exceed 25 PSI 22 Perform air system leak checks and service air dryer A amp B A With maximum pressure engine stopped and parking brake applied allow pressure to stabilize for at least 1 minute Observe the dash gauge pressures for 1 minute and note any pressure drop Air pressure drop s
36. the parking brake was released to the point the brakes were applied This is push rod travel and it should be as short as possible without brake drag and equal on the same axle Check the angle formed between the brake chamber push rod and slack adjuster arm It should be at least 90 degrees when the brakes are fully applied Refer to the vehicle s service manual for proper specifications All late model tractors are equipped with automatic slack adjusters If the orange band painted into grooves on the push rod is visible that indicates that the self adjuster is not working or that other foundation brake service may be required 44 Bearing play and condition A amp B Check the wheel bearing for excessive play Adjust if necessary Do not service wheel bearings except on brake service unless operating conditions warrant operation in hub deep water etc 45 Suspension springs shocks and hangers A amp B Examine all spring hangers shackles shackle pins and bushings for wear Check for sagging or broken spring leaves or broken center bolts Check the tightness of spring U bolts and check for indications of misaligned or shifted springs Examine shock absorbers for leaks loose brackets or worn grommets Check for loose axle positioning parts and signs of axle misalignment 46 Transmission and mountings A amp B A Manual Transmissions Inspect the shifter boot for deterioration and broken seal springs Check the trans
37. the vehicle NGV 2 tanks have a 15 year life from the date of manufacture and do not require recertification 77 Lines valves and regulators A amp B Check the condition of all lines Make sure they are not rubbing against any other components Ensure that the brake cable is not rubbing against the fuel tank or brackets Inspect the lines and valves for proper attachment Ensure that there are no kinks and that the lines are protected from damage Inspect the valve condition and the operation of the manual shut off valve Ensure that the shut off valve is properly labeled Inspect the regulators for damage On some systems the regulators have a filter inside service that filter during B PMls Refer to the vehicle s service manual for proper procedures 78 Reserved 79 Reserved When the CNG inspection is completed return to Line 66 Note Estimated inspection times for light delivery vehicles Estimated Inspection Time hours Level A 1 8 Level A with CNG 2 0 Level B 3 0 Level B with CNG Vehicle Maintenance Bulletin V 07 98 PMI Program Intermediate Delivery Vehicles PMI Guidelines for Intermediate Delivery Vehicles These tools are needed to perform the PMI Miscellaneous hand tools Spray lubricant Shop rags Flashlight Air pressure gauge Tread depth gauge Tire square Air chuck Grease gun Battery load tester scan tool if gas powered Engine analyzer with emission tester if gas po
38. the work order 19 Reserved 20 Reserved Circle Inspection 21 Tire inflation A amp B Examine condition of all tires for damage wear and proper inflation If a tire is 10 PSI or more low investigate the cause for the loss of air pressure and Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Administrative Vehicles make corrections Use a valve cap Ensure that tire pressure decals are the correct ones for the vehicle and are positioned properly Refer to Poster 49 Tire Pressure Chart for a list of proper tire pressures 22 Lug nuts wheels hubs and alignment A amp B Inspect lug nuts wheels and hubs for tightness and elongation around holes Check wheels and rims for cracks straightness missing lug nuts and broken studs Use a torque wrench to retorque the lug nuts Visually inspect the front tires Where there are signs of unusual tire wear investigate the cause of the wear problems Balance front tires and align front end when indicated by uneven wear or abnormal steering conditions 23 Tire probe condition and tread depths A amp B Probe tires and remove foreign objects such as nails or glass Check all tire tread depths Replace a tire if the tread is less than 2 32 inch or if winter conditions are a factor Record tread depth for each tire in the spaces provided on Form 4546 A 24 Bumpers reflectors and lenses A amp B Examine bumpers reflectors and lenses for dama
39. 22 Lug nuts wheels hubs and alignment Aa 90 Antifreeze protection level P Tire probe condition and tread depths iu fa 51 Alkalinity protection LF 432RE S21R J 32DR 32 Replace or recycle coalant as required Bumpers reflectors lenses and mud flaps 33 Radiator hoses and af Logos m dngs pasters and beltline 34 Belts and pulleys 3 Rear dor security and condition 29 Alternator and power steering Interior condition cargo door floors and roaf 56 Fuel lines fuel system and linkage Cargo restraining devices j7 Fuel filter air filter and PCV filter 29 Fuel cap door and filler neck 58 Clean battery post and cables i 30 Accident kit Battery box and hold downs PS Form 4546 B March 1998 PREVENTIVE MAINTENANCE INSPECTION GUIDELINES continued pa a Engine Compartment Area con t IS CNG Vehicles con t 60 Wiring and hoses d su 70 Wiring SL Banery load est vol eae 63 Alternator output test volts iiA 72 CNG labels 64 Regulator voltage INI BI 73 CNG components 65 Emission control systems 74 Emission control systems HC ppm CO atidle HC ppm CO at idle HC ppm CO 96 at 2500 RPM HC ppm CO __ at 2500 RPM CO 3b at idle Qe CO ___ 96 at idle CO gt a 6 at 2500 RPM Oe 926 CO at 2500 RPM ir dh Underneath Inspection pee ooo EM 6B Fill valve and starter au NE 69 Warning lights z Note If damage
40. B Cab Area 1 Review vehicle jacket modification orders and repair tags A amp B Prior to each preventive maintenance inspection review the vehicle jacket to determine the nature and extent of work to be performed Reviewing the vehicle jacket provides maintenance personnel with the vehicle s history Compare the current mileage with the mileage at the last PMI Examine the file to determine when items such as brake work and tune ups were performed last Review the vehicle records for any pending Vehicle Modification Orders and for any history of repetitive repairs Review Forms 4565 Vehicle Repair Tag 2 Road test A amp B Drive the vehicle and check the engine for smooth acceleration and power Check transmission slippage and shift points Check steering for ease of operation wander pulling etc Listen for any unusual noises 3 Leaks doors door locks handles and steps A amp B Check the operation of the doors latches locks and strikers Check door hinges and weather seals Inspect the handles for proper operation and security Check the alignment and the door for adjustment Check the door and window seals for wear and damage Check the condition of steps and step wells 4 Seat belt and interior A amp B Examine seat mounts seat coverings adjusting mechanisms seat belts retractors and anchors Check the sun visors and other inside cab components for operation and condition 5 Key ignition
41. B Check the differential fluid level and check for leaks Fill as necessary Check the breather hose for restrictions and for proper operation 45 Undercoating condition A amp B Inspect the condition of the undercoating Touch up the undercoating annually to ensure the long life cycle for postal vehicles After accident repairs are made reapply rustproofing 46 Reserved 47 Reserved 48 Reserved Engine Compartment Area 49 Engine compartment A amp B Raise hood and examine and lubricate hood latches hinges and hood support Fill windshield washer reservoir and check the level of the brake master cylinder Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Light Delivery Vehicles 50 Antifreeze protection level A amp B Before removing the radiator overflow tank cap squeeze the hoses to see if the system is pressurized or hot Carefully remove the radiator cap and check the seal Inspect the fluid level Test coolant mixture for freeze protection with a refractometer or test strip Add quantities as necessary to maintain a solution of 50 antifreeze and 50 water Record the protection level in the space provided on Form 4546 B 51 Alkalinity protection A amp B Test corrosion resistant properties of the coolant with a coolant test strip If test results are unsatisfactory drain flush and refill cooling system with a solution of 50 antifreeze and 50 water 52 Replace or recycle
42. B Compartment ATga ini a niod ie eR onra ke nedaoecae Cops bi dbcigi PREDI ANAN A RE d 28 Compressed Natural Sas ONG Vehicles Lilcucr kx neo uan ERO wires DU rITERYITEV EES BORE Bee es 34 RABAT I LII3 madu ceder tide apa did dudes Fiet Eit Uc Eo P ap FRA Depas quus ya ruga sa 34 Engine GOMPATENGM alla carddn aes Erro EERERaa CERA cet Eis DOE SR NR ECRANS RENE lh ote MS 35 Hndemesth Insaeatim iique seda Dua tera ITeTa owen antes SOTO oe eee ore te ae 35 June 1 1998 ii Contents PMI Program PMI Guidelines for Intermediate Delivery Vehicles ijea LERRA EE EET Y CBE AES fetes x cux Deen act eh baa a ua ip cto LUCAS se E S acm iste Aes lbs ain n n A s ge n pos 38 EAE ETE AREE E AE R EESE AEN EE EE ERE ge he BY oc eee aera CES 41 Ungemesth Ies OD LAIDEP 11s aiat x ora x adak ical la de erem oem aiias o large Ign t 42 Endine Compartiment ANOR 6 cuu summae ak ck RR ACRES RE ATE RC n d ELA 44 Compressed Natural Gas CNG Vehicles 1 1 ces titisicssisnisiniinieirsrisrant rensa wri 47 Eod ILI iras ote Sere es tnch Side Rh aw ARMS alag Sele dade Aaaa Pedal he Malki Race A blared a R MANERA i a ga E 47 ENGNG COMBARITIGI 8 soca ics aa ox HET rape RAI tux IdesuddesdcxiobuebRrrsrszdaergzresq i 48 unaermeait EDACH iuo vam tales pain ERR trs pee adsensu 4rd ruam uaruriut i 48 PA Guidelihes Tor Cargo Vang covenant nimimm IRA 73873 R46 PR i A 51 ou PANE re os 7 a 90 Depa Sued Ole ee ee Mo SECS BE aie eA Re RTT Ol er dez ATA ERA MU EM TAS
43. Check the wear rate of the shoes and compare the shoes to new shoes For example brake linings that have 4 32 inch remaining are not worn out if the vehicle has gone three or four inspections since the brakes were new The original amount of shoe may have been only 8 32 inch The inspector must balance brake safety against the risk of throwing away good lining material Brake linings with less than 2 32 inch must be replaced Inspect the parking brake cables to make sure they are operating properly secure and not frayed The B PMI ERT includes the time for the brake inspection If the brakes need to be inspected during an A PMI the inspection time must be written as a line item Form 4543 Vehicle Maintenance Work Order The estimated time to perform this brake inspection on an intermediate vehicle is 1 5 hours which includes the time to clean inspect and adjust all brakes 38 Bearing play and condition A amp B Check the wheel bearing for excessive play Adjust if necessary If the vehicle has been driven 25 000 miles since the last front wheel bearing service or if operating conditions warrant operation in hub deep water etc clean and pack the front wheel bearings and replace seals Always service bearings when performing brake service 39 Suspension springs shocks and hangers A amp B Examine all spring hangers shackles and bushings for wear Check for sagging or broken spring leaves or broken center bolts Inspect the
44. ECTION GUIDELINES ADMINISTRATIVE VEHICLES UNITED STATES POSTAL SERVICE Vehicle No Assigned Location Due Date In box before each item indicate condition as follows Ni Item is OK 0 Adjustment Made i Key ignition and door key assembly Fluid leaks and engine mounts Buzzer and warning device es Change oil filter and lubricate Starter action unusual sounds and neutral switch Steering tie rods and arms Gauges horn heater oil pressure and mirrors Brake linings LF 32 RF 32 Accessories glass windshield wipers and fan LR 32 RR 32 Steering play inches Bearing play and condition Parking brake and foot brake test o a Suspension springs shocks and hangers Transmission and mountings 3 Lights turn signals and back up lights 1l Exhaust systems converter and muffler Floor and underdash wiring i 2 Driveline alignment and condition Window window guides and regulator 43 Differential and breather Authorized cab decals and Label 70 Undercoating condition General paint and body condition MEX 2b E es eee et i lt rdc B Circle Inspection 23 Tire probe condition and tread depths LF JS2RRSO 41R 2 RR _y32 4 Bumpers reflectors and lenses Logos markings posters and beltline Interior condition floors and roof Alternator and power steering amr 27 Fuel cap
45. SE 52 Circle Inspection FERRY Y xni rre y edet ow wa xv soe de Scena daaa AA Eu Ep pi areis s ith MO Urdema mspsclon LUDE vis eux sco Wr eem Y ER E dr EOD Rand d aud LEE IE ED CIR PIS 58 Ende Coptparment AES maaa a r Saree a annn pees eoa 60 PMI Guidelines for Tractors ssesssssssssesssssso AT E sete a 65 LB GE oi iade BaARARMAREARRADARRRASRERCRASARESRUMANM A A IAE DIS HD 66 Bree Inspecteur s xata Norm XU Ro RA OS ele AERA RARO QURE IIR Aa MI Pg 70 GEIS insaeetlon ule iir aos as pes rancitadtoas iti svorsinedwendriadeiida big bita 74 pogine Gombaltment Pras s iosiadkeECliTRiR RRAWLRAWaRRVAASAMEXVAZATARAiqe Rees Be tib i PMI Guidelines for Trailers TT Pee Seo o N yore sath ab rq in ME Walk Around M 20420056259 49 T SS A n26 50009000005 QoS LEE ERES 214544555223 tee 82 Wheels Tires and Underneath LARES ses Tee eG ease As Aa tek hace Als AGE Appendix Forms Used inthe PMI Program 296565 32232955253 tas So iv Vehicle Maintenance Bulletin V 07 98 PMI Program Introduction Introduction Background The changes contained in this Bulletin are part of ongoing efforts to update and revise the Postal Service fleet s Preventive Maintenance Inspection PMI Program Our goal is to continually improve the reliability safety and appearance of Postal Service vehicles while controlling maintenance costs Il Effective Date This Bulletin is effective immediately upo
46. UNITED STATES eee Bc POSTAL SERVICE Preventive Maintenance Inspection PMI Program Vehicle Maintenance Bulletin V 07 98 June 1 1998 Transmittal Letter A Purpose This Vehicle Maintenance Bulletin describes the Preventive Maintenance Inspection PMI Program and the forms used in completing vehicle inspections B Distribution This bulletin is distributed to Manager Operations Programs Support Manager Vehicle Maintenance Manager Vehicle Maintenance Facility C Additional Copies Additional copies of this bulletin or of the forms used for vehicle inspections can be ordered from the Material Distribution Centers by submitting Form 7380 MDC Supply Requisition or by calling 800 332 0317 option 3 D Comments Written comments about this bulletin can be sent to VEHICLE MAINTENANCE US POSTAL SERVICE 475 L ENFANT PLZ SW RM 7142 WASHINGTON DC 20260 2802 E Cancellations This bulletin replaces Fleet Management Bulletin V 11 93 dated 2 25 93 Effective Date This bulletin is effective June 1 1998 era Michael F Spates Manager Delivery Contents InIToguctione io cis G04 Cede tees 5024 Ks EESTECPR FERES E EREETA TE Ey xA Jara wl EET eps T n E chad 3 ed era oar wera s SR pan BO a yak awe s anh dca ES d res Saco 9E ere 1 Il Effective Date XV SAO INS OD MEE S Kati EEL TCE LE Ter 1 Ill New Inspection Checklists seen SAG Hie odes MATRE n 1 IM LOVEIS OLTISDOCHON Sigue e pr o qu
47. V 07 98 PMI Program June 1 1998 Tractors correct ones for the vehicle and are positioned properly Refer to Poster 49 Tire Pressure Chart for a list of proper tire pressures 27 Lug nuts wheels hubs and alignment A amp B Inspect lug nuts wheels and hubs for tightness Check wheels and rims for cracks straightness unseated locking rings and broken or missing lugs studs or clamps Inspect for bleeding rust stains Check for loose or damaged lug nuts and elongated mounting stud holes Use a torque wrench to retorque the lug nuts Check the oil level in the hubs Visually inspect the front tires Where there are signs of unusual tire wear investigate the cause of the wear problems Balance front tires and align front end when indicated by uneven wear or abnormal steering conditions 28 Tire probe condition and tread depths A amp B Probe tires and remove foreign objects such as nails or glass Check all tire tread depths Replace a tire if its tread is less than 4 32 inch Use a straightedge to check that dual tires are matched to within 1 2 inch Replace any tire that is not matching Record the tread depth for each tire on Form 4546 E The tread design is to match on each axle 29 Bumpers reflectors lenses and mud flaps A amp B Examine bumpers reflectors and lenses for damage or environmental deterioration Examine condition of mud flaps and mounting for damage 30 Logos markings posters
