Vehicle Maintenance Bulletin V-07-98

Vehicle Maintenance Bulletin V-07-98
I
fir!!!!!~
UNITED STJJTES
~ POSTJJL 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 .
F.
Effective Date. This bulletin is effective June 1, 1998.
Michael F. Spates
Manager, Delivery
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
I. Background ........................................................................ .
II. Effective Date ...................................................................... .
Ill. New Inspection Checklists ................ .... ......... ..................... ........ .
IV. Levels of Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
V. Scheduling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
VI. Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
VII. Emission and Brake Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
VIII. PMI Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
PMI Guidelines for Administrative Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Cab Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Circle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Underneath Inspection/Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Engine Compartment Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Compressed Natural Gas (CNG) Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
Cab Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
Underneath Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
PMI Guidelines for Light Delivery Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
Cab Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
Circle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
Underneath Inspection/Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
Engine Compartment Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
Compressed Natural Gas (CNG) Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
Cab Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
Underneath Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
June 1, 1998
iii
Contents
PMI Program
PMI Guidelines for Intermediate Delivery Vehicles
37
Cab Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
Circle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
Underneath Inspection/Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
Engine Compartment Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
Compressed Natural Gas (CNG) Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
Cab Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
Underneath Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
PMI Guidelines for Cargo Vans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
Cab Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52
Circle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
Underneath Inspection/Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
Engine Compartment Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60
PMI Guidelines for Tractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
Cab Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
Circle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70
Underneath Inspection/Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
Engine Compartment Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
77
PMI Guidelines for Trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81
Walk Around .............. ·. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82
Wheels, Tires, and Underneath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84
Appendix: Forms Used in the PMI Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89
iv
Vehicle Maintenance Bulletin V-07 -98
Introduction
PMI Program
Introduction
I. 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.
II. Effective Date
This Bulletin is effective immediately upon receipt. Vehicle Maintenance
Facilities (VMFs) are required to use these new guidelines for all PMis,
including those performed by contractors.
Ill. New Inspection Checklists
The following forms have been revised and are included in this Bulletin:
•
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 GuidelinesCargo Vans
•
PS Form 4546-E, Preventive Maintenance Inspection Goide/ines Tractors
•
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 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 PM Is 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 PM I. 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:
2
•
500 or fewer miles per accounting period (6,500 or fewer miles per
year): 26 weeks.
•
501-1,000 miles per accounting period (6,501-13,000 miles per year):
17 weeks.
•
1,001-1,500 miles per accounting period (13,001-19,500 miles per
year): 13 weeks.
Vehicle Maintenance Bulletin V-07 -98
Introduction
PMI Program
In addition, please note:
June 1, 1998
•
All spotter tractors must be serviced every 200 hours of operation
regardless of miles traveled.
•
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.
•
The 1992 and 1997 Mack tractors must have an oil and filter change
every 25,000 miles or 600 hours, whichever comes first.
3
PMI Program
Administrative Vehicles
PMI Guidelines for
Administrative Vehicles
These tools are needed to perform the PMI:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
June 1, 1998
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
5
PMI Program
Administrative Vehicles
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 & 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 PM I. 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 & 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 & 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 & 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 & 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 & 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 lights go
6
Vehicle Maintenance Bulletin V-07 -98
PMI Program
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& 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 & 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 & 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 & 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 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 & 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 & B)
During each PMI, pressure clean the engine and chassis. Wash the vehicle
before performing repairs.
June 1. 1998
7
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. 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 & B)
Examine all lenses for cracks, deterioration, and brightness. Check all lights
for proper operation.
14. Floor and underdash wiring (A & 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 & 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 & 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 & 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 the work order.
19. Reserved
20. Reserved
Circle Inspection
21. Tire inflation (A & 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
8
Vehicle Maintenance Bulletin V-07 -98
PMI Program
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 & 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 & 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 & B)
Examine bumpers, reflectors, and lenses for damage or environmental
deterioration.
25. Logos, markings, posters, and beltline (A & 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 & 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 & 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.
28. Accident kit (A & 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.
June 1, 1998
9
Administrative Vehicles
PMI Program
29. Accident damage (list on diagram) (A & 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-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 & 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 & B)
Change engine oil and filter during each PM I. 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 & 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 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
10
Vehicle Maintenance Bulletin V-07-98
Administrative Vehicles
PMI Program
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 & 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 & 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-bolts. Examine shock
absorbers for leaks, damage, or worn grommets. On front wheel drive
vehicles, inspect the McPherson suspension system.
40. Transmission and mountings (A & 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 & B)
Examine complete exhaust system for leaks, damage, or loose hangers.
Examine catalytic converter for evidence of overheating.
42. Driveline, alignment, and condition (A & 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 & B)
Check the differential fluid level and check for leaks. Fill as necessary. Check
the breather hose for restrictions and for proper oper~tion.
June 1, 1998
11
Administrative Vehicles
PMI Program
44. Undercoating condition (A & 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
4 7. Reserved
48. Reserved
Engine Compartment Area
49. Engine compartment (A & 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 & 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-A.
51. Alkalinity protection (A & 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 & 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 & B)
Pressure test complete cooling system. Examine all hoses and connections
for leaks or wear. Inspect water pump. Replace hoses as needed.
12
Vehicle Maintenance Bulletin V-07-98
Administrative Vehicles
PMI Program
54. Belts and pulleys (A & 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 & 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 & 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 & 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 & 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 & 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 & 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 & 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 & 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 & 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.
June 1. 1998
13
Administrative Vehicles
PMI Program
64. Regulator voltage (A & 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 (1/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 1/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 1/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
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
14
Vehicle Maintenance Bulletin V-07 -98
Administrative Vehicles
PMI Program
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.
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 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, 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 (C0 2 ), hydrocarbon (HC), and oxygen (0 2 ). 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 read ings in the space
provided on Form 4546-A. If the basic engine and ignition conditions are
within specifications and the CO, C0 2 , HC, 0 2 , 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.
·
June 1, 1998
15
Administrative Vehicles
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
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 liM 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-A.
The 1/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.
