Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
UNIVERSITY
AUGUST, 2016
DECLARATION
I OKELLO JOB LAZARUS, do declare to the best of my knowledge, that this report is
originally mine; it is a true record of the work I undertook during my industrial training at KCCA
and has never been submitted for the award of a Degree in Bachelor of Science in Mechanical
Engineering or any other academic qualification to Makerere University or any other University
or academic institution of higher learning.
Signature.
Date
APPROVAL
This industrial training report has been submitted by the approval of the following:
Date
Signature
TONNY SENYANGE
Date
Signature
Dr. OLUPOT W. PETER.
ii
DEDICATION
This report is dedicated to my venerable mother Ms. Florence Auma who pays the greatest price
for my education. May the almighty God reward you abundantly.
iii
ABSTRACT
Industrial training is one of the requirements for the award of the Degree in Bachelor of Science
in Mechanical Engineering of Makerere University. As such, students are required to write and
submit reports at the end of their training.
This report is the record of the work I personally did during my industrial training at Kampala
Capital City Authority (KCCA) Mechanical Yard from June to August.2016.
It consists of four chapters which altogether explain the objectives of industrial training, entail
background information about KCCA, various activities carried out at the Mechanical Yard, the
hands-on activities which I took part in, the SWOT analysis of the institution and the skills
acquired, challenges faced, recommendations and conclusion.
Chapter one covers the objectives of industrial training, gives the background information about
KCCA including its core values, mission, vision, products and services provided and clientele.
Chapter two entails all the practical activities undertaken at the workshop giving for each
activity, the different tools and equipment used, technical procedures followed, common faults,
their causes and remedies.
Chapter three presents the SWOT analysis of the institution-its strengths, weaknesses,
opportunities and threats.
Chapter four covers the skills acquired, challenges faced, recommendations and conclusion.
iv
ACKNOWLEDGEMENTS
First and foremost, I would like to express my sincere gratitude and appreciation to God for His
unconditional love, guidance and protection; and for making the training a success. It is entirely by
His grace that I have reached this far in life in general and the academic journey in particular. Praise,
glory and honor be to Him!
I extend my heartfelt gratitude to the management of KCCA for granting me the valuable
opportunity to train at their Engineering Department.
In particular my appreciation goes to my training supervisor, Eng. Tonny Senyange for his
precious guidance and support rendered to me throughout the training.
I also thank all the staff of the KCCA Mechanical Yard for the great ideas and thoughts shared
with me during the entire training period and for their hospitality and cooperation that made it
inevitable for me to acquire the much desired practical knowledge and skills in the field of
Mechanical Engineering.
Special thanks also go to the Mechanical Engineering Department of Makerere University and
the University Administration at large for availing me with this study time so as to apply the
theoretical skills learnt in class into real life problem-solving situations and understanding of the
Mechanical Engineering profession at large.
With great honor and in a special way, I thank my University supervisor Dr. Olupot W. Peter for
his tremendous support and guidance rendered to me both during and after the training.
Sincere gratitude is also expressed to my fellow trainees with whom we shared valuable ideas;
for their support, company and continued team work exhibited during the entire industrial
training period.
I am immensely grateful to my spiritual leaders and friends: Pr. Micheal Nyisomeh, Pr. Dickson
Kanakulya, Sr. Mackrine Nyisomeh, Ms. Babirye Elizabeth Diana, Adoyo Evans Ouma, Segawa
Badiru, Mr. Brian Coutinho, Mrs. Mariam Coutinho and all the brethren of Christian Missionary
Fellowship International Kampala church, for their prayers, guidance and love and for pouring
spiritual wisdom into my life.
Most importantly, heartfelt thanks and love, to my mother Ms. Florence Auma for her
assistance, support, love, encouragement and inspiration, and for paying the greatest price for my
education.
Finally to all those who have supported my academic journey yet whose names are not
mentioned here, I am grateful and very much appreciate all your contributions.
May the ever good Lord immensely reward you all!