48. amage to their supervisor and indicate damage on the diagram on the reverse of Form 4546 A Do not defer repairs of accident damage to a later date Prepare a separate work order and code it as an accident 30 Reserved 31 Reserved 32 Reserved 33 Reserved Underneath Inspection Lube 34 Fluid leaks and engine mounts A amp B Before changing the engine oil inspect the engine and transmission for fluid leaks Check the radiator for leaks Inspect lower radiator hose for condition and leaks Examine motor mounts for deterioration and fatigue 35 Change oil filter and lubricate A amp B Change engine oil and filter during each PMI Clean all fittings perform complete lubrication and check fluid levels and condition in accordance with all items as shown on the lubrication chart Write the lube oil and filter as a line item on Form 4543 Vehicle Maintenance Work Order Note If the lubrication is performed by someone other than the person doing the PMI subtract 0 3 hours from PMI ERT 36 Steering tie rods and arms A amp B Check steering column shaft assembly and steering gear for any deficiency or looseness Examine all steering linkages and arms for wear looseness or damage Check steering damper for proper mounting and operation Rotate components and check for end play Examine ball joints kingpins for excessive wear or for excessive resistance to turning front wheels Check the condition of the ball joints
49. and beltline A amp B Check exterior markings and decals to ensure that exterior markings are not faded scratched torn or missing and that they are positioned properly Update decals as needed Check the beltline and vehicle numbers in the same manner Review Publication 500 G Vehicle Guidelines for more information on vehicle markings 31 Glad hands hoses and electrical plug A amp B Inspect the condition of the glad hands Replace glad hand seals annually Examine the condition of the intervehicular electrical cord and connector air hoses and storage connectors 32 Fifth wheel assembly B only Examine the fifth wheel locking and release mechanism surface condition tilting trunnions and mounting brackets Examine condition of ground strap and connections Examine quide ramps for loose or broken mounting bolts and welds During every PMI follow the instructions below A Periodic Inspections and Adjusiments Perform all of the following during each PMI Perform steam cleaning first to ensure a good inspection 71 Tractors 72 PMI Program 1 Inspection and Adjustment of Fifth Wheel Mounting and Assembly a Inspect the fifth wheel mounting for bent worn or broken parts Use a small pry bar to pry up each pivot ear If the top plate moves more than 1 2 inch replace or rebuild the mounting subassembly Check torque and replace any missing or damaged bolts Check for broken or distorted components and repa
50. assembly 35 Alr tanks valves hoses pipes d air gauge 6 Buzzerandwarningdevices d 36 Accident damage list on dlagrang oj pmoMwewesamgss ET js KT UR _ js 8 Starter action unusual sounds and neutral switch 31 Glad hands hoses and electrical plug Underneath M Steering play Inches i Lights turn signals and back up lights 3 Floor and underdash wiring l Brake linings LF 32 RF F Clutch operation pedal and pads NowDriven L 32 R 32 5 Window regulator and door hinges Driver Loo s R Safety equipment fire extinguisher and accident kit 3 Brake chamber push rod travel and slack adjusters Authorized cab decals and Label 70 Bearing play and condition Drain air reservoirs 15 Suspension springs shocks and hangers Low air warning system Transmission and mountings Alr preste build up time Governor range cutout ___ cut in Perform air system leak checks and service air dryer 7 3 Clean inside and out General paint and body condition 25 Wax vehicle Circle Inspection Engine E Area 26 Tire inflation BS 34 Engine compartment a 27 Lug nuts wheels hubs and alignment 28 Tire probe condition and tread depths LF 3 Replace or recycle coolant as required 32 Non driven L RO 32 LRI 32 RRI 32 RRO 32 iT Radiator hoses and leaks DrvwLRO 32LRI 32 RRI 32 RRO
51. ation on these systems If the vehicle is equipped with a block heater inspect the electrical cord and plug for damage 9 Gauges horn heater oil pressure and mirrors A amp B With the car on check the operation of all gauges Check the horn for operation and loudness Turn on the heater defroster and all other cab systems Check the oil pressure gauge when the engine starts If the engine is warm note this pressure Refer to the manufacturer s recommendations on the oil pressures for both idling and operating RPM Examine all mirrors and mounting attachments for loose or damaged parts Make sure that the mirrors are the proper mirrors for the vehicle and that they are in good condition 10 Accessories glass windshield wipers and fan A amp B Operate and examine all switches and controls Check windshield washer operation Examine all glass for cracks chips or lamination separation Check wiper arms and blades for operation and condition Examine ventilation fan if equipped for operation and safety quards 11 Steering play A amp B With the engine running and the wheels in a straight ahead position turn the steering wheel in one direction until the tires begin to pivot Note the position of the steering wheel Turn the wheel in the other direction until the tires start to move Total movement of the steering wheel before the wheels begin to move should not exceed 4 inches If the play exceeds this check for parts
52. aust system must be disconnected Disconnect the vacuum harness that leads to the EGR valve from the EGR solenoid Remove the vacuum pump from the manifold side of the EGR solenoid and connect to the vacuum harness Apply approximately 20 inches of vacuum Using a mirror observe the EGR diaphragm The diaphragm should move freely and hold a vacuum for at least 20 seconds Crank the engine but don t start it Observe the vacuum and valve position The valve is good if the valve moved to the seated position and the vacuum dropped If the vacuum does not hold or the diaphragm does not move check to see if the vacuum harness hose or valve is defective f After completing the EGR systems test make sure the system is reconnected Remember the LLV uses a negative backpressure EGR valve If the vehicle being tested uses a positive or standard EGR valve follow the instructions in the service manual 3 Park Neutral Switch Check the LLV s automatic transmission by testing the park neutral switch This can be performed by using a hand held Scan tool D Ignition Timing The next function test is the ignition timing Follow the procedure on the underhood emissions label 1 Start the engine Verify that the check engine light is not on If the light is on a code is stored in the Electronic Control Module ECM memory and the emission system needs to be serviced 2 With the engine at operating temperature ground the diagnostic connector l
53. be checked for leaks during the PMI Repair all leaks 76 Fuel tank A amp B Check the fuel tank mountings Check all bolts for tightness and torque if necessary Inspect the tank for corrosion cuts dents or bulges Damage to tanks must not exceed the tank manufacturer s criteria Inspect the condition of the CNG tank s fiber covering The tank must not have any exposed metal surfaces Make sure that the tank is not rubbing against any components Ensure that the DOT label is on the tank and is readable and review the expiration date to see when the tank was last certified Fuel tanks must be removed every 3 years to be hydrostatically pressure tested by a certified testing facility Acoustic tank testing may be substituted for the hydrostatic pressure test This test is done with the tank mounted on the vehicle NGV 2 tanks have a 15 year life from the date of manufacture and do not require recertification T7 Lines valves and regulators A amp B Check the condition of all lines Make sure they are not rubbing against any other components Ensure that the brake cable is not rubbing against the fuel tank or brackets Inspect the lines and valves for proper attachment Ensure that there are no kinks and that the lines are protected from damage Inspect Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Intermediate Delivery Vehicles the valve condition and the operation of the manual shut off valve Ensure that
54. be riveted to the dash 18 General paint and body condition A amp B Inspect all painted surfaces for deterioration and condition Repaint vehicles on an as needed basis as determined by the Manager Vehicle Maintenance Do not delay any wear and tear repairs painting or accident caused body work Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Light Delivery Vehicles 19 Wax vehicle B only Wax the vehicle at least once a year The estimated time to wax the vehicle is 1 hour Add this as a line item on the work order 20 Reserved Circle Inspection 21 Tire inflation A amp B Examine condition of all tires for damage wear and proper inflation If a tire is 10 PSI or more low investigate the cause for the loss of air pressure and make corrections Use a valve cap Ensure that tire pressure decals are the correct ones for the vehicle and are positioned properly Refer to Poster 49 Tire Pressure Chart for a list of proper tire pressures 22 Lug nuts wheels hubs and alignment A amp B Inspect lug nuts wheels and hubs for tightness and elongation around holes Check wheels and rims for cracks straightness missing lug nuts and broken studs Use a torque wrench to retorque the lug nuts Visually inspect the front tires Where there are signs of unusual tire wear investigate the cause of the wear problems Balance front tires and align front end when indicated by uneven wear or abnormal
55. d exhaust emission systems Restart the engine and verify that it is being operated in closed loop The tester will measure the emissions of four gases carbon monoxide CO carbon dioxide CO2 hydrocarbon HC and oxygen O2 Run the engine at 2250 to 2750 RPM for 30 consecutive seconds Record the readings in the space provided on Form 4546 B Run the engine at idle between 400 and 1010 RPM for 30 consecutive seconds Record the readings in the space provided on Form 4546 B If the basic engine and ignition conditions are within specifications and the CO CO HC Os and scan data meet OEM specifications do not perform any further tune up repairs However if a problem is indicated in the basic engine ignition or fuel emission system or if serial data are not within specifications perform a complete engine analysis and make repairs as necessary List the results and repairs on Form 4546 B C Functional Test 1 Fuel fill pipe leaded gas nozzle restrictor Insert the dowel into the gas tank filler neck The dowel must not fit into the fill pipe 2 EGR System This check has many variables Refer to the vehicle s emissions or service manual for the proper procedure a Begin by determining which EGR system is being used There are three types of EGR valves standard positive back pressure and negative back pressure Knowing the type of valve is very important since the testing procedures are different for each valve To
56. d locking rings and broken or missing lugs studs or clamps Inspect for bleeding rust stains Check for loose or damaged lug nuts and elongated mounting stud holes Use a torque wrench to retorque the lug nuts Check the oil level in the hubs Visually inspect the front tires Where there are signs of unusual tire wear investigate the cause of the wear problems Balance front tires and align front end when indicated by uneven wear or abnormal steering conditions 28 Tire probe condition and tread depths A amp B Probe tires and remove foreign objects such as nails or glass Check all tire tread depths Replace a tire if its tread is less than 4 32 Inch Use a straightedge to check that dual tires are matched to within 1 2 inch Replace any tire that is not matching Record the tread depth for each tire on Form 4546 D The tread design is to match on each axle Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Cargo Vans 29 Bumpers reflectors lenses and mud flaps A amp B Examine bumpers reflectors and lenses for damage or environmental deterioration Examine condition of mud flaps and mounting for damage 30 Logos markings posters and beltline A amp B Check exterior markings and decals to ensure that exterior markings are not faded scratched torn or missing and that they are positioned properly Update decals as needed Check the beltline and vehicle numbers in the same manner Review Publ
57. d slack adjusters When checking the brake chamber push rod travel air pressure system must be approximately 90 PSI to 100 PSI Stop the engine release the parking brake and apply and hold the brakes Measure the distance that the push rod traveled from the point the parking brake was released to the point the brakes were applied This is push rod travel and it should be as short as possible without brake drag and equal on the same axle Check the angle formed between the brake chamber push rod and slack adjuster arm It should be at least 90 degrees when the brakes are fully applied Refer to the vehicle s service manual for proper specifications All late model trailers are equipped with automatic slack adjusters If the orange band painted into grooves on the push rod is visible that indicates that the self adjuster is not working or that other foundation brake service may be required 27 Air tank mounting and valves A amp B Inspect air tank and drain valve for mounting and damage Open and drain tanks completely 28 Air lines hoses wiring and connections A amp B Inspect brake lines for leaks Check the condition of all air hoses and ensure that they are not rubbing against any metal components Check the condition of all wiring and ensure that no wiring is exposed 29 Axle alignment B only To check axle alignment on a single axle trailer install axle extension on left front axle install king pin adapter attach m
58. e and increase the engine speed to 300 RPM above idle The vehicle should not move If the vehicle moves the brakes need to be adjusted c Air dryer Some models of air dryers may require annual service Refer to the vehicle s service manual for service procedures 23 Clean inside and out A amp B During each PMI pressure clean the engine and chassis Wash the vehicle before performing repairs Take extreme precautions when washing inside of vehicles Note The estimated repair time ERT shown on the back of Form 4546 E was calculated assuming the use of an automatic truck washer Add 0 5 hours if the vehicle is hand washed and 0 3 hours for cleaning windows and inside of vehicle 24 General paint and body condition A amp B Inspect all painted surfaces for deterioration and condition Repaint vehicles on an as needed basis as determined by the Manager Vehicle Maintenance Do not delay any wear and tear repairs painting or accident caused body work 25 Wax vehicle B only Wax the vehicle at least once a year The estimated time to wax the vehicle is 1 hour Add this as a line item on the work order Circle Inspection 26 Tire inflation A amp B Examine condition of all tires for damage wear and proper inflation If a tire is 10 psi or more low investigate the cause for the loss of air pressure and make corrections Use a valve cap Ensure that lire pressure decals are the Vehicle Maintenance Bulletin
59. e 1 1998 Intermediate Delivery Vehicles Inspect the bulkhead and corners for damage Do not delay any wear and tear repairs painting or accident caused body work 20 Wax vehicle B only Wax the vehicle at least once a year The estimated time to wax the vehicle is 1 hour Add this as a line item on the work order Circle Inspection 21 Tire inflation A amp B Examine condition of all tires for damage wear and proper inflation If a tire is 10 psi or more low investigate the cause for the loss of air pressure and make corrections Use a valve cap Ensure that tire pressure decals are the correct ones for the vehicle and are positioned properly Refer to Poster 49 Tire Pressure Chart for a list of proper tire pressures 22 Lug nuts wheels hubs and alignment A amp B Inspect lug nuts wheels and hubs for tightness and elongation around holes Check wheels and rims for cracks straightness missing lug nuts and broken studs Use a torque wrench to retorque the lug nuts Visually inspect the front tires Where there are signs of unusual tire wear investigate the cause of the wear problems Balance front tires and align front end when indicated by uneven wear or abnormal steering conditions 23 Tire probe condition and tread depths A amp B Probe tires and remove foreign objects such as nails or glass Check all tire tread depths Replace a tire if its tread is less than 4 32 inch Use a straightedge to chec
60. e performing repairs Take extreme precautions when washing Inside of vehicles Note The estimated repair time ERT shown on the back of Form 4546 B was calculated assuming the use of an automatic truck washer Add 0 3 hours if the vehicle is hand washed and 0 2 hours for cleaning windows and inside of vehicle 13 Lights turn signals and back up lights A amp B Examine all lenses for cracks deterioration and brightness Check all lights for proper operation 14 Floor and underdash wiring A amp B Inspect the floor mats for wear and tear Examine wiring and harnesses for chafing and for proper connection and support Ensure that the wiring is neatly taped and secured 15 Mail tray and brackets A amp B Check the mail tray slide mechanism for proper operation Ensure that the brackets and bolts are secure Inspect supports for cracks 16 Window window locks regulator and door slides A amp B Test the windows and regulators to ensure they are working properly Inspect the window guides and locks for proper operation 17 Authorized cab decals and Label 70 A amp B Ensure that only authorized decals are present and that they are positioned properly on the dashboard for visibility Remove any unauthorized decals The following decals must be displayed in each vehicle a Look Before Backing decal b Label 70 Safety Check and Vehicle Dimensions c Ina 1 4 ton AMG Label 126 Owner Driver Caution must