16
Vehicle Maintenance Bulletin V-07-98
Administrative Vehicles
PMI Program
If vehicle is CNG powered, go to step 68.
66. List all repair actions on Form 4541 or 4543 (A & 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 & 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,
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-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 & 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 PM I. 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 & 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 & B)
Examine all wiring for chafing and for proper connection to the CNG
computer and vehicle computer.
June 1, 1998
17
Administrative Vehicles
PMI Program
71. CNG labels (A & 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 & 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 & 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 & 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 PM I. Repair all leaks.
76. Fuel tank (A&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.
18
Vehicle Maintenance Bulletin V-07-98
PMI Program
Administrative Vehicles
77. Lines, valves, and regulators (A & 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 PM Is. 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 administrative vehicles:
Estimated Inspection
Time (hours)
June 1. 1998
Level A
1.5
Level A with CNG
2.0
Level B
2.0
Level B with CNG
2.5
19
Light Delivery Vehicles
PMI Program
PMI Guidelines for
Light Delivery Vehicles
These tools are needed to perform the PMI:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
June 1, 1998
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
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 8).
Cab Area
1. Review vehicle jacket, modification orders, and repair
tags (A & 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 & 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 & 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 & 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 & 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 & 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
22
Vehicle Maintenance Bulletin V-07 -98
PMI Program
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&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 & 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 & 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 applicable) for operation and safety guards.
10. Steering play (A & 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 & 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.
June 1, 1998
23
Light Delivery Vehicles
PMI Program
12. Clean inside and out (A & 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-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 & B)
Examine all lenses for cracks, deterioration, and brightness. Check all lights
for proper operation.
14. Floor and underdash wiring (A & 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 & 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&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 & 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. In a 1/4 ton AMG, Label126, Owner-Driver Caution, must be riveted to the
dash.
18. General paint and body condition (A & 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.
24
Vehicle Maintenance Bulletin V-07 -98
PMI Program
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 & 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 & 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 & 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 & 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 & 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 & B)
Check the rear door lock for proper operation and security. Inspect the
overhead door pull-down strap and door seals.
June 1, 1998
25
Light Delivery Vehicles
PMI Program
27. Interior condition, cargo door, floors, and roof (A & 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 partition door for
proper operation.
28. Cargo restraining devices (A & 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 & 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 & 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 & 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 & 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 & 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
26
Vehicle Maintenance Bulletin V-07 -98
Light Delivery Vehicles
PMI Program
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 PM I, subtract 0.3 hours from PMI ERT.
36. Steering, tie rods, and arms (A & 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 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 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 & 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 & B)
Examine all spring hangers, shackles, and bushings for wear. Check for
sagging or broken spring leaves or broken center bolts. Inspect the cond ition
of the stabilizer bar. Check tightness of spring U-bolts. Examine shock
absorbers for leaks, damage, or worn grommets.
June 1, 1998
27
Light Delivery Vehicles
PMI Program
40. Transmission and mountings (A & 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 & B)
Examine complete exhaust system for leaks, damage, or loose hangers.
Examine catalytic converter for evidence of overheating.
42. Driveline, alignment, and condition (A & B)
Examine propeller shaft, universal joints, carrier bearing, and slip joint for
wear or damage.
43. Body hold downs, hoses, and wires (A & 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 & 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 & 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
4 7. Reserved
48. Reserved
Engine Compartment Area
49. Engine compartment (A & 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.
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Vehicle Maintenance Bulletin V-07 -98
PMI Program
Light Delivery Vehicles
50. Antifreeze protection level (A & 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 & 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 & 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 & 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 & 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 & 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 & 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 & 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 & 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.
June 1, 1998
29
PMI Program
Light Delivery Vehicles
59. Battery box and hold-downs (A & 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 & 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 & 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 & 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 & 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-B.
64. Regulator voltage (A & 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 (1/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
device or to allow a vehicle to operate if the vehicle fails this test.
The 1/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 1/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
30
Vehicle Maintenance Bulletin V-07 -98
PMI Program
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 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
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 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
June 1, 1998
31
PMI Program
Light Delivery Vehicles
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, 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 (C02 ), hydrocarbon (HC), and oxygen (0 2 ). 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, C0 2 , HC, 0 2 , 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 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
32
Vehicle Maintenance Bulletin V-07-98
Light Delivery Vehicles
PMI Program
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 exhaust 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
located 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.
June 1, 1998
33
Light Delivery Vehicles
PMI Program
The 1/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-B.
The 1/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 on Form 4541 or 4543 (A & 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 & 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-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 & 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 PM I. 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.
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Vehicle Maintenance Bulletin V-07 -98
Light Delivery Vehicles
PMI Program
69. Warning lights and engine operation (A & 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 & B)
Examine all wiring for chafing and for proper connection to the CNG
computer and vehicle computer.
71. CNG labels (A & 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 & 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 & 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-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 & 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 PM I. Repair all leaks.
June 1, 1998
35
Light Delivery Vehicles
PMI Program
76. Fuel tank (A&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.
77. Lines, valves, and regulators (A & 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 PM Is. 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)
36
Level A
1.5
Level A with CNG
2.0
Level B
3.0
Level B with CNG
3.5
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:
•
•
•
•
•
•
•
•
•
•
•
•
•
June 1, 1998
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 powered)
Diesel opacity meter (if state required)
37
Intermediate Delivery Vehicles
PMI Program
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 & 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 & 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 & B)
Check the operation of the doors, tracks, latches, locks, 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 & 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 & 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 & 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
38
Vehicle Maintenance Bulletin V-07-98
Intermediate Delivery Vehicles
PMI Program
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& 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 & 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 information 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 & 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 & 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.
11. Steering play (A & 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-C.
12. Parking brake and foot brake test (A & 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
June 1, 1998
39
Intermediate Delivery Vehicles
PMI Program
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 & 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 1f 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 & B)
Examine all lenses for cracks, deterioration, and brightness. Check all lights
for proper operation.