TABLE OF CONTENTS
DECLARATION ............................................................................................................................. i
APPROVAL ................................................................................................................................... ii
DEDICATION ............................................................................................................................... iii
ABSTRACT ................................................................................................................................... iv
ACKNOWLEDGEMENTS ............................................................................................................ v
TABLE OF CONTENTS ............................................................................................................... vi
LIST OF TABLES ......................................................................................................................... xi
LIST OF FIGURES ...................................................................................................................... xii
LIST OF ACRONYMS USED .................................................................................................... xiii
REFERENCES ............................................................................................................................. 44
LIST OF TABLES
Table 1: KCCA Directorates and their mandates ........................................................................... 5
Table 2: Steering system troubleshooting chart ............................................................................ 15
Table 3: Water pump troubleshooting chart ................................................................................. 18
Table 4: Clutch diagnosis/troubleshooting chart .......................................................................... 36
xi
LIST OF FIGURES
Figure 1: The KCCA logo............................................................................................................... 2
Figure 2: KCCA organizational structure. ...................................................................................... 7
Figure 3: Organizational Structure of the Directorate of Engineering and Technical services ...... 8
Figure 4: Recharging the battery................................................................................................... 13
Figure 5 : The removed water pump. ............................................................................................ 21
Figure 6:The unit that houses the water pump. ............................................................................. 21
Figure 7: Draining the hydraulic oil.............................................................................................. 26
Figure 8: Removing the broken leaf springs ................................................................................ 29
Figure 9: The broken leaf springs that were removed .................................................................. 29
Figure 10: Removing the tire ........................................................................................................ 32
Figure 11: Testing the voltage being received by the starter ........................................................ 35
Figure 12: The opened clutch system. .......................................................................................... 38
Figure 13: The removed pressure and clutch plates...................................................................... 38
xii
Alternating Current
CITIE
DD
Deputy Director
DED
E&TS
ED
Executive Director
ESD
EU
European Union
KCC
KCCA
km
Kilometer
kpa
kilopascal
NEMA
NGOs
Non-Governmental Organizations
NOA
Non-Asbestos
PH&ED
PPE
UIPE
ULS
UPDF
xiii
The city of Kampala faced a number of challenges, including the following that were listed in a
published report in 2011: High population, potholes, ineffective sanitation practices, traffic
congestion and increased death rates due to accidents.
Kampala was no longer reflecting a Capital city image in terms of governance and resource
allocation. It was not meeting the set standards and requirements of the central government like
sanitation, utilities and economic sector regulation.
The Parliament of Uganda, at the request of the cabinet, passed the Kampala Capital City
Authority Act in November 2010 to become effective on 1st. March .2011 that led to the birth of
KCCA. In a nutshell, the affairs of Kampala Capital city were brought under the direct
supervision of the central government of Uganda. The City Clerk, formerly the highest financial
officer in the city, was replaced by the Executive Director, who is answerable to the Minister for
Kampala. The elected mayor became the Lord Mayor, now a largely ceremonial position.
Lastly, in addition to the politically elected councilors, the expanded KCCA Council has
members from the following professional bodies, as full voting members: Uganda Institute of
Professional Engineers (UIPE), Uganda Society of Architects, Uganda Medical and Dental
Practitioners Council and Uganda Law Society (ULS).
1.3.2 Administrative divisions of Kampala
Kampala is divided into five divisions, each headed by a popularly elected mayor. The divisions
are preserved under the KCCA Act. They are: Nakawa, Makindye, Central, Kawempe and
Rubaga.
1.3.3 Mission statement of KCCA
To deliver quality services to the city
The meaning of the key words: Delivering-providing and facilitating the delivery of public
services in the city. Quality-top of the range of services offered to residents and visitors in the
city. Services-public services and innovative thinking that enables citizens and visitors realize
their individual and community goals, and City-the people, natural resources, physical
infrastructure and landscape within the defined territory of Kampala.
1.3.4 Vision statement of KCCA
To be a vibrant, attractive and sustainable city
3
The meaning of the key words: Vibrant-a healthy, economic and socially viable city. Attractivean admirable, green, secure and hospitable city. Sustainable-an efficient use of the environment,
protection of the biodiversity and natural ecosystem.