61. ease note m All spotter tractors must be serviced every 200 hours of operation regardless of miles traveled m All vehicles except for the 1992 and 1997 Mack tractors see below must have an oil and filter change at least every 5 000 miles They may not be driven more than 5 000 miles between oil and filter changes n The 1992 and 1997 Mack tractors must have an oil and filter change every 25 000 miles or 600 hours whichever comes first June 1 1998 3 PMI Program Administrative Vehicles PMI Guidelines for Administrative Vehicles These tools are needed to perform the PMI Miscellaneous hand tools Spray lubricant Shop rags Flashlight Air pressure gauge Tread depth gauge Air chuck Grease gun Battery load tester Scan tool Engine analyzer with emission tester Anti freeze test strips Coolant pressure tester Coil adapter Torque wrench Filter wrench June 1 1998 5 Administrative Vehicles PMI Program Explanation of Form 4546 A Preventive Maintenance Inspection Guidelines Administrative Vehicles Fill in the vehicle number assigned location due date for PMI and the type of PMI level A or B Cab Area 1 Review vehicle jackets modification orders and repair tags A amp B Prior to each preventive maintenance inspection review the vehicle jacket to determine the nature and extent of work to be performed Reviewing the vehicle jacket provides maintenance personnel with the vehicle s
62. elds Local management must ensure that all brakes are properly maintained Once a year remove all wheels to inspect brake assemblies linings and drums Check for missing non functioning loose contaminated or cracked parts such as brake drum shoes rotors pads linings brake chamber chamber mounting push rods or slack adjusters Check for S cam roll over Check for audible air leaks around brake components and lines Check hoses brake lines and chambers for leaks Ensure that these items do no rub against any components Examine slack adjusters and links Ensure the operation of automatic slack adjusters if applicable Adjust all brakes Replace brake linings that have 8 32 inch or less of lining material remaining Record the findings on Form 4546 E On the yearly brake inspection write line item Pull all wheels and drums for brake inspection on Form 4543 Vehicle Maintenance Work Order The estimated time to perform this brake inspection on a single axle tractor is 2 hours This time includes adjustment of the wheel bearings and replacement of the seals Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Tractors 43 Brake chamber push rod travel A amp B When checking the brake chamber push rod travel air pressure system must be approximately 90 PS to 100 PSI Stop the engine release the parking brake and apply and hold the brakes Measure the distance that the push rod traveled from the point
63. es replacement use only a cap with the same Original Equipment Manufacturers OEM features Failure to use the correct cap can result in a malfunctioning system Check the condition of fuel lines hoses and connections 4 Catalytic converter Examine all connections for signs of leaking exhaust 5 Exhaust gas recirculation EGR system Ensure the solenoid is in good condition and not stuck open Check that the vacuum hose is connected to the valve 6 Fuel injection sensors and connectors Inspect the wiring and connections to all fuel injectors sensors switches and to the electronic control module Check that all connectors are properly fastened and the system has not been modified After all items have been located and passed the visual inspection proceed to the tail pipe emission section of the test If any of the visual items did not pass repair all items before performing the tail pipe emission test B Tail Pipe Emission Section Below are guidelines for performing and recording engine analysis and emission test results for the vehicles Use these instructions to complete items for each type of vehicle All emission readings must be taken at 2500 RPM and then retested at idle Record the results in the spaces provided on Form 4546 A The engine must be at normal operating temperature while performing the tail pipe test Turn off all accessories Put the vehicle in park or neutral Secure the emergency brake and insert w
64. etal tape and measure the distance from the axle to the axle extension Repeat this procedure for the right front axle Compare the two measurements If the measurements vary more than 1 8 inch align the axle To check axle alignment on a tandem axle trailer first check the left side by measuring from the left front axle to the left rear axle Repeat this procedure for the right side Compare the two measurement If the measurements vary more than 1 8 inch align the rear axle 30 Body cross members A amp B Check the condition of all body cross members for cracks and broken welds 31 Undercoating condition A amp B Inspect the condition of the undercoating Touch up the undercoating annually to ensure the long life cycle for postal vehicles After accident repairs are made reapply rustproofing 32 List all repair actions on Form 4547 or 4543 A amp B List all repair actions on Form 4541 Order Invoice for Vehicle Repair or Form 4543 Vehicle Maintenance Work Order Schedule work generated by the PMI Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Trailers 33 Quality assurance road test A amp B After the required repairs have been completed pull the trailer Check the trailer for wander and pulling Listen for any unusual noise Check brake stopping ability and parking brake holding ability When the quality assurance road test is satisfactorily completed enter the work order number
65. excessive play Adjust if necessary If the vehicle has been driven 25 000 miles since the last front wheel bearing service or if operating conditions warrant operation in hub deep water etc clean and pack the front wheel bearings and replace seals Always service bearings when performing brake service 39 Suspension springs shocks and hangers A amp B Examine all spring hangers shackles and bushings for wear Check for sagging or broken spring leaves or broken center bolts Inspect the condition of the stabilizer bar Check tightness of spring U bolls Examine shock absorbers for leaks damage or worn grommets On front wheel drive vehicles inspect the McPherson suspension system 40 Transmission and mountings A amp B Check transmission fluid level and condition Service transmissions only to correct a deficiency or if transmission fluid smells burned or contains metal or friction material particles If fluid level is adequate and is not burned or contaminated do not service If doubtful about fluid condition drain out a sample for closer examination Examine transmission mounts for deterioration Check the transmission cooler lines to make sure they are not rubbing against any other components Inspect the speedometer cable and attachment Ensure there are no kinks or leaks and that the cable bends smoothly and is protected from possible damage 41 Exhaust systems converter and muffler A amp B Examine complete ex
66. f it does investigate the cause and repair as needed If the trailer is not hooked to a tractor perform the air system test with an air system tester and shop air using the following procedure Install the two test glad hands to the corresponding trailer glad hands Apply approximately 120 PSI to the emergency side of the trailer s air system and approximately 80 PSI to the service side of the system Allow the air pressure to stabilize for 1 minute Observe the dash gauge pressures for 1 minute and note any pressure drop Air pressure should not drop more than 1 PSI in 1 minute and the air in the emergency side should not bleed into the service side 8 Lights and turn signals A amp B Examine all lenses for cracks deterioration and brightness Check all lights for proper operation 9 Electrical junction box A amp B Inspect the condition of the junction box and electrical receptacle Ensure that the mounting is secure Examine wiring and harnesses for chafing and for proper connection and support To prevent corrosion coat the terminals with a liberal application of dielectric grease 10 Rear door and seals A amp B Inspect the overhead door pull down strap and door seals Replace any damaged panels Inspect and lube rear door spring assembly cable rollers door hinges and other moving parts Operate and lube the cargo vent hardware 11 Logos markings and beltline A amp B Check exterior markings and decal
67. ge or environmental deterioration 25 Logos markings posters and beltline A amp B Check exterior markings and decals to ensure they are not faded scratched torn or missing and that they are positioned properly Update decals as needed Check the beltline and vehicle numbers in the same manner Review Publication 500 G Vehicle Guidelines for more information on vehicle markings 26 Interior condition floors and roof A amp B Check the condition of the interior including floors seats and headliner Inspect the roof and side panels for holes signs of leaks or other damage 27 Fuel cap door and filler neck A amp B Remove the filler cap and inspect the cap seal and retaining chain If equipped Check the integrity of the no leaded fuel nozzle restrictor in the fuel filler pipe Ensure that the restrictor has not been removed or enlarged The hole must be small enough to prevent the entry of a leaded fue nozzle In some states a special tool must be used for this test Inspect and lubricate the door hinge and spring 28 Accident kit A amp B Ensure that the forms compartment contains Item 087 H Accident Report Kit and the vehicle s operator s manual Remove all other debris from the forms compartment Administrative Vehicles 10 PMI Program 29 Accident damage list on diagram A amp B During each PMI maintenance employees must inspect the vehicle for accident damage report any d
68. good condition and not stuck open Check that the vacuum hose is connected to the valve 6 Fuel injection sensors and connectors Inspect the wiring and connections to all fuel injectors sensors switches and to the electronic control module Check that all connectors are properly fastened and the system has not been modified After all items have been located and passed the visual inspection proceed to the tail pipe emission section of the test If any of the visual items did not pass repair all items before performing the tail pipe emission test B Tail Pipe Emission Section Below are guidelines for performing and recording engine analysis and emission test results for the vehicles Use these instructions to complete items for each type of vehicle All emission readings must be laken at 2500 31 Light Delivery Vehicles 32 PMI Program RPM and then retested at idle Record the results in the spaces provided on Form 4546 B The engine must be at normal operating temperature while performing the tail pipe test Turn off all accessories Put the vehicle in park or neutral Secure the emergency brake and insert wheel chocks or raise the drive axle s off the ground Pre condition the vehicle by running the vehicle for 4 minutes at 2 000 RPM Turn the engine off Connect the vehicle to an engine analyzer and an infrared four gas exhaust analyzer and computer scanner for a careful examination of basic engine ignition fuel an
69. h CNG is 2 0 hours ERT to perform a B PMI on an administrative vehicle is 2 0 hours ERT to perform a B PMI on an administrative vehicle equipped with CNG is 2 5 hours Completed by Date Work Order No Odometer PS Form 4546 A March 1998 UNITED STATES POSTAL SERVICE PREVENTIVE MAINTENANCE INSPECTION GUIDELINES Ba LIGHT DELIVERY VEHICLES UNITED STATES POSTAL SERVICE Vehicle No In box before each item indicate condition as follows Item is OK 0 Adjustment Made EN 34 Fluid leaks and engine mounts rq 35 Change oil filter and lubricate BERE 36 Steering tie rods and arms Brake linings LF 32 RF 32 LR 32 RR 32 inches i 38 Bearing play and condition Parking brake and foot brake test Steering play Suspension springs shocks and hangers Clean inside and out Transmission and mountings Lights turn signals and back up lights 41 Exhaust systems converter and muffler Floor and underdash wiring Driveline alignment and condition Mail tray and brackets Body hold downs hoses and wires 3 Window window locks regulator and door slides 4 Differential and breather Authorized cab decals and Label 70 Undercoating condition 8 General paint and body condition DIY epatis E Hi EE ns 42i RJ ES NOE RR Pr Circle Inspection Engine Compartment Area im 49 Engine compartment Tire inflation
70. h the mileage at the last PMI Examine the file to determine when items such as brake work and tune ups were performed last Review the vehicle records for any pending Vehicle Modification Orders and for any history of repetitive repairs Review Forms 4565 Vehicle Repair Tag 2 Road test A amp B Drive the vehicle and check the engine for smooth acceleration and power Check transmission slippage and shift points Check steering for ease of operation wander pulling etc Listen for any unusual noises If the vehicle also is powered by compressed natural gas CNG perform part of the road test with the engine running on CNG 3 Leaks doors handles and steps A amp B Check the operation of the doors tracks latches locks hinges and strikers Check door rails rollers and weather seals Inspect the handles for proper operation and security Check the door and window seals for wear and damage Check the condition of steps and step wells 4 Seat belt and interior A amp B Examine seat mounts seat coverings adjusting mechanisms seat belts retractors and anchors Check the sun visors and other inside cab components for operation and condition 5 Key ignition and door key assembly A amp B Check the keys for cracks and signs of wear Inspect the lock assemblies for signs of wear Lubricate all lock assemblies with spray lubricant 6 Buzzer and warning devices A amp B Ensure that all warning lights loca
71. haust system for leaks damage or loose hangers Examine catalytic converter for evidence of overheating 42 Driveline alignment and condition A amp B Examine propeller shaft universal joints carrier bearing and slip joint for wear or damage If vehicle has front wheel drive inspect the condition of the drive axles CV joints and CV boots 43 Differential and breather A amp B Check the differential fluid level and check for leaks Fill as necessary Check the breather hose for restrictions and for proper operation 11 Administrative Vehicles 12 PMI Program 44 Undercoating condition A amp B Inspect the condition of the undercoating Touch up the undercoating annually to ensure a long life cycle for postal vehicles After accident repairs are made reapply rustproofing 45 Reserved 46 Reserved 47 Reserved 48 Reserved Engine Compartment Area 49 Engine compartment A amp B Raise hood and examine and lubricate hood latches hinges and hood support Fill windshield washer reservoir and check the level of the brake master cylinder 50 Antifreeze protection level A amp B Before removing the radiator overflow tank cap squeeze the hoses to see if the system is pressurized or hot Carefully remove the radiator cap and check the seal Inspect the fluid level Test coolant mixture for freeze protection with a refractometer or test strip Add quantities as necessary to maintain a solution of
72. he coolant with a coolant test strip This engine is equipped with a cooling system filter and treatment system that must be serviced at each PMI Supplemental coolant conditioners such as Nalcool may be used and their condition may be tested by coolant test kits If test results are unsatisfactory drain flush and refill cooling system with a solution of 50 antifreeze and 50 water Replace coolant filter annually Add make up coolant and chemical conditioners required to ensure adequate cooling system protection 56 Replace or recycle coolant as required A amp B Replace or recycle coolant as required by the type of coolant used The service requirement might differ between coolant manufacturers Refer to the coolant manufacturer s recommendations concerning the change or recycle interval 57 Radiator hoses and leaks A amp B Pressure test complete cooling system Examine all hoses and connections for leaks or wear Inspect water pump Replace hoses as needed 58 Belts and pulleys A amp B Check all belts for condition alignment and proper tension When adjusting belts use a belt tension gauge Inspect all pulleys for alignment and condition Check for unusual noise Examine damper for deterioration or excessive vibration Examine water pump idler pulley and fan hub for noise or vibrations 77 Tractors 78 PMI Program 59 Alternator and power steering A amp B Check alternator terminal connections