15. Floor and underdash wiring (A & 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 & B)
Check the vehicle's fire extinguisher and emergency warning kits (if required)
per Section 243 of Handbook P0-701. 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&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 & 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 & B)
Inspect all painted surfaces for deterioration and condition. Repaint vehicles
on an as-needed basis, as determined by the Manager, Vehicle Maintenance.
40
Vehicle Maintenance Bulletin V-07-98
Intermediate Delivery Vehicles
PMI Program
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 & 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 & 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 & 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 1/4 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 & 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 & 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 & B)
Check the rear door lock for proper operation and security. Inspect the
overhead door pull-down strap and door seals.
June 1, 1998
41
Intermediate Delivery Vehicles
PMI Program
27. Interior condition, cargo door, floors, and roof (A & 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 & 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 & 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 & 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 & B)
During each PM I, 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 & 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 & 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 fatigue.
35. Change oil, filter, and lubricate (A & B)
Change engine oil and filter during each PMI. Clean all fittings , perform
complete lubrication, and check fluid levels and condition in accordance
42
Vehicle Maintenance Bulletin V-07-98
I
Intermediate Delivery Vehicles
PMI Program
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 PM I, subtract 0.3 hours from PMI ERT.
36. Steering, tie rods, and arms (A & 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. 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 & 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 & 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-bolts. Examine shock
absorbers for leaks, damage, or worn grommets.
June 1, 1998
43
Intermediate Delivery Vehicles
PMI Program
40. Transmission and mountings (A & 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 & B)
Examine complete exhaust system for leaks, damage, or loose hangers.
42. Driveline, alignment, and condition (A & 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 & 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 & B)
Check the differential fluid level and check for leaks. Fill as necessary. Check
the breather hose for proper operation.
45. Undercoating condition (A & 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
4 7. Reserved
48. Reserved
Engine Compartment Area
49. Engine compartment and engine (A & 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.
44
Vehicle Maintenance Bulletin V-07 -98
Intermediate Delivery Vehicles
PMI Program
50. Antifreeze protection level (A & 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-C.
51. Alkalinity protection (A & 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 & 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 & 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 & 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 & 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 & 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 & 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.
June 1, 1998
45
Intermediate Delivery Vehicles
PMI Program
59. Battery box and hold-downs (A & 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 & 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 & 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 & 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 & 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-C.
64. Regulator voltage (A & 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. Examine 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 & B)
List all repair actions on FC?rm 4541, Order Invoice for Vehicle Repair, or
Form 4543, Vehicle Maintenance Work Order. Schedule work generated by
the PMI.
46
Vehicle Maintenance Bulletin V-07 -98
PMI Program
Intermediate Delivery Vehicles
67. Quality assurance road test (A & 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-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 & 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 & 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 & B)
Examine all wiring for chafing and for proper connection to the CNG
computer and vehicle computer.
71. CNG labels (A & 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.
June 1, 1998
47
Intermediate Delivery Vehicles
PMI Program
Engine Compartment
72. CNG labels (A & 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 & 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 & 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 PM I. Repair all leaks.
76. Fuel tank (A&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.
77. Lines, valves, and regulators (A & 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
48
Vehicle Maintenance Bulletin V-07 -98
PMI Program
Intermediate Delivery Vehicles
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 PM Is. 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
June 1, 1998
A
1.5
Level A with CNG
2.0
LevelS
3.0
Level B with CNG
3.5
49
Cargo Vans
PMI Program
PMI Guidelines for Cargo Vans
These tools are needed to perform the PMI:
•
•
•
•
•
•
•
•
•
•
•
June 1, 1998
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)
51
PMI Program
Cargo Vans
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 8).
Cab Area
1. Review vehicle jacket, modification orders, and repair
tags (A & 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 PM I. 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 & 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 & 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 & 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 & 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 & 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 Program
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 & 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& 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 & 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, windshield wipers, fan, and radio
(A & 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 & 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 4546-0.
12. Lights, turn signals, and back-up lights (A & B)
Examine all lenses for cracks, deterioration, and brightness. Check all lights
for proper operation.
June 1, 1998
53
PMI Program
Cargo Vans
13. Floor and underdash wiring (A & 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 & 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 & 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&B)
Check the vehicle's fire extinguisher and emergency warning kits per Section
243 of Handbook P0-701. 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 & 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 & 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 & 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 & 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
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.
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Vehicle Maintenance Bulletin V-07 -98
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Cargo Vans
21. Governor range (A & 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 & 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 & 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.
June 1, 1998
55
PMI Program
Cargo Vans
23. Clean inside and out (A & B)
During each PM I, 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 & 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 & 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 & 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 & 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.
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Vehicle Maintenance Bulletin V-07-98
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Cargo Vans
29. Bumpers, reflectors, lenses, and mud flaps (A & 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 & 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. Rear door security and condition (A & 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 & 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 & 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 & 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 & B)
Examine tank mounting brackets for damage. Examine tanks, hoses, valves,
and plumbing for damage or chafing.
36. Accident damage (list on diagram) (A & 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-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 & B)
Inspect lift gate (if applicable) for proper operation. Lubricate all moving
parts. Check the latching mechanisms and safety locks for proper operation.
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Cargo Vans
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 & 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 & 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 and slack adjusters
(A& 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)
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 shields.
Local management must ensure that all brakes are properly maintained.
Once a year, remove all wheels to inspect brake assemblies, lin,ings, 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
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Vehicle Maintenance Bulletin V-07 -98
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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& 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 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 & 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 & 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 & 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 kinks or leaks and
that the cable bends smoothly and is protected from damage.
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47. Exhaust systems (A & 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 & 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 & B)
Check fluid level and fill as necessary. Clean vent assembly and examine
housing for indication of leaks.
50. Undercoating condition (A & 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 & 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 & 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 & 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 & 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
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Vehicle Maintenance Bulletin V-07 -98
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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 & 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 & 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 & 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 & 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 & 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 & 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-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.
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64. Clean battery post and cables (A & 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 & 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 & 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 & 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 & 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 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 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 & 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 & 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 & 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.