1.3.5 Core values of KCCA
Client care, Integrity, Teamwork, Innovativeness, and Excellence (CITIE).
The meaning of key words: Client care-we shall attend to needs of clients fairly, professionally
and in timely manner. Integrity-we shall be honest, transparent and accountable in the execution
of our work. Teamwork-we shall support and respect each other. Innovativeness-we shall use
creative approaches in addressing needs of clients. Excellence-we shall deliver a high standard
of performance that exceeds expectations of clients.
1.3.6 Services offered by KCCA
The Authority is mandated with provision of services in the city that enables residents and businesses
operating in the city to function in an environment that supports development. These services are: Health
services, Waste management, Education, Probation and social welfare, Gender mainstreaming, Youth and
community development, and Credit facilities.
MANDATE
Directorate of
Administration and Human
Resource Management.
Directorate of Physical
Planning.
Directorate of Treasury
Services.
Directorate of Public Health To facilitate and provide support to ensure health and productivity of
Services and Environment.
citizens; and a clean, habitable and sustainable community for the city.
Directorate of Education
and Social services.
Collection.
Directorate of Internal
Audit.
DEPUTY DIRECTOR
BUILDINGS
OPERATIONS
MANAGER
DEPUTY DIRECTOR
ROADS
MECHANICAL DEPARTMENT
ELECTRICAL DEPARTMENT
MECHANICAL ENGINEERS
ELECTRICAL ENGINEERS
MECHANICAL TECHNICIANS
ELECTRICAL TECHNICIANS
CASUAL WORKERS
CASUAL WORKERS
2.2.1 Common faults of the car battery, their causes and remedies
The following are the common faults associated with the car battery; their causes and
corrections.
2.2.1.1 Low charge
This is caused by leaving the battery in uncharged condition for a long time and also when
battery usage exceeds battery capacity.
Solution: The best solution for this problem is to recharge the battery. A jump start as well as
a trickle charger can be used for this operation. A trickle charger is most commonly used. It
delivers electricity to the battery from a power outlet in a slow, steady stream. It has an
electric cord with a plug and two jumper cables with alligator clips.
Procedures.
Before starting the recharging process, Safety must be observed. Since the battery acid is
hazardous, be sure to take adequate precautions when handling old battery terminals to
protect skin and clothing.
The following procedures are involved in charging the car battery;
a. Clean the battery terminals.
Check the terminals of the battery and clean them. Do not touch the terminals if they
are covered with a whitish powder. This is dried Sulphuric acid which can burn bare
skin and hands. Use a manual sand paper pad to wipe around the terminals or get a
10
b.
c.
d.
e.
wet cloth and apply a layer of baking soda (Sodium bicarbonate) to the cloth. Care
should be taken not to allow the solution to make contact with skin and clothing.
Rub the terminals down with the removal system, and ensure that they are ready to
receive the wires.
Remove the cell caps.
On many batteries, there is a series of small caps, these caps are known as cell caps,
and they have to be removed before a battery charger can be used, otherwise gases
created by charging will not be able to escape into the atmosphere.
Attach the charger cables.
Make sure that the car is turned off and then attach the cables or wires to the battery
terminals. The charger has two wires; the one which has to be connected to the red
or positive terminal and the other which is connected to the negative terminal. Make
sure that the two wires do not touch each other. This is because the wires spark when
they touch; causing ignition of the hydrogen gas that surrounds the battery. This
could cause nasty burns and serious injuries or even cause an explosion.
Turn on the charger.
Once both terminals are connected, connect the charger to the electric outlet. Turn
on the current and the battery will charge itself. Leave the charger on for sufficient
amount of time. Turn off the charger and check the reading on it. If the reading is
less than an Ampere, then you can unplug the charger.
Check the battery.
After charging, check the battery to find out whether it works. Use the hydrometer to
find out the amount of electric energy in the fluid or turn on the engine. If the battery
still does not turn on, then the battery might have to get replaced.