73. heel chocks or raise the drive axle s off the ground Pre condition the vehicle by running the vehicle for 4 minutes at 2 000 RPM Turn the engine off Connect the vehicle to an engine analyzer and an infrared four gas exhaust analyzer and computer scanner for a careful examination of basic engine ignition fuel and exhaust emission systems Restart the engine and verify that it is being operated in closed loop The tester will measure the emissions of four gases carbon monoxide CO carbon dioxide CO5 hydrocarbon HC and oxygen O5 Run the engine at 2250 to 2750 RPM for 30 consecutive seconds Record the readings in the space provided on Form 4546 A Run the engine at idle between 400 and 1010 RPM for 30 consecutive seconds Record the readings in the space provided on Form 4546 A If the basic engine and ignition conditions are within specifications and the CO COs HC Oz and scan data meet OEM specifications do not perform any further tune up repairs However if a problem is indicated in the basic engine ignition or fuel emission system or if serial data are not within specifications perform a complete engine analysis and make repairs as necessary List the results and repairs on Form 4546 A 15 Administrative Vehicles 16 PMI Program C Functional Test 1 Fuel fill pipe leaded gas nozzle restrictor Insert the dowel into the gas tank filler neck The dowel must not fit into the fill pipe 2 EGR System
74. hield wipers fan and radio A amp B Operate and examine all switches and controls Check windshield washer operation Examine all glass for cracks chips or lamination separation Check wiper arms and blades for operation and condition Examine ventilation fan for operation and safety guards Inspect the radio mounting and connections if applicable 11 Steering play A amp B With the engine running and the wheels in a straight ahead position turn the steering wheel in one direction until the tires begin to pivot Note the position of the steering wheel Turn the wheel in the other direction until the tires start to move Total movement of the steering wheel before the wheels begin to move should not exceed 4 inches If the play exceeds this check for parts that are worn or out of adjustment Enter the amount of play in inches on Form 4546 D 12 Lights turn signals and back up lights A amp B Examine all lenses for cracks deterioration and brightness Check all lights for proper operation 53 Cargo Vans 54 PMI Program 13 Floor and underdash wiring A amp B Inspect the floor mats for wear and tear Examine wiring and harnesses for chafing and for proper connection and support Ensure that the wiring is neatly taped and secured 14 Pedal and pads A amp B Inspect all pedals for wear Make sure that the air brake pedal is clear from other components 15 Window regulator and door hinges A a
75. history Compare the current mileage with the mileage at the last PMI Examine the file to determine when items such as brake work and tune ups were performed last Review the vehicle records for any pending Vehicle Modification Orders and for any history of repetitive repairs Review Forms 4565 Vehicle Repair Tag 2 Road test A amp B Drive the vehicle and check the engine for smooth acceleration and power Check transmission slippage and shift points Check steering for ease of operation wander pulling etc Listen for any unusual noises If the vehicle also is powered by compressed natural gas CNG perform part of the road test with the engine running on CNG 3 Leaks doors and handles A amp B Check the operation of the doors latches locks hinges strikers and weather seals Inspect the handles for proper operation and security Check the door and window seals for wear and damage 4 Seat belt and interior A amp B Examine seat mounts seat coverings adjusting mechanisms seat belts retractors and anchors Check the sun visors and other inside cab components for operation and condition 5 Key ignition and door key assembly A amp B Check the keys for cracks and signs of wear Inspect the lock assemblies for signs of wear Lubricate all lock assemblies with spray lubricant 6 Buzzer and warning devices A amp B Ensure that all warning lights located on the dash temporarily light when the ignition
76. hould not exceed 2 PSI in 1 minute B Get a block of woad to hold down the foot valve With maximum pressure engine stopped and parking brake released apply and hold the brakes Allow pressure to stabilize for 1 minute Observe the dash gauge pressures for 1 minute and note any pressure drop Air pressure drop should not exceed 3 PSI in 1 minute C With maximum pressure and engine idling at 600 900 RPM manually operate the park control valve As the control valve button is pulled out and pushed in check that the parking brake is applied and released promptly D Parking brake and foot brake test A amp B 1 Parking brake check Start the engine apply the foot brake and apply the parking brake With the foot brake still applied put the transmission in drive and increase the engine speed to 300 RPM above idle The vehicle should not move If the vehicle moves the brakes need to be adjusted 2 Service brake check Start the engine and run at rated speed until the air pressure reaches governor cut out pressure Return engine speed to idle Release the parking brake PP valves in Apply and hold the brakes Put the transmission in drive and increase the engine speed to 300 RPM above idle The vehicle should not move If the vehicle moves the brakes need to be adjusted 3 Air dryer Some models of air dryers may require annual service Refer to the vehicle s service manual for service procedures 25 Cargo Vans PMI Prog
77. icable brake components for leaks Check the wear rate of the shoes and compare the shoes to new shoes For example brake linings that have 4 32 inch remaining are not worn out if the vehicle has gone three or four inspections since the brakes were new The original amount of shoe may have been only 8 32 inch The inspector must balance brake safety against the risk of throwing away good lining material Brake linings with less than 2 32 inch must be replaced Inspect the parking brake cables to make sure they are operating properly secure and not frayed The B PMI ERT includes the time for the brake inspection If the brakes need to be inspected during an A PMI the inspection time must be written as a line item on Form 4543 Vehicle Maintenance Work Order The estimated time to perform this brake inspection on a light delivery vehicle is 0 5 hours which includes time to clean inspect and adjust all brakes 38 Bearing play and condition A amp B Check the wheel bearing for excessive play Adjust if necessary If the vehicle has been driven 25 000 miles since the last front wheel bearing service or if operating conditions warrant operation in hub deep water etc clean and pack the front wheel bearings and replace seals Always service bearings when performina brake service 39 Suspension springs shocks and hangers A amp B Examine all spring hangers shackles and bushings for wear Check for sagging or broken spring leaves
78. ication 500 G Vehicle Guidelines for more information on vehicle markings 31 Rear door security and condition A amp B Check the rear door lock for proper operation and security Replace any damaged panels Inspect the overhead door pull down strap and door seals Check the condition and operation of the rear door protection bar 32 Interior condition cargo door floors and roof A amp B Inspect the cargo light s for proper operation With the rear door pulled down inspect the roof floor and side panels for holes signs of leaks or other damage Inspect and lube rear door spring assembly cable rollers door hinges and other moving parts Operate and lube the cargo vent hardware Inspect the roof bows to ensure that the roof is attached properly 33 Cargo restraining devices A amp B Check the E tracks Ensure no bolts are loose or missing from the tracks Inspect the track slots for cracks and wear 34 Fuel cap vent and filler neck A amp B Check the fuel filler pipe Remove the filler cap and inspect the cap seal and retaining chain Inspect the vent Check for loose mounting leaks or other tank damage 35 Air tanks valves hoses pipes and air gauge A amp B Examine tank mounting brackets for damage Examine tanks hoses valves and plumbing for damage or chafing 36 Accident damage list on diagram A amp B During each PMI maintenance employees must inspect the vehicle for acc
79. ident damage report any damage to their supervisor and indicate damage on the diagram on the reverse of Form 4546 D Do not defer repairs of accident damage to a later date Prepare a separate work order and code it as an accident 37 Lift gate A amp B Inspect lift gate if applicable for proper operation Lubricate all moving parts Check the latching mechanisms and safety locks for proper operation 97 Cargo Vans 58 PMI Program Paint lift gates as follows Use postal white to paint the parts that park above the vehicle frame Use black to paint the parts of the lift gates that park below the frame Paint all walking surfaces with non skid paint 38 Reserved Underneath Inspection Lube 39 Fluid leaks and engine mounts A amp B Before changing engine oil inspect the engine and transmission for fluid leaks Check the radiator for leaks Inspect lower radiator hose for condition and leaks Examine motor mounts for deterioration and torque 40 Change oil filter and lubricate A amp B Change engine oil and filter during each B PMI or every 10 000 miles whichever comes first Service the oil centrifuge when changing the oil Perform complete lubrication and check fluid levels and condition in accordance with all items as shown on the manufacturer s lubrication chart Write the lube oil and filter as a line item on Form 4543 Vehicle Maintenance Work Order Note If the lubrication is performed by someone
80. in the space provided at the bottom of Form 4546 F Sign and date the form Return the vehicle to service 34 Reserved 35 Reserved Note Estimated inspection times for trailers Estimated Inspection Time hours Level A single axle 1 5 Level A tandem axle L8 Level B single axle 25 Level B tandem axle 3 0 The B PMI and the follow up repairs satisfy the Federal Annual Vehicle Inspection as prescribed in the Federal Motor Carrier Safety Regulations 87 PMI Program Appendix Appendix Forms Used in the PMI Program The following forms are used in the PMI program Instructions for completing these forms are included in this bulletin See the transmittal letter at the beginning of this bulletin for information on ordering these forms These forms can be reproduced locally until they are received from the material distribution centers MDCs PS Form 4546 A Preventive Maintenance Inspection Guidelines Administrative Vehicles PS Form 4546 B Preventive Maintenance Inspection Guidelines Light Delivery Vehicles PS Form 4546 C Preventive Maintenance Inspection Guidelines Intermediate Delivery Vehicles PS Form 4546 D Preventive Maintenance Inspection Guidelines Cargo Vans PS Form 4546 E Preventive Maintenance Inspection Guidelines Tractors PS Form 4546 F Preventive Maintenance Inspection Guidelines Trailers June 1 1998 B9 UNITED STATES POSTAL SERVICE PREVENTIVE MAINTENANCE INSP
81. ing wheel and shift lever are clean When the quality assurance road test is satisfactorily completed enter the work order number and odometer reading in the spaces provided at the bottom of Form 4546 A Sign and date the form Return the vehicle to service Compressed Natural Gas CNG Vehicles Cab Area 68 Fill valve and starter interrupt switch A amp B Check the condition of the fill valve and dust cover On some CNG systems the dust cap must be in place to engage the starter Ensure that the interrupt switch is operating properly Some models of CNG systems have a filter located in the fill line If the vehicle is equipped with this filter service the filter during each PMI See the vehicle s service manual for proper servicing procedures Check all components and connections for leaks using a non ammonia soap solution and an electronic leak detector It is important that all connections be checked for leaks during the PMI Repair all leaks 69 Warning lights and engine operation A amp B Start the engine With the engine running on CNG check the operation of the engine All CNG vehicles have a light on the dash to inform the driver what fuel the engine is operating on Check the operation of this light Check the operation of the engine hour meters for both CNG and gasoline 70 Wiring A amp B Examine all wiring for chafing and for proper connection to the CNG computer and vehicle computer 17 Administra
82. inks or leaks and that the cable bends smoothly and is protected from damage 59 Cargo Vans 60 PMI Program 47 Exhaust systems A amp B Examine complete exhaust system for leaks damage or loose hangers Examine exhaust pipes and stack for evidence of leaking joints Ensure the exhaust does not make contact with any fuel water air or electrical lines 48 Driveline alignment and condition A amp B Inspect the drive shaft for correct phasing Examine drive shaft universal joints and slip joints for wear or damage 49 Differential and breather A amp B Check fluid level and fill as necessary Clean vent assembly and examine housing for indication of leaks 50 Undercoating condition A amp B Inspect the condition of the undercoating Touch up the undercoating annually to ensure the long life cycle for postal vehicles After accident repairs are made reapply rustproofing Check for corrosion of all chassis components 51 Body hold downs hoses and wires A amp B Inspect the vehicle body hold downs to make sure they are intact and tight Ensure that all hoses and wires are properly secured to the chassis 52 Reserved Engine Compartment Area 53 Engine compartment and cab lifting system A amp B Examine cab lock lever and safety catches for broken springs Check cab till latches for proper adjustment Check springs in tilt assist torsion unit Examine tilt trunnions Inspect the cab lifti
83. ion fan if applicable for operation and safety quards 10 Steering play A amp B With the engine running and the wheels in a straight ahead position turn the steering wheel in one direction until the tires begin to pivot Note the position of the steering wheel Turn the wheel in the other direction until the tires start to move Total movement of the steering wheel before the wheels begin to move should not exceed 1 1 2 inches If the play exceeds this check for parts that are worn or out of adjustment Enter the amount of play in inches on Form 4546 B 11 Parking brake and foot brake test A amp B Check brake stopping ability and parking brake holding ability Apply the foot brake With the foot brake applied apply the parking brake Put the transmission into drive Slowly accelerate engine to approximately 500 RPM above idle Allow the engine to return to idle then place the gear selector to reverse and again slowly accelerate to 500 RPM above idle If the vehicle does not move in either direction the parking brake is properly adjusted If the vehicle moves the parking brake must be adjusted Adjust the parking brake after inspecting servicing the rear brakes To adjust remove the set screw and adjust the brake Reinstall the set screw after the adjustment 23 Light Delivery Vehicles 24 PMI Program 12 Clean inside and out A amp B During each PMI pressure clean the engine and chassis Wash the vehicle befor
84. ir or replace as needed b Check the operation and adjustment of the fifth wheel locking mechanism Use the appropriate procedure for the type of locking mechanism If the locks cannot be properly adjusted due to wear rebuild or replace the fifth wheel WARNING Improper adjustment can cause improper locking of the mechanism 2 Type A Lock Adjustment highway tractors The lock adjustment screw is found in the crotch on the right side a Close the locks with the Holland lock tester P N TF TLN 1000 b Tighten the adjustment screw using a 1 2 inch Allen wrench or Allen socket extension Turn clockwise until tight c Loosen the adjustment screw by turning it counterclockwise 1 1 2 turns The locks are now properly adjusted d Using the Holland lock tester verify this adjustment by locking and unlocking the mechanism several times 3 Type B Lock Inspection spotter tractor Note Spotter tractor fifth wheels have no adjustment Check for excessive wear and proper operation a Close the locks and insert a Holland Plug P N TF 0237 in the locks b Check for excessive wear The plug should fit freely However if the plug can be moved forwards and backwards more than 1 2 inch rebuild the top plate This top plate has no adjustment c Verify proper operation of the locking mechanism by locking and unlocking the mechanism several times with the Holland lock tester P N TF TLN 1000 If the locking mechanism fails to loc
85. is more than normal wear and tear a separate work order must be written and coded as an accident ERT to perform an A PMI on a light delivery vehicle is 1 5 hours ERT to perform an A PMI on a light delivery vehicle equipped with CNG is 2 0 hours ERT to perform a B PMI on a light delivery vehicle is 3 0 hours ERT to perform a B PMI on a light delivery vehicle equipped with CNG is 3 5 hours e ae i P5 Form 4546 B March 1998 UNITED STATES POSTAL SERVICE PREVENTIVE MAINTENANCE INSPECTION GUIDELINES Bz INTERMEDIATE DELIVERY VEHICLES EAT Eee STATE POSTAL SERVICE ERVICE w Leaks doors handles and steps Seat belt and interior Key senio and door jov aonihl Fluid leaks and engine mounts i Buzzer and warning devices 35 Change oil filter and lubricate Starter action unusual sounds and neutral switch 36 Steering tie rods and arms Cold weather starting aids Brake linings LF 32 RF 32 Gauges horn heater oil pressure and mirrors LR 32RR Accessories glass windshield wipers and fan 38 Bearing play and condition Steering play inches suspension springs shocks and hangers Ire 0 Transmission and mountings imt Exhaust systems converter and muffler 4 Lights turn signals and back up lights Driveline alignment and condition Floor and underdash wiring Body hold downs hoses and wires Differential and breathe