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73. List all repair actions on Form 4541 or 4543 (A & 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 & 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-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)
Level A
2.0
Level B
3.5
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
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PMI Guidelines for Tractors
These tools are needed to perform the PMI:
•
•
•
•
•
•
•
•
•
•
•
•
•
June1,1998
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
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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 B).
Cab Area
1. Review vehicle jacket, modification orders, and repair
tags (A & 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 & 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 & 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 & 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 & 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 & 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
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out. If the lights and warning devices are not working correctly, refer to the
manufacturer's service manual.
7. Cold weather starting aids (A & 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& 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 & 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, windshield wipers, fan, and radio
(A& 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 & 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 & B)
Examine all lenses for cracks, deterioration, and brightness. Check all lights
for proper operation.
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13. Floor and underdash wiring (A & 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 & 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 & 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& B)
Check the vehicle's fire extinguisher and emergency warning kits per Section
243 of Handbook P0-701. 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 & 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 & 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 & 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 & 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
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Vehicle Maintenance Bulletin V-07 -98
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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 & 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-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& 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 & B)
1. Tractor with manual transmission
a. Parking brake check
Start the engine, 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 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
June 1, 1998
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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 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.
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 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.
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 & B)
During each PM I, 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 & 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 & 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
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Vehicle Maintenance Bulletin V-07 -98
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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 & 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 & 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 & 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 & 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 & 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 (8 only)
Examine the fifth wheel locking and release mechanism, surface condition,
tilting trunnions, and mounting brackets. Examine condition of ground strap
and connections. Examine guide ramps for loose or broken mounting bolts
and welds. During every PMI, follow the instructions below:
A. Periodic Inspections and Adjustments
Perform all of the following during each PM I. Perform steam cleaning first to
ensure a good inspection.
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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 repair 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 lock 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
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Vehicle Maintenance Bulletin V-07-98
Tractors
PMI Program
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 Too Loose
a) Check plunger adjustment.
b) Check the plunger springs 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 & 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 & 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 & B)
Examine tank mounting brackets for damage. Examine tanks, hoses. valves,
and plumbing for damage or chafing.
36. Accident damage (list on diagram) (A & 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
June 1, 1998
73
PMI Program
Tractors
Underneath Inspection/Lube
39. Fluid leaks and engine mounts (A & 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 & 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 & 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 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 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.
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Vehicle Maintenance Bulletin V-07-98
Tractors
PMI Program
43. Brake chamber push-rod travel (A & 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 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 & 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 & 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 & B)
A. Manual Transmissions
Inspect the shifter boot for deterioration and broken seal springs. Check the
transmission mounts, shift linkage, and U joints for wear or deterioration.
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.
June 1, 1998
75
Tractors
PMI Program
47. Exhaust systems (A & 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 & 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 & B)
Check fluid level and fill as necessary. Clean vent assembly and examine
housing for indication of leaks.
50. Undercoating condition (A & 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 & 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 PM I, check nuts for proper torque. Inspect the condition of springs,
radius rod, and torque rod bushing. 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 ride height. If it is not, refer to the vehicle's service
manual for proper repair procedure.
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Vehicle Maintenance Bulletin V-07-98
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Tractors
Engine Compartment Area
53. Engine compartment and cab lifting system (A & 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 & 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 & 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
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 & 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 & 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 & 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.
June 1, 1998
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PMI Program
59. Alternator and power steering (A & 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 & 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 & 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 & 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 & 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 & 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 & 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.
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Vehicle Maintenance Bulletin V-07 -98
PMI Program
Tractors
68. Starter cranking test (A & 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 & 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 & 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-E.
71. Engine (A & 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 & 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 & 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.
June 1, 1998
79
Tractors
PMI Program
75. Reserved
76. Reserved
77. Reserved
78. Reserved
Note:
Estimated inspection times for tractors:
Estimated Inspection
Time (hours)
Level A
2.0
Level B
3.5
The B PMI and the follow-up repairs satisfy the Federal Annual Vehicle
Inspection, as prescribed in the Federal Motor Carrier Safety Regulations.
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Vehicle Maintenance Bulletin V-07 -98
PMI Program
Trailers
PMI Guidelines for Trailers
These tools are needed to perform the PMI:
•
•
•
•
•
•
•
•
•
•
•
•
June 1, 1998
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
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 & 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 PM I. 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 & B)
Raise and lower the landing 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 & B)
Inspect the condition of the glad-hands. Replace glad-hand seals annually.
Inspect and clean the seven-pin connector.
4. Road test (A & 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 & 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 & 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.
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Vehicle Maintenance Bulletin V-07 -98
Trailers
PMI Program
7. Perform air system leak checks and drain air tanks
(A& B)
Drain all air tanks to 0 PSI. If the trailer \S 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. If 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 & B)
Examine all lenses for cracks, deterioration, and brightness. Check all lights
for proper operation.
9. Electrical junction box (A & 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 & 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 & 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.
12. Bumpers, reflectors, lenses, and mud flaps (A & 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.
June 1, 1998
83
Trailers
PMI Program
13. General paint and body condition (A & 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 & B)
During each PM I, 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 (list on diagram) (A & B)
During each PM I, 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 & 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 & 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 & 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 & 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
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Vehicle Maintenance Bulletin V-07 -98
Trailers
PMI Program
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 & 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 & B)
Perform complete lubrication, and check fluid levels and condition in
accordance with all items as shown on the manufa_cturer'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 & B)
Examine all spring hangers, shackles, 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.
23. Radius rods and bushings (A & B)
Check all radius rods, bolts, and bushings for tightness and condition.
24. Coupler plate and king pin condition (A & 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.
June 1, 1998
85
Trailers
PMI Program
26. Brake chamber push-rod travel and 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 & B)
Inspect air tank and drain valve for mounting and damage. Open and drain
tanks completely.
28. Air lines, hoses, wiring, and connections (A & 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 metal 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 & B)
Check the condition of all body cross members for cracks and broken welds.
31. Undercoating condition (A & 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 4541 or 4543 (A & 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.