2.2.1.2 Sulphation
If the battery is allowed to stand in a discharged state either on or off the vehicle for a long
period of time, a chemical reaction takes place which permanently impairs the performance
and life of the battery. It can be seen as a fine white/grey coating of the positive plate. This is
called sulphation.
Solution: Clean the battery terminal.
Procedures:
The following procedures can be taken to clean the battery terminal.
a. Check the battery terminals to see if there is a fine white/grey coating on the
positive plate and the non-metallic luster on the negative plate.
b. Do not touch the terminals if they are covered with a whitish powder. This is dried
sulfuric acid and it can burn bare hands.
c. Use a manual sand paper pad to wipe around the terminals or get a wet cloth and
apply a layer of baking soda (Sodium bicarbonate) to the cloth.
11
d. Take care not to allow the solution to make contact with skin and clothing. Rub the
terminals down with the removal system.
2.2.1.3 Wear and tear due to ageing
As the battery is charging and discharging, the active materials within the battery plates are in
motion in order to release electricity stored by the battery. This leads to the wear and tear of
the battery when used for a long period of time.
Remedy:
Ensure that the correct battery in the right condition has been used in the right
application.
12
Recharge the battery; lightings and flashers should not be left on.
The battery terminals were checked and cleaned using a manual sand paper.
The cell caps were removed.
The charger cables were attached with the car turned off.
The charger was turned on for the battery to charge itself.
The battery was checked to find out whether it worked after charging and it
functioned properly.
The recharging operation is shown in Fig. 4 below.
13
2.3 Diagnosis and correction of power steering faults of a Ford Ranger Double cabin
Power steering problems can make controlling the vehicle much harder especially around
curves and corners. The power steering unit of the car uses a hydraulic system that takes a lot
of the steering strain off of the driver. This system builds up pressure as the wheel is turned;
and pushes the tires to either side as the car is turned. When there are power steering
problems, the driver will instantly notice the difference as it becomes very hard to turn the
steering wheel.
2.3.1 Common faults with the steering system, their causes and remedies
The common problems associated with the power steering system; their causes and solutions
are summarized in table 2 below.
14
Hard steering
Leaking hoses
and seals
Tight / loose
steering / valve
assembly out of
hydraulic
balance
Noises
POSSIBLE CAUSE(S).
REMEDY(IES).
(1) Inflate tires to recommended
pressures.
(2) Tighten or replace belt.
(3) Refill reservoir with proper fluid
check for leaks.
(4) Tighten or replace parts:
Lubricate all fittings.
(5) Align front end.
(6) Disassemble and inspect
component parts. Repair or replace
as necessary.
(7) Bleed system. Refill and check
for leaks.
(8) Disassemble pump. Check for
worn or damaged parts. Check for
leaks in the system.
(9) Clean or replace lines.
(10) Replace or adjust valves.
(11) Re-engineer.
(1) Remove oil to proper level.
(2) Replace or adjust O-ring in
pump reservoir.
(3) Re-torque to specifications.
(4) Replace.
(5) Replace hose assembly.
1 Loose belts.
2 Low fluid, air in system.
3 Foreign matter in system.
4 Improper lubrication.
5 Interference in linkage.
6 Steering gear mountings loose.
7 Incorrect adjustment or wear in rack or box.
8 Wear in pump.
15
Veer or wander
Wheel oscillation
e. Never check for leaks by hand, hydraulic oil under pressure can penetrate the skin and
cause severe injury.