86. k or has too much slack rebuild or replace the top plate This top plate has no adjustment d Lubricate by applying a light rust resistant oil to all moving parts B Fifth Wheel Sliding Mechanism Inspections and Adjustments 1 Adjustment of Locking Plungers a Loosen the locking nut and turn adjusting bolt out counterclockwise b Disengage and engage the locking plungers Check that the plungers are securely seated without binding c Turn adjusting bolt in clockwise until it contacts the rack Turn adjusting bolt an additional 1 2 turn and then tighten the locking nut securely CAUTION Proper adjustment of the sliding bracket locking plungers must be performed at installation and maintained at regular intervals Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Tractors by use of the adjusting bolts provided on both sides proper adjustment is required for proper operation and for proper load transfer and distribution 2 Adjustment of Locking Plungers When They Won t Release to Permit Sliding of the Fifth Wheel a Check the air cylinder for proper operation Replace if necessary b Check plunger adjustment c If adjusted plunger binds on pocket grind the top plunger edges 1 16 inch reinstall and adjust as in step B 1 Use a Holland TF TIN 2500 spring compressor to install the plunger 3 Adjustment of Locking Plungers When They Are Toa Loose a Check plunger adjustment b Check the plunger s
87. k that dual tires are matched to within 1 4 inch Replace any tire that is not matching Record the tread depth for each tire on Form 4546 C The tread design is to match on each axle 24 Bumpers reflectors lenses and mud flaps A amp B Examine bumpers reflectors and lenses for damage or environmental deterioration Examine condition of mud flaps and mounting for damage 25 Logos markings posters and beltline A amp B Check exterior markings and decals to ensure that exterior markings are not faded scratched torn or missing and that they are positioned properly Update decals as needed Check the beltline and vehicle numbers in the same manner Review Fleet Management Bulletin V 18 94 for more information on vehicle markings 26 Rear door security and condition A amp B Check the rear door lock for proper operation and security Inspect the overhead door pull down strap and door seals 41 Intermediate Delivery Vehicles PMI Program 42 27 Interior condition cargo door floors and roof A amp B Inspect the cargo light s With the rear door pulled down inspect the roof and side panels for holes signs of leaks or other damage Inspect and lube rear door spring assembly cable rollers door hinges and other moving parts Operate and lube the cargo vent hardware Check the partition door for proper operation 28 Cargo restraining devices A amp B Check the E tracks Ensure no bolts are loose
88. key is in the on position After the engine starts ensure lights go G Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Administrative Vehicles out If the lights and warning devices are not working correctly refer to the manufacturer s service manual 7 Starter action unusual sounds and neutral switch A amp B Ensure that the engine will not crank in other than neutral or park Note the sound of the starter operation 8 Gauges horn heater oil pressure and mirrors A amp B With the car on check the operation of all gauges Check the horn for operation and loudness Turn on the heater defroster and all other cab systems Check the oil pressure gauge when the engine starts If the engine is warm note this pressure Refer to the manufacturer s recommendations on the oil pressures for both idling and operating RPM Examine all mirrors and mounting attachments for loose or damaged parts Make sure the mirrors are the proper mirrors for the vehicle and that they are in good condition 9 Accessories glass windshield wipers and fan A amp B Operate and examine all switches and controls Check windshield washer operation Examine all glass for cracks chips or lamination separation Check wiper arms and blades for operation and condition Examine ventilation fan if equipped for operation and safety guards 10 Steering play A amp B With the engine running and the wheels in a straigh
89. ll the procedures have been completed print the results from the analyzer and staple the printout to the work order as part of the permanent record A Visual Inspection 1 Positive crankcase ventilation PCV system Examine all the PCV hoses connections and grommets for deterioration Replace valve if necessary 2 The thermostatic air cleaner Inspect system to ensure all hoses and the heat stove tube are connected Check for kinked plugged or deteriorated hoses Check for the presence and condition of the gasket seal between the air cleaner and the throttle With air cleaner assembly installed the damper door should be open to outside air Start the engine and watch the damper door in air cleaner snorkel When the engine is first started the damper door should move and close off outside air As the air cleaner warms up the damper door should open slowly to outside air If the air cleaner fails to operate as described above perform a vacuum motor check If it operates the door may not be moving at the right temperature If a driveability problem occurs during warm up perform a temperature sensor check 3 Evaporative emission control system Check operation of the total system Replace vapor canister if it is damaged or if fuel is leaking from the bottom Replace filter at the bottom of the Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Administrative Vehicles canister If a fuel tank filler cap requir
90. mission mounts shift linkage and U joints for wear or deterioralion Inspect the transmission for leaks Check the fluid level B Automatic Transmissions Examine transmission mounts for deterioration Check the transmission cooler lines for leaks and chaffing Drain and refill automatic transmission fluid annually or every 50 000 miles whichever comes first Some vehicles with automatic transmission have both internal and external filters Change the internal filter only when the transmission pan is removed for adjustments or overhaul Change the external filter only when prompted by the warning light on the dash panel or every 3 years whichever comes first Inspect the speedometer cable and attachment Ensure there are no kinks or leaks and that the cable bends smoothly and is protected from damage 75 Tractors 76 PMI Program 47 Exhaust systems A amp B Examine complete exhaust system for leaks damage or loose hangers Examine exhaust pipes and stack for evidence of leaking joints Ensure the exhaust does not make contact with any fuel water air or electrical lines 48 Driveline alignment and condition A amp B Inspect the drive shaft for correct phasing Examine drive shaft universal joints and slip joints for wear or damage 49 Differential and breather A amp B Check fluid level and fill as necessary Clean vent assembly and examine housing for indication of leaks 50 Undercoating condition A
91. mp B Test the windows regulators and door hinges to ensure they are working properly Inspect the window guides for proper condition 16 Safety equipment fire extinguisher and accident kit A amp B Check the vehicle s fire extinguisher and emergency warning kits per Section 243 of Handbook PO 701 Check the seal on the fire extinguisher Inspect the contents of the warning kits Replace the fire extinguisher and contents of the warning kits as necessary Ensure that the forms compartment contains Item 087 H Accident Report Kit and the vehicle s operator s manual Remove all other debris from the forms compartment 17 Authorized cab decals and Label 70 A amp B Ensure that only authorized decals are present and that they are positioned properly on the dashboard for visibility Remove any unauthorized decals The following decals must be displayed in each vehicle a Look Before Backing decal b Label 70 Safety Check and Vehicle Dimensions 18 Drain air reservoirs A amp B Drain all air brake reservoirs to 0 PSI Do not drain the air starter tank at this time Close all drain valves after draining air system 19 Low air warning system A amp B Start the engine and run at high idle The warning light and buzzer for low air pressure should be on When the air pressure reaches approximately 60 PSI the warning light and buzzer should go off 20 Air pressure build up time A amp B Before performing
92. n A amp B Inspect the condition of the undercoating Touch up the undercoating annually to ensure the long life cycle for postal vehicles After accident repairs are made reapply rustproofing 46 Reserved 47 Reserved 48 Reserved Engine Compartment Area 49 Engine compartment and engine A amp B Raise hood and examine and lubricate hood latches hinges and hood support Fill windshield washer reservoir and check the level of the brake master cylinder If the vehicle is diesel powered perform scheduled engine maintenance and adjustments in accordance with the manufacturer s recommendations Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Intermediate Delivery Vehicles 50 Antifreeze protection level A amp B Before removing the radiator overflow tank cap squeeze the hoses to see if the system is pressurized or hot Carefully remove the radiator cap and check the seal Inspect the fluid level Test coolant mixture for freeze protection with a refractometer or test strip Add quantities as necessary to maintain a solution of 5095 antifreeze and 5095 water Record the protection level in the space provided on Form 4546 C 51 Alkalinity protection A amp B Test corrosion resistant properties of the coolant with a coolant test strip If test results are unsatisfactory drain flush and refill cooling system with a solution of 5096 antifreeze and 5096 water 52 Replace or recycle coolant a
93. n Form 4541 or 4543 A amp B List all repair actions on Form 4541 Order Invoice for Vehicle Repair or Form 4543 Vehicle Maintenance Work Order Schedule work generated by the PMI 67 Quality assurance road test A amp B After the required repairs have been completed drive the veh cle and check engine for acceleration smoothness and power Check transmission shift pattern Check steering for ease of operation wander pulling etc Listen for any unusual noise Check brake stopping ability and parking brake holding ability Before vehicle is released for service ensure that seat seatbelt steering wheel and shift lever are clean When the quality assurance road test is satisfactorily completed enter the work order number and odometer reading in the spaces provided at the bottom of Form 4546 B Sign and date the form Return the vehicle to service Compressed Natural Gas CNG Vehicles Cab Area 68 Fill valve and starter interrupt switch A amp B Check the condition of the fill valve and dust cover On some CNG systems the dust cap must be in place to engage the starter Ensure that the interrupt switch is operating properly Some models of CNG systems have a filter located in the fill line If the vehicle is equipped with this filter service the filter during each PMI See the vehicle s service manual for proper servicing procedures Check all components and connections for leaks using a non ammonia soap solution and
94. n receipt Vehicle Maintenance Facilities VMFs are required to use these new guidelines for all PMls including those performed by contractors Ill New Inspection Checklists The following forms have been revised and are included in this Bulletin a PS Form 4546 A Preventive Maintenance Inspection Guidelines Administrative Vehicles a PS Form 4546 B Preventive Maintenance Inspection Guidelines Light Delivery Vehicles n PS Form 4546 C Preventive Maintenance Inspection Guidelines Intermediate Delivery Vehicles u PS Form 4546 D Preventive Maintenance Inspection Guidelines Cargo Vans Li PS Form 4546 E Preventive Maintenance Inspection Guidelines Tractors n PS Form 4546 F Preventive Maintenance Inspection Guidelines Trailers Instructions for completing these forms are included in this bulletin See the transmittal letter at the beginning of this bulletin for information on ordering these forms Copies of these forms are included in the Appendix of this bulletin These forms can be reproduced locally until they are received from the material distribution centers MDCs June 1 1998 1 Introduction PMI Program IV Levels of Inspection These guidelines have been changed to allow for two levels of inspection A and B In all cases the B level inspection is more in depth and takes more time than the A level inspection This two tiered approach allows VMFs to perform the necessary level of PMI based on
95. nals 25 Brake linings 9 Electrical junction box m Wu Lo 2 RISO Bi E 10 Rear door and seals ri ES peat L 2 R 32 m ie ll Logos markings and beltline hewilive d 26 12 Bumpers reflectors lenses and mudflaps ZER 27 Air tank mounting and valves Brake chambers push rod travel and slack adjusters Alr lines hoses wiring and connections T 29 Axle alignment HR 30 Body cross members Note If damage is more than normal wear and tear a separate work order must be written and coded as an accident ERT to perform an A PMI on either a single axle or tandem axle trailer is 1 5 hours ERT to perform a B PMI on a single axle trailer is 2 5 hours ERT to perform a B PMI on a tandem axle trailer js 3 0 hours Completed by i Work Order No Odometer PS Form 4546 F March 1998
96. nding gear Check operation of gear in low and high range Inspect the landing gear mounting and brackets Inspect pad mounting for damage alignment and condition 3 Glad hands and connectors A amp B Inspect the condition of the glad hands Replace glad hand seals annually Inspect and clean the seven pin connector 4 Road test A amp B Pull the trailer a short distance Check brake stopping ability and parking brake holding ability Check the trailer for handling and tracking 5 Test brakes for proper operation A amp B Ensure that brakes are operational when foot brake is applied Ensure that trailer brakes are operational when trolley valve is applied 6 Emergency brake valve operation A amp B With the trailer hooked to a tractor ensure that trailer brakes are operational when tractor protection valve is pulled If brakes are not operational investigate the cause and repair as needed B2 Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Trailers 7 Perform air system leak checks and drain air tanks A amp B Drain all air tanks to 0 PSI If the trailer is hooked to a tractor make sure the engine is turned off and the parking brake is released Allow the pressure to stabilize for 1 minute Apply and hold the brakes Allow the pressure to stabilize for 1 minute Observe the dash gauge pressures for 1 minute and note any pressure drop Air pressure drop should not exceed 4 PSI in 1 minute I
97. ned terminals Make sure the battery posts bolts are properly tightened Intermediate Delivery Vehicles PMI Program 46 59 Battery box and hold downs A amp B Examine battery box for signs of corrosion Clean and paint box if needed Check hold downs for looseness and tighten if needed 60 Wiring and hoses A amp B Check for proper routing of all wiring and hoses including electrical wiring and fuel hoses Ensure that these components are not rubbing against each other or any other metal surface 61 Battery load test A amp B Perform a battery load test using a volt amp tester Sun VAT 60 or equal equipment Record the results in the space provided on Form 4546 C On vehicles equipped with dual batteries test each battery separately 62 Starter cranking test A amp B Perform a starter cranking test using a volt amp tester Sun VAT 60 or equal equipment Record the results in the space provided on Form 4546 C 63 Alternator output test A amp B Perform an alternator output test using a volt amp lester Sun VAT 60 or equal equipment Record the results in the space provided on Form 4546 C 64 Regulator voltage A amp B Perform a regulator test using a volt amp tester Sun VAT 60 or equal equipment Record the results in the space provided on Form 4546 C 65 Emission control systems B only Inspect the engine for all related emission control components and test for their correct operation E
98. ng system for proper operation Fill windshield washer reservoir 54 Antifreeze protection level A amp B Before removing the radiator overflow tank cap squeeze the hoses to see if the system is pressurized or hot Carefully remove the radiator cap and check the seal Inspect the fluid level Test coolant mixture for freeze protection with a refractometer or test strip Add quantities as necessary to maintain a solution of 50 antifreeze and 50 water Record the protection level in the space provided on Form 4546 D 55 Alkalinity protection and water filter A amp B Test corrosion resistant properties of the coolant with a coolant test strip This engine is equipped with a cooling system filter and treatment system that must be serviced at each PMI Supplemental coolant conditioners such as Nalcool may be used and their condition may be tested by coolant test Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Cargo Vans kits If test results are unsatisfactory drain flush and refill cooling system with a solution of 50 antifreeze and 50 water Replace coolant filter annually Add make up coolant and chemical conditioners required to ensure adequate cooling system protection 56 Replace or recycle coolant as required A amp B Replace or recycle coolant as required by the type of coolant used The service requirement might differ between coolant manufacturers Refer to the coolant manufacturer s rec