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Trailers
PMI Program
33. Quality assurance road test (A & 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 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
1.5
Level B. single-axle
2.5
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.
June 1, 1998
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 (MOCs).
PS Form 4546-A, Preventive Maintenance Inspection GuidelinesAdministrative Vehicles
PS Form 4546-B. Preventive Maintenance Inspection GuidelinesLight Delivery Vehicles
PS Form 4546-C, Preventive Maintenance Inspection GuidelinesIntermediate Delivery Vehicles
PS Form 4546-0, Preventive Maintenance Inspection GuidelinesCargo Vans
PS Form 4546-E, Preventive Maintenance Inspection Guidelines Tractors
PS Form 4546-F, Preventive Maintenance Inspection GuidelinesTrailers
June 1, 1998
89
UNITED STATES POSTAL SERVICE
PREVENTIVE MAINTENANCE INSPECTION GUIDELINES
ADMINISTRATIVE VEHICLES
UNITED STATES
POSTAL SERVICE ..
Vehicle No.
Assigned Location
Due Date
Type PMI
In box before each item indicate condition as follows:
1;/) Iten1 is O'K
A
B
( 0) Adjustment Made
Cab Area
(X) Repairs Needed
A
(--) Not Applicable
B
!. Review vehicle jacket, mod orders. and repair tags
31.
2. Road test
32.
.,
.:>. Leaks. doors, and handles
33 .
4. Seat. belt, and interior
Underneath Inspect/Lube
;).
,- Key. ignition. and door key assembly
34. Fluid leaks and engine mounts
6. Buzzer and warning devices
35. Change oil, filter. and lubricate
7. Starter action. unusual sounds, and neutral switch
36. Steering, tie rods, and arms
8. Gauges. horn. heater, oil pressure. and mirrors
37. Brake linings
LR - -/32 RR _ _/32
9. Accessories. glass. windshield wipers , and fan
10. Steering play _ _ inches
38. Bearing play and condition
11. Parking brake and foot brake test
39. Suspension, springs. shocks. and hangers
12. Clean inside and out
40. Transmission and mountings
13. Lights, turn signals, and back-up lights
41. Exhaust systems , converter, and muffler
14. Floor and underdash wiring
42. Driveline, alignment. and condition
15. Window, window guides. and regulator
43. Differential and breather
16. Authorized cab decals and Label 70
44. Undercoating condition
17. General pai.nt and body condition
45.
18. Wax vehicle
4G.
19.
47.
20.
48.
Circle Inspection
Engine Compartment Area
21. Tire inflat.ion
49. Engine compartment
22. Lug nuts , wheels, hubs. and alignment
50. Antifreeze protection level _ _ °F
23. Tire probe, condition and tread depths
51. Alkalinity protection
LF _ _/32RF _ _/32 LR _ _/32 RR _ _/32
PS F'orm
-
LF _ _/32 RF _ _/32
52. Replace or recycle coolant as required
24 . Bumpers. reflectors, and lenses
53. Radiator, hoses, and leaks
25. Logos. mar!;ings. posters. ;md beltline
54. Belt> and pulleys
ZG. Interior condition, floors, and roof
55. Alternator and power steering
27. Fuel cap, door, and filler neck
56. Fuel lines, fuel system. and linkage
28. Accident kit
57. Fuel filter, air filter, and PCV filter
29. Accident damage (list on diagram)
58. Clean battery post and cables
30.
59. Battery box and hold-downs
4::~46-A
March 1998
PREVENTIVE MAINTENANCE INSPECTION GUIDELINES
A
B
Engine Compartment Area (con't)
60. Wiring and hoses
Start~r
volts
t~st
_ _ volts _ _ amps
Oz
Oz
96
0'
/0
72. CNG
lab~ls
73. CNG components
65. Emission control systems
_ _ ppm
_ _ ppm
lab~ls
Engine Compartment
64. Regulator voltag~ _ _ volts
HC
HC
CNG Vehicles (con't)
71. CNG
cranking tf:'st _ _ amps
63. Alternator output
B
70. Wiring
61. Battery load test
62.
A
co
co
%at
%at
%at
% at
COz
COz
idle
2500 RPM
idle
2500 RP!v!
74 . Emission control systems
_ _ ppm
HC
co
_
_ ppm
HC
co
Oz
Oz
9b
COz
%
C02
66. List all repair actions on Form 4541 or 4543
Underneath Inspection
67. Quality assurance road test
75. Leak checks
CNG Vehicles
76. Fuel tank
Cab Area
77. Lines. valves. and regulators
68. Fill valve and starter interrupt switch
78.
69 . Warning ligllts and engine operation
79.
---=
%at idle
% at 2500 RPivf
%at idle
'Yo at 2500 RPM
'tF
IDDIIIIIII Illll±fWIDDI
Note: If damage is more than normal wear and tear, a separate work order must be written and coded ns nn accident.
ERT to perform an ''A" Pl'vfl on an administrative vehicle is 1.5 hours. ERT to perform an "A'' PMI on an administrative vehicle
equipped with CNG is 2.0 hours. ERT to perfom1 a "B" PMI on an administrative vehicle is 2.0 hours. ERT to perfmm a "B" Pl\·11
on an administrative vehicle equipped with CNG is 2.5 hours.
Compkted by
PS Form 4546-A March 1998
Date
Work Order No.
Odometer
UNITED STATES POSTAL SERVICE
PREVENTIVE MAINTENANCE INSPECTION GUIDELINES
LIGHT DELIVERY VEHICLES
UNITED STdTES
POST.IlL SERVICE ..
IAssigned Location
Vehicle No.
IType ofPMI
Due Date
In box before each item indicate condition as follows:
C'·h
( 0 l Aqjustment
Item is OK
A
B
~.:lade
(X) Repairs Needed
A
Cab Area
H Nut Applicable
B
I. Review vehicle jacket. mod orders, and repair tags
31. Accident damage (list on diagram)
2. Road test
32.
3 . Leaks, doors. handles, and steps
33.