99. nsmission shift pattern Check steering for ease of operation wander pulling etc Listen for any unusual noise Check brake stopping ability and parking brake holding ability Before vehicle is released for service ensure that seat seatbelt steering wheel and shift lever are clean When the quality assurance road test is satisfactorily completed enter the work order number and odometer reading in the spaces provided at the bottom of Form 4546 D Sign and date the form Return the vehicle to service 75 Reserved 76 Reserved 77 Reserved 78 Reserved Note Estimated inspection times for cargo vans Estimated Inspection Time hours 29 3 5 Level A Level B The B PMI and the follow up repairs satisfy the Federal Annual Vehicle Inspection as prescribed in the Federal Motor Carrier Safety Regulations June 1 1998 63 PMI Program Tractors PMI Guidelines for Tractors June 1 1998 These tools are needed to perform the PMI Miscellaneous hand tools Spray lubricant Shop rags Flashlight Air pressure gauge Tread depth gauge Tire square Air chuck Grease gun Battery load tester Diesel opacity meter if state required Axle spacing tool Fifth wheel adjustment tools 65 Tractors 66 PMI Program Explanation of Form 4546 E Preventive Maintenance Inspection Guidelines Tractors Fill in the vehicle number assigned location due date for PMI and the type of PMI level A or
100. ocated under the dash The check engine light will begin to flash With timing equipment connected check and adjust the average timing of cylinders one and four to specifications Remove the ground from the diagnostic connector E Check Engine Light Test The final function test is on the emission control check engine or system malfunction light indicator Turn the ignition key to the on position the check engine light should come on Turn the ignition key to the off position the light should go off Start the engine The check engine light should be off when the engine is started and running 33 Light Delivery Vehicles 34 PMI Program The I M testing procedure is now complete If the vehicle fails any part of the testing it must be repaired and then retested After the test is complete print one copy of the vehicle inspection report VIR Sign it and staple it to the work order and Form 4546 8 The I M test procedures must be performed on all light delivery vehicles including those powered by compressed natural gas CNG Procedures may vary depending on the type of vehicle being tested Persons performing emissions tests should refer to that vehicle s service manual In some states vehicles may be subjected to further testing at a state centralized test facility Local management must ensure that all state required tests are performed If vehicle is CNG powered go to step 68 66 List all repair actions o
101. ogram June 1 1998 Cargo Vans out If the lights and warning devices are not working correctly refer to the manufacturer s service manual 7 Cold weather starting aids A amp B Check operation of the cold weather starting system usually a glow plug or ether system See manufacturer s shop manual for proper operation This vehicle is also equipped with a block heater Inspect the electrical cord and plug for damage 8 Starter action unusual sounds and neutral switch A amp B For vehicles equipped with automatic transmission ensure that the engine will not crank except in neutral or park Note the sound of the starter operation there should be no unusual noises 9 Gauges horn heater oil pressure and mirrors A amp B With the car on check the operation of all gauges Check the horn for operation and loudness Turn on the heater defroster and all other cab systems Check the oil pressure gauge when the engine starts If the engine is warm note this pressure Refer to the manufacturer s recommendations on the oil pressures for both idling and operating RPM Examine all mirrors and mounting attachments for loose or damaged parts Make sure that the mirrors are the proper mirrors for the vehicle and that they are in good condition Some models may have heated and remote controlled mirrors For these mirrors check the operation of the heating element and the motorized controls 10 Accessories glass winds
102. ommendations concerning the change or recycle interval 57 Radiator hoses and leaks A amp B Pressure test complete cooling system Examine all hoses and connections for leaks or wear Inspect water pump Replace hoses as needed 58 Belts and pulleys A amp B Check all belts for condition alignment and proper tension When adjusting belts use a belt tension gauge Inspect all pulleys for alignment and condition Check for unusual noise Examine damper for deterioration or excessive vibration Examine water pump idler pulley and fan hub for noise or vibrations 59 Alternator and power steering A amp B Check alternator terminal connections and mounting Check the fluid level of the power steering pump Ensure there are no leaks Examine pump and mounting bracket for condition and check for loose or broken bolts 60 Fuel lines fuel system and linkage A amp B Inspect fuel lines for routing and leaks Inspect fuel injection system linkage and lubricate as needed Examine linkage levers connectors and return springs for wear or interference 61 Fuel filter s B only Replace all fuel filters annually or more frequently as necessary 62 Emission control devices A amp B Inspect the engine for all related emission control components Ensure their correct operation Examine crankcase emission system regulator Examine all hoses connections and grommets for deterioration 63 Air filter restriction
103. on 15 Floor and underdash wiring A amp B Inspect the floor mats for wear and tear Examine wiring and harnesses for chafing and for proper connection and support Ensure that the wiring is neatly taped and secured 16 Safety equipment and fire extinguisher A amp B Check the vehicle s fire extinguisher and emergency warning kits if required per Section 243 of Handbook PO 701 Check the seal on the fire extinguisher Inspect the contents of the warning kits if required Replace the fire extinguisher and contents of the warning kits if required as necessary 17 Window window locks regulator and door slides A amp B Test the windows and regulators to ensure they are working properly Inspect the window guides and locks for proper operation Check that the door slides are in satisfactory condition and operate properly 18 Authorized cab decals and Label 70 A amp B Ensure that only authorized decals are present and that they are positioned properly on the dashboard for visibility Remove any unauthorized decals The following decals must be displayed in each vehicle a Look Before Backing decal b Label 70 Safety Check and Vehicle Dimensions 19 General paint and body condition A amp B Inspect all painted surfaces for deterioration and condition Repaint vehicles on an as needed basis as determined by the Manager Vehicle Maintenance Vehicle Maintenance Bulletin V 07 98 PMI Program Jun
104. or missing from the tracks Inspect the track slots for cracks and wear 29 Fuel cap door and filler neck A amp B Remove the filler cap and inspect the cap seal and retaining chain if equipped Check the integrity of the gas tank 30 Accident kit A amp B Ensure that the forms compartment contains Item 087 H Accident Report Kit and the vehicle s operator s manual Remove all other debris from the forms compartment 31 Accident damage list on diagram A amp B During each PMI maintenance employees must inspect the vehicle for accident damage report any damage to their supervisor and indicate damage on the diagram on the reverse of Form 4546 C Do not defer repairs of accident damage to a later date Prepare a separate work order and code it as an accident 32 Lift gate A amp B Inspect lift gate if equipped for proper operation Lubricate all moving parts Check the latching mechanisms and safety locks for proper operation Paint lift gates as follows Use postal white to paint the parts that park above the vehicle frame Use black to paint the parts of the lift gates that park below the frame Paint all walking surfaces with non skid paint 33 Reserved Underneath Inspection Lube 34 Fluid leaks and engine mounts A amp B Before changing engine oil inspect the engine and transmission for fluid leaks Check the radiator for leaks Inspect lower radiator hose for condition and leaks Examine moto
105. oration and torque 40 Change oil filter and lubricate A amp B Change engine oil and filter during each B PMI or every 10 000 miles whichever comes first Service the oil centrifuge when changing the oil Perform complete lubrication and check fluid levels and condition in accordance with all items as shown on the manufacturer s lubrication chart Write the lube oil and filter as a line item on Form 4543 Vehicle Maintenance Work Order Note If the lubrication is performed by someone other than the person doing the PMI subtract 0 7 hours from PMI ERT 41 Steering tie rods and arms A amp B Check steering column shaft assembly and steering gear for any deficiency or looseness Examine all steering linkage and arms for wear looseness or damage Check steering damper for proper mounting and operation Rotate components and check for end play Examine kingpins for excessive wear Lubricate the tie rods and other steering components Inspect the power steering hoses and connections to ensure the hoses are not rubbing leaking or deteriorating 42 Brake linings B only It is not necessary to remove the wheels on every inspection to examine the condition of the brake linings However on every service make a visual inspection of the brake drum and lining This may be done by viewing the lining through the inspection hole in the dust shields or by removing the dust shields After brake inspection reinstall the dust shi
106. orized decals are present and that they are positioned properly on the dashboard for visibility Remove any unauthorized decals The following decals must be displayed in each vehicle a Look Before Backing decal b Label 70 Safety Check and Vehicle Dimensions 18 Drain air reservoirs A amp B Drain all air brake reservoirs to 0 PSI Do not drain the air starter tank at this time Close all drain valves after draining air system 19 Low air warning system A amp B Start the engine and run at high idle The warning light and buzzer for low air pressure should be on When the air pressure reaches approximately 60 PSI the warning light and buzzer should go off 20 Air pressure build up time A amp B Before performing the air pressure build up time test make sure that the air starter air reservoir contains at least 100 PSI Continue running the engine at Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Tractors high idle Start timing when the air pressure gauge reaches 85 PSI and stop timing when the air pressure gauge reaches 100 PSI The air pressure should build up from 85 PSI to 100 PSI within 40 seconds Note The average build up time is approximately 15 seconds 21 Governor range A amp B Reduce service air pressure to governor cut in pressure by fanning the brake pedal Continue running the engine at high idle The air pressure gauge will start to increase at approximately 100 PSI N
107. ote the cut in pressure The governor will allow the air pressure to increase to approximately 120 PSI Note the cut out pressure When the governor reaches cut out pressure the air dryer will cycle If the air dryer does not cycle perform service on the air dryer Refer to the vehicle s service manual for proper serving procedures Enter the cut in and cut out pressures on Form 4546 E The difference between cut in and cut out pressure must not exceed 25 PSI 22 Perform air system leak checks and service air dryer A amp B A With maximum pressure engine stopped and parking brake applied allow pressure to stabilize for at least 1 minute Observe the dash gauge pressures for 1 minute and note any pressure drop Air pressure drop should not exceed 2 PSI in 1 minute B Get a block of wood to hold down the foot valve With maximum pressure engine stopped and parking brake released apply and hold the brakes Allow pressure to stabilize for 1 minute Observe the dash gauge pressures for 1 minute and note any pressure drop Air pressure drop should not exceed 3 PSI in 1 minute C With maximum pressure and engine idling at 600 900 RPM manually operate the park control valve As the control valve button is pulled out and pushed in check that the parking brake is applied and released promptly D Parking brake and foot brake test A amp B 1 Tractor with manual transmission a Parking brake check Start the engine push the clutch
108. pedal down releasing the clutch and put the transmission in high gear Increase engine speed to 300 RPM above idle Slowly let up the clutch pedal engaging the clutch The vehicle should not move and the engine should stall before the clutch is fully engaged If the vehicle moves the brakes need to be adjusted b Service brake check Start the engine and run at rated speed until the air pressure reaches governor cut out pressure Release the spring brakes PP valves in Apply and hold the brakes Push the clutch pedal down releasing the clutch and put the transmission in high gear Increase engine speed to 300 RPM above idle Slowly let up the clutch pedal engaging the clutch The vehicle should 69 Tractors 70 PMI Program not move and the engine should stall before the clutch is fully engaged If the vehicle moves the brakes need to be adjusted 2 Tractor with automatic transmission a Parking brake check start the engine apply the foot brake and apply the parking brake With the foot brake stili applied put the transmission in drive and increase the engine speed to 300 RPM above idle The vehicle should not move If the vehicle moves the brakes need to be adjusted b Service brake check start the engine and run at rated speed until the air pressure reaches governor cut out pressure Return engine speed to idle Release the parking brake PP valves in Apply and hold the brakes Put the transmission in driv
109. posts bolts are properly tightened 29 Light Delivery Vehicles 30 PMI Program 59 Battery box and hold downs A amp B Examine battery box for signs of corrosion Clean and paint box if needed Check hold downs for looseness and tighten if needed 60 Wiring and hoses A amp B Check for proper routing of all wiring and hoses including electrical wiring and fuel hoses Ensure that these components are not rubbing against each other or any other metal surface 61 Battery load test A amp B Perform a battery load test using a volt amp tester Sun VAT 60 or equal equipment Record the results in the space provided on Form 4546 B 62 Starter cranking test A amp B Perform a starter cranking test using a volt amp tester Sun VAT 60 or equal equipment Record the results in the space provided on Form 4546 B 63 Alternator output test A amp B Perform an alternator outpul test using a volt amp tester Sun VAT 60 or equal equipment Record the results in the space provided on Form 4546 B 64 Regulator voltage A amp B Perform a regulator test using a volt amp tester Sun VAT 60 or equal equipment Record the results in the space provided on Form 4546 B 65 Emission control systems B only The vehicle emissions inspection maintenance I M program tests the emission system Follow the step by step procedure as outlined Note It is unlawful to modify or render inoperative any emission control
110. prings for proper compression Replace if necessary c Check for plunger wear and replace if necessary Use a Holland TF TIN 2500 spring compressor to remove and reinstall the plungers Adjust the plungers as described in step B 1 33 Fuel cap vent and filler neck A amp B Check the fuel filler pipe Remove the filler cap and inspect the cap seal and retaining chain Inspect the vent Check for loose mounting leaks or other tank damage 34 Cat walk steps and grab handles A amp B Examine step plates and cat walk for bent or broken brackets Check grab handle mountings 35 Air tanks valves hoses pipes and air gauge A amp B Examine tank mounting brackets for damage Examine tanks hoses valves and plumbing for damage or chafing 36 Accident damage list on diagram A amp B During each PMI maintenance employees must inspect the vehicle for accident damage report any damage to their supervisor and indicate damage on the diagram on the reverse of Form 4546 E Do not defer repairs of accident damage to a later date Prepare a separate work order and code it as an accident 37 Reserved 38 Reserved 73 Tractors 74 PMI Program Underneath Inspection Lube 39 Fluid leaks and engine mounts A amp B Before changing engine oil inspect the engine and transmission for fluid leaks Check the radiator for leaks Inspect lower radiator hose for condition and leaks Examine motor mounts for deteri
111. provided on Form 4546 E 71 Engine A amp B Perform scheduled engine maintenance and adjustments in accordance with the manufacturer s recommendations 72 Emissions B only Observe the exhaust smoke If there is excessive smoke investigate the cause Some states may require an opacity meter to test diesel engine exhaust Refer to local emission ordinances 73 List all repair actions on Form 4541 or 4543 A amp B List all repair actions on Form 4541 Order Invoice for Vehicle Repair or Form 4543 Vehicle Maintenance Work Order Schedule work generated by the PMI 74 Quality assurance road test A amp B After the required repairs have been completed drive the vehicle and check engine for acceleration smoothness and power Check transmission shift pattern Check steering for ease of operation wander pulling etc Listen for any unusual noise Check brake stopping ability and parking brake holding ability Before vehicle is released for service ensure that seat seatbelt steering wheel and shift lever are clean When the quality assurance road test is satisfactorily completed enter the work order number and odometer reading in the spaces provided at the bottom of Form 4546 E Sign and date the form Return the vehicle to service 79 Tractors 80 PMI Program 75 Reserved 76 Reserved 77 Reserved 78 Reserved Note Estimated inspection times for tractors Estimated Inspection Time hours
112. puhRtra Posse qu Renee Pee TDS be PO RIES PSRs Pee E 2 Mi SSODSOu ligu qu eee aha eee WEY Or OPES P DOC TERE OPES UES EERE EE RE TET ORO 2 VI Parts Replacement uocem wave ene mnn 294 2 Vi Erniesinn snd Erake JOSS phenineere VATA PRESTA AR M RANEWUr NN Xv CR VC Vaga t d deux 2 VU BRL PELeOblahot Jeu ues WyUIBNTPPPPTErCQ k OroRk Urbino sir uz see ee eee 2 PMI Guidelines for Administrative Vehicles ariaa 5 EA ANA taiao bira raa aaa r a rga HEE aar a N ere ee aa SIIS INSGECHON a eaan ma AR KOR STAT POA GS Ores a a nee eas A E 8 Underneath Inspection Lube VPE adler BoA PON TTA Ld autem sate Pas Pada Se Rete dm 10 Engine Compartment Area 0 cc eee MIDS FEL CARA FEES RRL CROLEORETINES eae 12 Compressed Natural Gas CNG Vehicles 20 cece eee eee eee eer ere nn TIT 17 Ab AGO oleo ne dI Lond Rp dupRKOnAAR ZEIPAANANELDUO Peed Tr eet ttre res IAIA EFE 17 Engine Compartment cg ex vias u e v eth ag No Val va ap VITE Y S 18 Underneath Inspection VERAS AA PA STD e e LA PALA CAI LIAE UPC LEGI PE eem 18 PMI Guidelines for Light Delivery Vehicles eeeeeeenee 21 Cab ABO oc it pia ae RyaxileasamadawGHATEARRUOPR MRAAO LER ERE Sees E Wak RSS RadIPR CU 22 Goeinspcllol s aan reexeapa i a REERBLDUDHBAERIRERACARAERE Sasso ns Tene Bis PHS HES Elwes 25 Uriderneattiinspaeli niLUDS cddsic05 5 bog e tap rox epr rpi ipe o REP PbRI ERI E 26 Endifi
113. r Undercoating condition Authorized cab decals and Label 70 ay 9 General paint and body condition 20 Wax vehicle Circle Inspection is ee M CELL ICI stanti I dH tee iN Ce UJ MIL C777 707777 3B Fuel lines fuel system and linkage es s tene eT Battery box and hold downs PREVENTIVE MAINTENANCE INSPECTION GUIDELINES continued a a Engine Compartment Area con t pA a CNG Vehicles con t jl Battery load test I alts E 71 CNG labels Starter cranking test amps Engine Compartment DEB 72 CNG labels neo volts Alternator output test amps Regulator voltage 74 Emission control systems j9 Emission control systems HC ppm CO 26 at idle HC ppm CO at idle HC ppm CO 26 at 2500 RPM CO 6 at 2500 RPM D 96 CO at idle CO So at idle at 2300 RPM Oz 95 CO at 2900 RPM List all repair actions on Form 4541 or 4543 pu NECI A ERR RN BH CNG Vehicles BRE o Tl ae 68 Fill valve and starter interrupt switch 69 Warning lights and engine operation Note If damage is more than normal wear and tear a separate work order must be written and coded as an accident ERT to perform an A PMI on an intermediate delivery vehicle is 1 5 hours ERT to perform an A PMI on an intermediate delivery vehicle equipped with CNG is 2 0 hours ERT to perform a B PMI on an
114. r damage On some systems the regulators have a filter inside service that filter during B PMls Refer to the vehicle s service manual for proper procedures 78 Reserved 79 Reserved When the CNG inspection is complete return to Line 66 Note Estimated inspection times for administralive vehicles Estimated Inspection Time hours Level A 1 5 Level A with CNG 2 0 Level B 2 0 Level B with CNG 2 5 19 PMI Program Light Delivery Vehicles PMI Guidelines for Light Delivery Vehicles These tools are needed to perform the PMI Miscellaneous hand tools Spray lubricant shop rags Flashlight Air pressure gauge Tread depth gauge Air chuck Grease gun Battery load tester Scan tool Engine analyzer with emission tester Anti freeze test strips Coolant pressure tester Coil adapter Torque wrench Oil filter wrench June 1 1998 21 Light Delivery Vehicles PMI Program Explanation of Form 4546 B Preventive Maintenance Inspection Guidelines Light Delivery Vehicles Fill in the vehicle number assigned location due date for PMI and the type of PMI level A or B Cab Area 1 Review vehicle jacket modification orders and repair tags A amp B Prior to each preventive maintenance inspection review the vehicle jacket to determine the nature and extent of work to be performed Reviewing the vehicle jacket provides maintenance personnel with the vehicle s history Compare the current mileage wit
115. r mounts for deterioration and fatigue 35 Change oil filter and lubricate A amp B Change engine oil and filter during each PMI Clean all fittings perform complete lubrication and check fluid levels and condition in accordance Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Intermediate Delivery Vehicles with all items as shown on the manufacturer s lubrication chart Write the lube oil and filter as a line item on Form 4543 Vehicle Maintenance Work Order Note If the lubrication is performed by someone other than the person doing the PMI subtract 0 3 hours from PMI ERT 36 Steering tie rods and arms A amp B Check steering column shaft assembly and steering gear for any deficiency or looseness Examine all steering linkage and arms for wear looseness or damage Check steering damper for proper mounting and operation Rotate components and check for end play Examine ball joints kingpins for excessive wear or for excessive resistance to turning front wheels Check the condition of the ball joints and other steering components Lubricate the tie rods and other steering components inspect the power steering hoses and connections to ensure the hoses are not rubbing leaking or deteriorating 37 Brake linings B only Remove all wheels to inspect brake assemblies linings and drums Record the findings in the spaces provided on Form 4546 C Check all applicable brake components for leaks
116. r s recommendations on the oil pressures for both idling and operating RPM Examine all mirrors and mounting attachments for loose or damaged parts Make sure that the mirrors are the proper mirrors for the vehicle and that they are in good condition Some models may have heated and remote controlled mirrors For these mirrors check the operation of the heating element and the motorized controls 10 Accessories glass windshield wipers fan and radio A amp B Operate and examine all switches and controls Check windshield washer operation Examine all glass for cracks chips or lamination separation Check wiper arms and blades for operation and condition Examine ventilation fan for operation and safety guards Inspect the radio mounting and connections if applicable 11 Steering play A amp B With the engine running and the wheels in a straight ahead position turn the steering wheel in one direction until the tires begin to pivot Note the position of the steering wheel Turn the wheel in the other direction until the tires start to move Total movement of the steering wheel before the wheels begin to move should not exceed 4 inches If the play exceeds this check for parts that are worn or out of adjustment Enter the amount of play in inches on Form 4546 E 12 Lights turn signals and back up lights A amp B Examine all lenses for cracks deterioration and brightness Check all lights for proper operation 67
117. ram 23 Clean inside and out A amp B During each PMI pressure clean the engine and chassis Wash the vehicle before performing repairs Take extreme precautions when washing inside of vehicles Note The estimated repair time ERT shown on the back of Form 4546 D was calculated assuming the use of an automatic truck washer Add 0 5 hours if the vehicle is hand washed and 0 3 hours for cleaning windows and inside of vehicle 24 General paint and body condition A amp B Inspect all painted surfaces for deterioration and condition Repaint vehicles on an as needed basis as determined by the Manager Vehicle Maintenance Do not delay any wear and tear repairs painting or accident caused body work 25 Wax vehicle B only Wax the vehicle at least once a year The estimated time to wax the vehicle is 1 hour Add this as a line item on the work order Circle Inspection 26 Tire inflation A amp B Examine condition of all tires for damage wear and proper inflation If a tire is 10 psi or more low investigate the cause for the loss of air pressure and make corrections Use a valve cap Ensure that tire pressure decals are the correct ones for the vehicle and are positioned properly Refer to Poster 49 Tire Pressure Chart for a list of proper tire pressures 27 Lug nuts wheels hubs and alignment A amp B Inspect lug nuts wheels and hubs for tightness Check wheels and rims for cracks straightness unseate
118. range band painted into grooves on the push rod is visible that indicates that the self adjuster is not working or that other foundation brake service may be required 44 Bearing play and condition A amp B Check the wheel bearing for excessive play Adjust if necessary Do not service wheel bearings except on brake service unless operating conditions warrant operation in hub deep water etc 45 Suspension springs shocks and hangers A amp B Examine all spring hangers shackles shackle pins and bushings for wear Check for sagging or broken spring leaves or broken center bolts Check the tightness of spring U bolls and check for indications of misaligned or shifted springs Examine shock absorbers for leaks loose brackets or worn grommets Check for loose axle posilioning parts and signs of axle misalignment 46 Transmission and mountings A amp B Examine transmission mounts for deterioration Check the transmission cooler lines for leaks and chaffing Drain and refill automatic transmission fluid annually or every 50 000 miles whichever comes first Some vehicles with automatic transmission have both internal and external filters Change the internal filter only when the transmission pan is removed for adjustments or overhaul Change the external filter only when prompted by the warning light on the dash panel or every 3 years whichever comes first Inspect the speedometer cable and attachment Ensure there are no k
119. roper lubrication of the system by cranking the engine several times A light mist of diesel fuel should come from the exhaust of the starter On later model cargo vans the starters are self lubricated Inspect the air starter air system for leaks Drain the moisture from the air starter air tank 69 Alternator output test A amp B Perform an alternator output test using a volt amp tester Sun VAT 60 or equal equipment Record the results in the space provided on Form 4546 D 70 Regulator voltage A amp B Perform a regulator test using a volt amp tester Sun VAT 60 or equal equipment Record the results in the space provided on Form 4546 D 71 Engine A amp B Perform scheduled engine maintenance and adjustments in accordance with the manufacturer s recommendations 72 Emissions B only Observe the exhaust smoke If there is excessive smoke investigate the cause Some states may require an opacity meter to test diesel engine exhaust Refer to local emission ordinances Vehicle Maintenance Bulletin V 07 98 PMI Program Cargo Vans 73 List all repair actions on Form 4541 or 4543 A amp B List all repair actians on Form 4541 Order Invoice for Vehicle Repair or Form 4543 Vehicle Maintenance Work Order Schedule work generated by the PMI 74 Quality assurance road test A amp B After the required repairs have been completed drive the vehicle and check engine for acceleration smoothness and power Check tra
120. s Ensure that these items do no rub against any components Examine slack adjusters and links Ensure the Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Cargo Vans operation of automatic slack adjusters if applicable Adjust all brakes Replace brake linings that have 8 32 inch or less of lining material remaining Record the findings on Form 4546 D On the yearly brake inspection write line item Pull all wheels and drums for brake inspection on Form 4543 Vehicle Maintenance Work Order The estimated time to perform this brake inspection on a cargo van is 2 hours This time includes adjustment of the wheel bearings and replacement of the seals 43 Brake chamber push rod travel and slack adjusters A amp B When checking the brake chamber push rod travel air pressure system must be approximately 90 PSI to 100 PSI Stop the engine release the parking brake and apply and hold the brakes Measure the distance that the push rod traveled from the point the parking brake was released to the point the brakes were applied This is push rod travel and it should be as short as possible without brake drag and equal on the same axle Check the angle formed between the brake chamber push rod and slack adjuster arm It should be at least 90 degrees when the brakes are fully applied Refer to the vehicle s service manual for proper specifications All late model cargo vans are equipped with automatic slack adjusters If the o
121. s required A amp B Replace or recycle coolant as required by the type of coolant used The service requirement might differ between coolant manufacturers Refer to the coolant manufacturer s recommendations concerning the change or recycle interval 53 Radiator hoses and leaks A amp B Pressure test complete cooling system Examine all hoses and connections for leaks or wear Inspect water pump Replace hoses as needed 54 Belts and pulleys A amp B Check all belts for condition alignment and proper tension When adjusting belts use a belt tension gauge Inspect all pulleys for alignment and condition 55 Alternator and power steering A amp B Check alternator terminal connections and mounting Check the fluid level of the power steering pump Ensure there are no leaks 56 Fuel lines fuel system and linkage A amp B Inspect fuel lines for routing and leaks Inspect carburetor or fuel injection system linkage and lubricate as needed 57 Air filter restriction and service fuel filter s B only Test air filter restriction Record reading on Form 4546 C Replace air filter when restriction exceeds 25 inches water Service fuel filter s annually or more frequently as necessary 58 Clean battery post and cables A amp B Clean battery posts and cables Clean the terminals with a wire brush If very corroded clean the area with a solution of baking soda and water Apply protective spray to the clea
122. s to ensure that exterior markings are not faded scratched torn or missing and that they are positioned properly Update decals as needed Check the beltline and vehicle numbers in the same manner Review Publication 500 G Vehicle Guidelines for more information on vehicle markings 12 Bumpers reflectors lenses and mud flaps A amp B Examine bumpers reflectors and lenses for damage or environmental deterioration Examine condition of mud flaps and mounting for damage Inspect the Interstate Commerce Commission I C C bumper for cracks and damage Repair as needed 83 Trailers B4 PMI Program 13 General paint and body condition A amp B Inspect all painted surfaces for deterioration and condition Repaint vehicles on an as needed basis as determined by the Manager Vehicle Maintenance Inspect the bulkhead corners and fiberglass reinforced panels FRPs for damage Check the body caulking to prevent panel damage and electrolysis of the body rail Do not delay any wear and tear repairs painting or accident caused body work 14 Cleaning inside and out A amp B During each PMI steam or pressure clean the trailer chassis Note The estimated repair time ERT shown on the back of Form 4546 F was calculated assuming the use of an automatic truck washer Add 0 5 hours if the trailer is hand washed and 0 2 hours for sweeping the inside of the trailer Do not wash the inside of trailers 15 Accident damage
123. se for condition and leaks Examine motor mounts for deterioration and fatigue 35 Change oil filter and lubricate A amp B Change engine oil and filter during each PMI Clean all fittings perform complete lubrication and check fluid levels and condition in accordance with all items as shown on the manufacturer s lubrication chart Write Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Light Delivery Vehicles the lube oil and filter as a line item on Form 4543 Vehicle Maintenance Work Order Note If the lubrication is performed by someone other than the person doing the PMI subtract 0 3 hours from PMI ERT 36 Steering tie rods and arms A amp B Check steering column shaft assembly and steering gear for any deficiency or looseness Examine all steering linkage and arms for wear looseness or damage Check steering damper for proper mounting and operation Rotate components and check for end play Examine ball joints kingpins for excessive wear or for excessive resistance to turning front wheels Check the condition of the ball joints and other steering components Lubricate the tie rods and other steering components Inspect the power steering hoses and connections to ensure the hoses are not rubbing leaking or deteriorating 37 Brake linings B only Remove all wheels to inspect brake assemblies linings and drums Record the findings in the spaces provided on Form 4546 B Check all appl