4. Seat, belt. and interior
Underneath Inspect/Lube
5. Key, ignition , and door key assembly
34. Fluid leaks and engine mounts
6. Buzzer and warning devices
35. Change oil, filter. and lubricate
7. Starter action. unusttal sounds. and neutral switch
36. Steering, tie rods, and arms
8. Gauges, horn. heater, oil pressure. and mirrors
37. Brake linings
RF _ _/32
10. Steering play _ _ inches
38. Bearing play and <:ondition
11. Parking brake and foot brake test
39. Suspension. springs. shocks, and hangers
12. Clean inside and out
40. Transmission and mountings
1:3. Lights. turn signals. and back-up lights
41. Exhaust systems. converter, and muffler
14. Floor and underdash wiring
42. Drivellne. alignment. and condition
15. Mail tray and brackets
43. Body hold downs . hoses. and
16. Window, window locks. regulator, and door slir.lrs
44. Differential and breather
17.
Authoriz~d
cab decals and Label 70
wire~~
45. Undercoating condition
18. General paint and body condition
46.
19. Wax vehicle
47.
20.
48.
Cirde Inspection
Engine Compartment Area
21. Tire inflation
49. Engine compartment
22. Lug nuts. wheels, hubs, and alignment
50. Antifreeze protection level _ _''F
23. Tire probe , condition and tread depths
51. Alkalinity protection
LF - -/32 RF _ _/32 LR _ _i32RR _ _132
-
- -/32
LR _ _/32 RR _ _/32
9. Accessories, glass. windshield wipers, and fan
~
LF
52. Replace or recycle coolant as required
24. Bumpers. reflectors. lenses. and mud flaps
53. Radiator, hoses. and leaks
25. Logos, markings. posters. and beltline
54. Belts and pulleys
26. Rear door security and condition
55. Alternator and power steering
2"1. Interior cond.ition, cargo door. floors, ,md roof
5G. Fuel lines, fuel system. and linkage
28. Cargo restraining devices
"~7
Jl.
29. Fuel cap. door. and filler neck
58. Cltan battery post and cables
30. Accident kit
59. BMtery box and hold-downs
PS' Form 4:.46-B March 1998
Fuel filter. air filter , ,md PCV filter
PREVENTIVE MAINTENANCE INSPECTION GUIDELINES
A
B
Engine Compartment Area {con't)
60. Wiring and hoses
61. Battery load test
A
B
CNG Vehicles (con't)
70. Wiring
volts
71. CNG labels
62. Starter cranking test _ _ amps
Engine Compartment
63. Alternator output test _ _ volts _ _ amps
72. CNG labels
64. Regulator voltage _ _ volts
73. CNG components
65 . Emission control systems
HC:
HC
Oz
0:
_ _ ppm
_ _ ppm
co
co
~A)
C02
%
COz
74. Emission control systems
%at
%at
%at
%at
HC
idle
2500 RPM
idle
2500 RPM
66. List all repair actions on Form 4541 or 4543
HC
Oz
_ _ ppm
_ _ ppm
02
0/
10
0/
/0
co
co
COz
COz
%at
%at
%at
%at
idle
2500 RPM
idle
2500 RPM
Underneath Inspection
75. Leak checks
67. Quality assurance road test
CNG Vehicles
76 . Fuel tank
Cab Area
77. Lines, valves, and
68. Fill valve and starter interrupt switch
78.
69. Warning lights and engine operation
79.
r~gula tors
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 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'" Pl\·11 on a light delivery vehicle is 3.0 hours. ERT to perform a ''B" PMI on a light
delivety vehicle equipped with CNG is 3.5 hours.
Completed by
PS Form 4546-B Marrh 1998
Date
Work Order No.
Odometer
~
UNITED STATES POSTAL SERVICE
PREVENTIVE MAINTENANCE INSPECTION GUIDELINES
INTERMEDIATE DELIVERY VEHICLES
UNirt:O ST~TES
POSTdL SEtlYI(F.,.
Vehicle No.
I Assigned Location
~-·
·o
--·-
--
~
m~~
--,~
w
~-c..le
I Type of PMI
I Due Date
(-) Not Applicable
ab A ea
A
B
I. Review vehicle jacket, mod orders. and repair tags
31. Accident damage (list on diagram)
2. Road test
32. Lift gate
3. Leaks. doors. handles. and steps
33.
4. Seat. belt. and interior
Underneath Inspect/Lube
5. Key. ignition . and door key assembly
34. Fluid leaks and engine mounts
G. Buzzer and warning devices
35. Change oil. fllter, and lubricate
7. Starter action. unusual sounds. and neutral switch
36. Steering. tie rods. and arms
8. Cold weather starting aids
37. Brake linings
LF _ _/32 RF _ _/32
LR ,,,,,,,__ /32 RR ,,,.,_/32
9. Gauges. horn . heater. oil pressure. and mirrors
10. Accessories. glass. windshield wipers. and fan
38. Bearing play and c·ondition
11. Steering play _ _ inches
39. :,uspension. ;prings. shocks. and hangers
40. Tr<tnsmission <tnd mountings
11
E'<lnu~t
systems. converter. and muffler
14 . Lights, turn signals, and back-up lights
Drivelin~.
alignment. and condition
15. Floor and underdash wiring
Body hold-downs. hoses, ilnd
wir~~
Differential and hreather
1'1. Window. window locks , regulator. and door slides
Undercoating con dillon
18. Author.ized cab decals and Label 70
19. General paint and body condition
20. W<LX vehicle
Circle Inspection
Engine Compartment Area
49 . Engine compartrnent and engine
50. Antifreeze protection level _ _''F
51. Alkalinity protection
52. Replace or recycle coolant as required
53. Radiator. hoses, and leaks
54. Belts and pulleys
55. Alternator and power steering
56. Fuel lines. fuel system. and
57. Air filter
r~striction
linkag~
- - in inches and service fttel
58. Clean battery post and cables
59. Battery box and hold-downs
·1
filters
PREVENTIVE MAINTENANCE INSPECTION GUIDELINES
A
B
Engine Compartment Area (con't)
60. Wiring and hoses
61 . Batte1y load test
A
B
CNG Vehicles (con't)
70. Wiring
volts
l.