124. ssure and make corrections Use a valve cap Ensure that tire pressure decals are the Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Trailers correct ones for the vehicle and are positioned properly Refer to Poster 49 Tire Pressure Chart for a list of proper tire pressures 20 Tire probe condition and tread depths A amp B Probe tires and remove foreign objects such as nails or glass Visually inspect tires for signs of unusual wear and investigate the cause of wear problems Check all tire tread depths Replace a tire if its tread is less than 4 32 inch Use a straightedge to check that dual tires are matched to within 1 2 inch Replace any tire that is not matching Record the tread depth for each tire on Form 4546 F The tread design is to match on each axle 21 Lube trailer or check automatic lube system A amp B Perform complete lubrication and check fluid levels and condition in accordance with all items as shown on the manufacturer s lubrication chart If the trailer has an automatic lube system check the lines for leaks and fill the reservoir as needed Write the lube as a line item on Form 4543 Vehicle Maintenance Work Order Note If the lubrication is performed by someone other than the person doing the PMI subtract 0 2 hours from PMI ERT 22 Springs spring pins U bolts and shackles A amp B Examine all spring hangers shackles and bushings for wear Check for sagging or broken
125. t ahead position turn the steering wheel in one direction until the tires begin to turn Note the position of the steering wheel Turn the wheel in the other direction until the tires start to move Total movement of the steering wheel before the wheels begin to move should not exceed 1 1 2 inches If the play exceeds this check for parts that are worn or out of adjustment Enter the amount of play in inches on Form 4546 A 11 Parking brake and foot brake test A amp B Check brake stopping ability and parking brake holding ability Apply the foot brake With the foot brake applied apply the parking brake Put the transmission into drive Slowly accelerate engine to approximately 500 RPM above idle Allow the engine to return to idle then place the gear selector to reverse and again slowly accelerate to 500 RPM above idle If the vehicle does not move in either direction the parking brake is properly adjusted If the vehicle moves the parking brake must be adjusted Adjust the parking brake after inspecting servicing the rear brakes To adjust remove the set screw and adjust the brake Reinstall the set screw after the adjustment 12 Clean inside and out A amp B During each PMI pressure clean the engine and chassis Wash the vehicle before performing repairs Administrative Vehicles PMI Program Note The estimated repair time ERT shown on the back of Form 4546 A was Calculated assuming the use of an automatic truck washer
126. ted on the dash temporarily light when the ignition key is in the on position After the engine starts ensure the lights go 22 Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Light Delivery Vehicles out If the lights and warning devices are not working correctly refer to the manufacturer s service manual 7 Starter action unusual sounds and neutral switch A amp B Ensure that the engine will not crank except in neutral or park Note the sound of the starter operation Remove the shift lever and inspect the condition of the lever Replace lever if worn 8 Gauges horn heater oil pressure and mirrors A amp B With the car on check the operation of all gauges Check the horn for operation and loudness Turn on the heater defroster and all other cab systems Check the oil pressure gauge when the engine starts If the engine is warm note this pressure Refer to the manufacturer s recommendations on the oil pressures for both idling and operating RPM Examine all mirrors and mounting attachments for loose or damaged parts Make sure that the mirrors are the proper mirrors for the vehicle and that they are in good condition 9 Accessories glass windshield wipers and fan A amp B Operate and examine all switches and controls Check windshield washer operation Examine all glass for cracks chips or lamination separation Check wiper arms and blades for operation and condition Examine ventilat
127. that are worn or out of adjustment Enter the amount of play in inches on Form 4546 C 12 Parking brake and foot brake test A amp B Check brake stopping ability and parking brake holding ability Apply the foot brake With the foot brake applied apply the parking brake Now put the transmission into drive Slowly accelerate engine to approximately 500 RPM above idle Allow the engine to return to idle then place the gear selector to reverse and again slowly accelerate to 500 RPM above idle If the vehicle does not move in either direction the parking brake is properly adjusted If 39 Intermediate Delivery Vehicles PMI Program 40 the vehicle moves the parking brake must be adjusted Adjust the parking brake after inspecting servicing the rear brakes To adjust remove the set screw and adjust the brake Reinstall the set screw after the adjustment 13 Clean inside and out A amp B During each PMI pressure clean the engine and chassis Wash the vehicle before performing repairs Take extreme precautions when washing inside of vehicles Note The estimated repair time ERT shown on the back of Form 4546 C was calculated assuming the use of an automatic truck washer Add 0 5 hours if the vehicle is hand washed and 0 3 hours for cleaning windows and inside of vehicle 14 Lights turn signals and back up lights A amp B Examine all lenses for cracks deterioration and brightness Check all lights for proper operati
128. the shut off valve is properly labeled Inspect the regulators for damage On some systems the regulators have a filter inside service that filter during B PMIs Refer to the vehicle s service manual for proper procedures 78 Reserved 79 Reserved When the CNG inspection is completed return to Line 66 Note Estimated inspection times for intermediate vehicles Estimated Inspection Time hours Level A 1 5 Level A with CNG 2 0 Level B 3 0 Level B with CNG 3 9 49 PMI Program Cargo Vans PMI Guidelines for Cargo Vans These tools are needed to perform the PMI Miscellaneous hand tools Spray lubricant Shop rags Flashlight Air pressure gauge Tread depth gauge Tire square Air chuck Grease gun Battery load tester Diesel opacity meter if state required June 1 1998 51 Cargo Vans PMI Program Explanation of Form 4546 D Preventive Maintenance Inspection Guidelines Cargo Vans Fill in the vehicle number assigned location due date for PMI and the type of PMI level A or B Cab Area 1 Review vehicle jacket modification orders and repair tags A amp B Prior to each preventive maintenance inspection review the vehicle jacket to determine the nature and extent of work to be performed Reviewing the vehicle jacket provides maintenance personnel with the vehicle s history Compare the current mileage with the mileage at the last PMI Examine the file to determine when items such as brake
129. tion door for proper operation 28 Cargo restraining devices A amp B Check the E tracks Ensure no bolts are loose or missing from the tracks Inspect the track slots for cracks and wear 29 Fuel cap door and filler neck A amp B Remove the filler cap and inspect the cap seal and retaining chain if equipped Check the integrity of the no leaded fuel nozzle restrictor in the fuel filler pipe Ensure that the restrictor has not been removed or enlarged The hole must be small enough to prevent the entry of a leaded fuel nozzle In some states a special tool must be used for this test Inspect and lubricate the door hinge and spring 30 Accident kit A amp B Ensure that the forms compartment contains Item 087 H Accident Report Kit and the vehicle s operator s manual Remove all other debris from the forms compartment 31 Accident damage list on diagram A amp B During each PMI maintenance employees must inspect the vehicle for accident damage report any damage to their supervisor and indicate damage on the diagram on the reverse of Form 4546 B Do not defer repairs of accident damage to a later date Prepare a separate work order and code it as an accident 32 Reserved 33 Reserved Underneath Inspection Lube 34 Fluid leaks and engine mounts A amp B Before changing the engine oil inspect the engine and transmission for fluid leaks Check the radiator for leaks Inspect lower radiator ho
130. tive Vehicles 18 PMI Program 71 CNG labels A amp B Inspect the vehicle to ensure that the CNG labels blue diamond are properly positioned on the vehicle Refer to Publication 500 G Vehicle Guidelines for proper location of decals Inspect the manual shut off label which is located near the shut off valve Engine Compartment 72 CNG labels A amp B Check the condition of the CNG label which must be located in the engine compartment area Verify that the label identifies the system manufacturer operating pressure installation date and tank expiration date or recertification date Vehicles operated in California must also have a Bureau of Automotive Repair BAR emission label 73 CNG components A amp B Check all CNG components Check for proper operation of the system Refer to the vehicle s service manual 74 Emission control systems B only With the vehicle running on CNG recheck the tail pipe gases according to the procedures outlined in item 65 Record the emission control systems results in the spaces provided on Form 4546 A Compare the gasoline and CNG emissions readings If the two sets of readings differ a great deal recheck the engine operation Underneath Inspection 75 Leak checks A amp B Check all components and connections for leaks using a non ammonia soap solution or a methane detector It is important that all connections be checked for leaks during the PMI Repair all leaks
131. tors lenses and mud flaps emu 59 Alternator and power steering Lagos markings posters and beltline EE 60 Fuel lines fuel system and linkage PS Form 4546 D March 1998 PREVENTIVE MAINTENANCE INSPECTION GUIDELINES continued 61 Fuel filter s EI 62 Emission Ee devices 63 Air filter restriction inches Clean battery post and cables 33 Battery box and hold downs Wiring and hoses Battery load test valts Starter cranking test Alternator output test volts We Deliver For You on We Deliver For You Note If damage is more than normal wear and tear a separate work order must be written and coded as an accident ERT to perform an A PMI on a cargo van is 2 0 hours ERT to perform a B PMI on a cargo van is 3 5 hours Completed by Work Order No Odometer PS Form 4546 D March 1998 UNITED STATES POSTAL SERVICE Ba PREVENTIVE MAINTENANCE INSPECTION GUIDELINES m P TRACTORS x Vehicle No Assigned Location Type PM In Um before each ltem indicate condition as follows V Item is OK 0 Adjustment Made X Repairs Needed Not Applicable EG 1 Review vehicle jacket mod orders and repair tags m m 2 Road test 32 Fifth wheel assembly i siiri 3 Leaks doors door locks handles and steps uh E 33 Fuel cap vent and filler neck a Seat beit andimerior P 34 Cat walk steps and grab handles ne 5 Key ignition and door key
132. ure all hoses and the heat stove tube are connected Check for kinked plugged or deteriorated hoses Check for the presence and condition of the gasket seal between the air cleaner and the throttle With air cleaner assembly installed the damper door should be apen ta outside air Start the engine and watch the damper door in air cleaner snorkel When the engine is first started the damper door should move and close off outside air As the air cleaner warms up the damper door should open slowly to outside air If the air cleaner fails to operate as described above perform a vacuum motor check If it operates the door may not be moving at the right temperature If a driveability problem occurs during warm up perform a temperature sensor check 3 Evaporative emission control system Check operation of the total system Replace vapor canister if it is damaged or if fuel is leaking from the bottom Replace filter at the bottom of the canister If a fuel tank filler cap requires replacement use only a cap with the same Original Equipment Manufacturers OEM features Failure to use the correct cap can result in a malfunctioning system Check the condition of fuel lines hoses and connections 4 Catalytic converter Examine all connections for signs of leaking exhaust The condition of converter may be checked following the procedures listed in the LLV technical manual 5 Exhaust gas recirculation EGR system Ensure the solenoid is in
133. wered Diesel opacity meter if state required June 1 1998 37 Intermediate Delivery Vehicles PMI Program 38 Explanation of Form 4546 C Preventive Maintenance Inspection Guidelines Intermediate Delivery Vehicles Fill in the vehicle number assigned location due date for PMI and the type of PMI level A or B Cab Area 1 Review vehicle jacket modification orders and repair tags A amp B Prior to each preventive maintenance inspection review the vehicle jacket to determine the nature and extent of work to be performed Reviewing the vehicle jacket provides maintenance personnel with the vehicle s history Compare the current mileage with the mileage at the last PMI Examine the file to determine when items such as brake work and tune ups were performed last Review the vehicle records for any pending Vehicle Modification Orders and for any history of repetitive repairs Review Forms 4565 Vehicle Repair Tag 2 Road test A amp B Drive the vehicle and check the engine for smooth acceleration and power Check transmission slippage and shift points Check steering for ease of operation wander pulling etc Listen for any unusual noises If the vehicle also is powered by compressed natural gas CNG perform part of the road test with the engine running on CNG 3 Leaks doors handles and steps A amp B Check the operation of the doors tracks latches locks and strikers Check door rails rollers
134. work and tune ups were performed last Review the vehicle records for any pending Vehicle Modification Orders and for any history of repetitive repairs Review Forms 4565 Vehicle Repair Tag 2 Road test A amp B Drive the vehicle and check the engine for smooth acceleration and power Check transmission slippage and shift points Check steering for ease of operation wander pulling etc Listen for any unusual noises 3 Leaks doors door locks handles and steps A amp B Check the operation of the doors latches locks and strikers Check door hinges and weather seals Inspect ihe handles for proper operation and security Check the alignment and the door for adjustment Check the door and window seals for wear and damage Check the condition of steps and step wells 4 Seat belt and interior A amp B Examine seat mounts seat coverings adjusting mechanisms seat belts retractors and anchors Check the sun visors and other inside cab components for operation and condition 5 Key ignition and door key assembly A amp B Check the keys for cracks and signs of wear Inspect the lock assemblies for signs of wear Lubricate all lock assemblies with spray lubricant 6 Buzzer and warning devices A amp B Ensure that all warning lights located on the dash temporarily light when the ignition key is in the on position After the engine starts ensure the lights go 52 Vehicle Maintenance Bulletin V 07 98 PMI Pr
135. xamine crankcase depression regulator Examine all hoses connections and grommets for deterioration For non diesel powered vehicles connect the vehicle to an engine analyzer and an infrared exhaust analyzer to examine the ignition induction and combustion systems Tune up engine only if emissions levels cannot be brought into specifications by adjustment or if the examination indicates other problems See Light Delivery Guidelines for more information on emission testing for gasoline powered vehicles If vehicles are diesel powered observe the exhaust smoke If there is excessive smoke investigate the cause Some states may require an opacity meter to test diesel engine exhaust Refer to local emission ordinances If vehicle is CNG powered go to step 68 66 List all repair actions on Form 4541 or 4543 A amp B List all repair actions on Form 4541 Order Invoice for Vehicle Repair or Form 4543 Vehicle Maintenance Work Order Schedule work generated by the PMI Vehicle Maintenance Bulletin V 07 98 PMI Program June 1 1998 Intermediate Delivery Vehicles 67 Quality assurance road test A amp B After the required repairs have been completed drive the vehicle and check engine for acceleration smoothness and power Check transmission shift pattern Check steering for ease of operation wander pulling etc Listen for any unusual noise Check brake stopping ability and parking brake holding ability Before vehicle is

Vehicle Maintenance Bulletin V-07-98

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