2.
volts
71. CNG labels
62. Starter cranking test _ _ amps
Engine Compartment
63. Altemator output test _._volts _ _ amps
72. CNG labels
64. Regulator voltage _ _ volts
73. CNG components
65. Emission control systems
HC
_ _ ppm
HC
_ _ ppm
co
co
02
9b
C02
%at idle
%at 2500 RPM
%at idle
01
04)
C02
%at 2500 RPM
74. Emission conrrol systems
HC
_ _ ppm
CO
HC
_ _ ppm
CO
%
%
C02
COz
GG. List all repair actions on Form 4541 or 4543
Underneath Inspection
67. Quality assurance road test
'15. Leak checks
CNG Vehicles
76. Fuel tank
Cab Area
77. Lines. valves . and regulators
68. Fill valv!' and starrer intenupt switch
78.
69. Warning lights and engine operation
79
% at idle
% at 2500 RPM
%at idle
0;., at 2500 RP!vl
0
0
Note: If damage is more than n01mal 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" PMl on an intermediate delivery
vehicle equipped with CNG is 2.0 hours. ERT to perform a "B" PMI on an intermediate delive1y vehicle is 3.0 hours. ERT to perform a
"B" PMI on an intennediate
vehicle
with CNG is 3.5 hours.
PS Fonn 4546-C Marl'h 1998
UNITED STATES POSTAL SERVICE
PREVENTIVE MAINTENANCE INSPECTION GUIDELINES
CARGO VANS
~
Wt~,lrlbt
v
UNITED ST~TES
POST.4L SERVICE ..
Vehicle No.
1
Due Date
Assigned Location
1
Type PM
In box before each item indicate condition as follows:
( 0 ) Adjustment Made
C'.IJ Item is OK
A
B
(X) Repairs Needed
A
Cab Area
(--) Not Applicable
B
1. Rtview vehicle jacket, mod orders, and repair tags
31. Rear door security and condition
2. Road test
32. Interior condition, cargo door. floors, and roof
:~.
Leaks. doors, door locks, handles, and steps
33. Cargo restraining devices
4. Seat, belt, and interior
34. Fuel cap, vent, and filler neck
5. Key, ignition, and door key assembly
35. Air tanks, valves, hoses, pi.pes, and air gauge
6. Buzzer and warning devices
36. Acddent damage (list on diagram)
7. Cold weather starting aids
37 . Lift gate
8. Starter action. Lmusual sounds, and neutral switch
38.
\).
Gauges, horn, heater. oil pressure, and mirrors
Underneath Inspect/Lube
10. Accessories. glass, windshield wipers. fan, and radio
39. Fluid leaks and engine mounts
11. Steering play _ _ inches
40. Change oil, filter , and lubricate
12. Lights. turn signals. and back-up lights
41. Steering, tie rods. and arms
13. Floor and underdash wiring
42. Bra 1\e linings
14. Pedal and pads
LF _ _/32 .RF - -i32
LR _ _/32 RR _ _!32
15. Window, regulator, and door hinges
16. Safety equipment, fire extinguisher, and accident kit
[''{ .
43. Brake chamber push-rod travel and slack
44 . Bearing play and condition
Authorized cab decals and Label 70
18. Drain air reservoirs
45. Suspension, springs. shocks, and hangers
19. Low air warning system
46. Transmission and mountings
20. Air pressure build-up time _____ .. sec .
47. Exhaust systems
21. Governor range
cut out
--
cut in
48. Driveline, alignment, and condition
--
22. Perform air system leak checks and service air dryer
49. Differential and breather
23 . Clean inside and out
50. Undercoating condition
24. General paint and body wndition
51. Body hold-downs. hoses, and wires
25. Wax vehicle
52.
Engine Compartment Area
Circle Inspection
26. Tire inflation
53. Engine compartment and cab lifting system
27. Lug nuts, wheels, hubs, and alignment
54. Antifreeze protection level _ _ "F
28 . Tire probe , condition, and tread depths
55. All;alinily protection and water filter
LF _ _/32
RF _ _/32
LRO __/32 LRI __i32RRI--/32 RRO _
56 Replace or recycle coolant as required
/32
5'1. Radiator, hoses. and leaks
58. Belts and pulleys
.,
at~usters
29. Bumpers. reflectors, lenses, and mud flaps
59. Alt.ernator and power stef'ring
30. Logos , markings, posters, and beltline
60 . Fuel lines. fuel system , and linkage
PS Form 4546-D March 1998
u JJ~
If
PREVENTIVE MAINTENANCE INSPECTION GUIDELINES
B
A
B
61. Fuel filter(s)
70. Regulator voltage
62. Emission control devices
71. Engine
63. Air filter restriction
inches
volts
72. Emissions
64. Clean battery post and cables
73. List all repair actions on Form 4541 or 4543
65. Battery b('X and hold-downs
74. Quality assurance road test
66. Wiring and hoses
75.
67. Battery load test _ _ volts
76.
6B. Starter cranking test
77.
69. Alternator output test _ _ volts _ _ amps
78.
We Deliver For You.
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.
van is 3.5 hours.
Completed by
PS Form 4546-D March 1998
Date
Work Order No.
Odometer
UNITED STATES POSTAL SERVICE
PREVENTIVE MAINTENANCE INSPECTION GUIDELINES
TRACTORS
j1Jl
Vehicle No.
1
Assigned Location
Due Date
1 Type
-
PM
In box before each item indicate condition as follows:
C~l
A
( 0 ) Adjustment Made
Item is OK
B
(Xl Repairs Needed
A
Cab Area
B
31. Glad-hands. hoses, and electrical plug
2. Road test
32 . Fifth wheel assembly
3. Leaks, doors, door Jocks, handles, and steps
33. Fuel cap, vent. and filler neck
4. Seat, belt, and interior
34. Cat walk, steps. and grab handles
5. Key, ignition. and door key assembly
35. Air tanks, valves, hoses, pipes. and air gauge
6. Buzzer and warning devices
36. Accident damage (list on diagram)
7. Cold weather starting aids
37.
8. Starter action, unusual sounds, and neutral switch
38.
9. Gauges, horn, heater, oil pressure, and mirrors
Underneath Inspect/Lube
10. Accessories. glass, windshidd wipers. fan. and radio
39. Fluid leaks and engine mounts
11. Steering play _ _ inches
40. Change o.il, filter, and lubricate
12. Lights. turn signals . and back-up lights
41. Steeri.ng. tie rods. and arms
13. Floor and underdash wiring
42. Brake linings
15 . Window. regulator. and door hinges
LF _ _/32 RF _ _/32
Nou-Driven
L _ _/32
R _ _/32
Driven
L _ _/32
R _ _/32
16. Safety equipment, fire extinguisher, and accident kit
43 . Brake chamber push-rod travel and slack acUusters
17 . Authorized cab decals and Label 70
44. Bearing play and condition
18. Drain air reservoirs
45. Suspension. springs. shocks, and hangers
19. Low air warning system
46. Transmission and mountings
20. Air pressure build-up timE' _ _
21. Governor range
~
(-) Not Applicable
1. Review vehicle jacket, mod orders. and repair tags
14. Clutch operation, pedal, and pads
cut out - -
sec.
wt in - -
47. Exhaust systems
48. Driveline, alignment. and condition
22. Perform air system leak chP.cks and service air dryer
49. Differential and breather
23. Clean inside and out
50. Undercoating condition
24 General paint and body condition
51. Automatic lubrication system
25. Wax vehicle
52 . Air suspension system
Circle Inspection
Engine Compartment Area
26. Tire inflation
53. Engine compartment ,md cab lifting system
27 . Lug nuts, wheels. hubs. and alignment
54. Antifreeze protection level _ _°F
28. Tire probe. condition, and tread depths
55. Alkalinity protection and water filter
LF ___/32
Non-~riven-LRO
RF _ _/32
__/32LRJ __/32 RRI _ _132 RRO _/32
56. Replace or recycle coolant as required
57. Radiator. hoses. and leaks
Drivrn-LRO __l:l2 LRI --/32 RRI __/32RRO _ _/32
58. Belts and pulleys
29. Bumpers, reflectors. lenses, and mud flaps
59. Alternator and power steering
30. Logos. markings, posters, and beltline
60. Fuel lines, fuel system. and linkage
PS Form 4546-E Marr.h Hl9ll
~
l_(t ?)1JillJ~I(~
IJNITF.t) Sl;!!TES
POSTdl. SEf/YtCE ••
PREVENTIVE MAINTENANCE INSPECTION GUIDELINES
A
B
B
61. Fuel filter(s)
70. Regulator voltage _ _ volts
62. Emission control devices
71. Engine
63. Air filter restriction
in('hes
72. Emissions
64. Clean battery post and cables
73. List all repair actions on Form 4541 or 4543
65. Battery box and hold-downs
74. Quality assurance road test
66 . Wiring and hoses
75.
67. Battery !c,ad test _ _ volts
76.
68 . Starter cranking test
77.
69. Alternator output test _ _ volts _ _ amps
78.
Note: lf damage is more than normal wear and tear, a separate work order must be written and coded as an accident.
a '·B'' PMI on a tractor is 3.5 hours.
Completed by
PS Form 4546-E March 1998
Date
Work Order No.
Odometer
UNITED STATES POSTAL SERVICE
PREVENTIVE MAINTENANCE INSPECTION GUIDELINES
TRAILERS
UNITED ST.OTES
POSTAL SERVICE ..
Vehicle No.
Assigned Location
1
In box before each item indicate condition as follows:
(~) Item is OK
( 0 j Adjustment Made
A
B
Due Date
1 Type PM
(-) Not Applicable
(X) Repairs Needed
20. Tire probe, condition. and tread depths
Walk Around
LF _ _/32
1. Review vehicle jacket. mod orders, and repair tags
Non-driven-LRO __/32 LRI
--/32 RRI_ _/32 RRO _ _!32
Drive11-LRO _ _132 LRI
--/32 RRI__/32 RRO _ _/32
2 Landing gear assembly
3. Glad-hands and connectors
4. Road test
21. Lube trailer or check automatic lube system
5. Test brakes for proper operation
22. Springs. spring pins, U bolts. and shackles
G. Emergency brake valve operation
23. Radius rods and bushings
7. Perform air system leak checks and drain air tanks
8. Lights and turn signals
9. Electrical junction box
iO. Rear door and seals
A
B
RF _ _/32
-=
24. Coupler plate and king pin condition
"
2S. Brake llnings
from
L
-----/''''
r~
l't>()f
L
/32
R
-.)t~
/32
--m
11. Logos. markings, and beltline
26. Brake chambers push-rod travel and slack adjusters
12. Bumpers, reflectors. lenses. and mudflaps
27. Air tank, mounting. and valves
13. General paint and body condition
28. A1r lines. hoses, wiring. and connections
14. Cleaning inside and out
29. Axle alignment
15. Accident damage (list on diagram)
30. Body cross members
16. Interior condition. floors, and roof
31. Undercoating condition
17. Cargo restraining devices
32. List all repair actions on Form 4541 or 4543
Wheels, Tires, and Underneath
33. Quality assurance road test
18. Lug nuts, wheels, rims. hubs. and spacers
34.
19. Tire intlation
35.
.
!Ill
~J\or
1\:__
·--
"f'
~-
~oJ(o1
-.... ..~/
'~
........==-----:=.-
~
~
JP
-
=r;E:!!'J.'::'?F...:=!!
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" PM! on
either a single-a'<.le or tandem-axlt' trailer is 1.5 hours. ERT to perfonn a "B'" PM! on a single-axle trailer is 2.5 hours. ERT to pertorm a "B" PMI on
a tandem-axle traikr is 3.0 hours.
Completed by
-
PS Form 4546-I• March 1998
Date
Work Order No.
Odometer
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