2.3.4 Technical procedures followed
The following procedures were observed during the operation.
a. The vehicle was parked on a clean, dry, solid surface, the parking brake was
set, the rear wheels blocked and the transmission placed in neutral.
b. Using the hydraulic jack, the front end of the vehicle was raised until the tires
had cleared the surface.
c. The hood of the vehicle was tilted.
d. The drain pan was placed under the steering gear to catch the steering fluid.
e. The pressure and return lines from the steering gear were removed to drain the
fluid.
f. The area around the reservoir cap was wiped off with a clean towel, the bolt
was removed from canister type reservoirs and the cover was removed.
g. Using the filter wrench, the filter was removed from the canister and the filter
elements discarded.
h. The inside of the reservoir canister was wiped clean with a clean shop towel.
i. With the hoses disconnected, the steering wheel was slowly turned from full
left to full right several times to purge oil from the steering gear.
j. The pressure and return lines to the steering gear were attached and tightened.
k. A new filter element was installed in the reservoir.
l. The reservoir cap was cleaned with a solvent; the old gasket was removed
from the cap and replaced with a new gasket.
m. The reservoir was filled with new steering fluid, the reservoir cover was
installed and the bolt tightened.
n. The vehicle was started and allowed to idle.
o. The fluid level was checked and filled as needed.
p. The vehicle was steered from full left to full right several times and the fluid
level checked again and fluid was added.
q. All fittings and hoses were visually checked for external leaks. Reservoir was
not allowed to empty during start up as pump damage could result.
r. The vehicle was shut off, the drain pan removed and the vehicle was lowered
until the tires contacted the surface and removed the jack.
s. The cab was lowered.
2.4 Replacement of water pump of a Cesspool truck
The engine of a vehicle needs coolant just as much as it needs oil. Engine coolant helps
protect against high heat. It is cycled from the radiator throughout the engine, absorbing heat
from engine operation and then allowing that heat to wick away into the atmosphere at the
17
radiator. The water pump is the key to making the entire system work. It is an impeller pump,
buried under the timing belt cover on the side of the engine. The pump is operated by the
drive belt of the engine as the belt turns, the pump turns. Blades on the pump force the
coolant to flow through the engine.
When the water pump fails or is beginning to wear out, it can lead to complete engine failure.
The water pump is the key to making the entire system work. Like any other mechanical
device, they will produce a few warning signs that they are wearing out.
2.4.1 Common faults with water pumps, their causes and remedies
Table 3 below shows common faults with water pump, their causes and remedies.
Table 3: Water pump troubleshooting chart
Fault
Weep hole leakage.
Appearance: The internal
mechanical seal of the pump
seals the shaft towards the
cooling circuit, protecting the
bearings by preventing coolant
from passing into the bearing
assembly. When a water pump
is new, some seepage from the
weep hole is normal as it takes
about ten minutes of operation
for the mechanical seal to
properly seat itself (break-in
period). More pronounced
seepage and drips from the
weep hole after this break-in
period or a large coolant bleed
mark around the weep hole are
abnormal and indicate
impending water pump failure.
Leakage from the mounting
surface.
Appearance: Seepage, drips or
large coolant bleed marks on or
around the mounting surface or
on the housing.
Cause(s)
Contaminated
coolant is the main
cause of weep hole
leakage.
Remedy(ies)
compatible coolant or
mixing coolants of
different chemistries.
Another possible
cause may be a
defective pressure
cap causing air
bubbles, accelerating
the rust process.
Deposit build-up.
Contaminated
Appearance: Deposits, sludge
coolant, nonand scale build up on the inside, compatible coolant or
clogging the water pump and
mixing coolants of
hampering proper functioning
different chemistries.
of its individual components.
Cavitation.
Appearance: Vapor cavities
(bubbles) in the coolant
collapse with explosive force,
pock marking the individual
components of the pump. The
pockmarked areas then corrode
away.
The formation of
bubbles at the
coolant inlet of the
pump. As the
pressure increases in
the system, the
bubbles implode and
cause harm.
Damaged bearing.
Appearance: With the engine
off, check the condition of the
bearing by looking for any sideto-side play at the shaft. Apply
hand pressure there should be
no play at all. Also, rumbling or
screeching noises coming from
the water pump indicate a worn
bearing.
Misaligned belt
causes excessive
wear. An overtensioned belt causes
overload on the
bearing, accelerating
wear. A damaged
mechanical seal
allows coolant to
leak through the
bearings and wash
away the lubricator.
A misaligned belt
causes excessive
wear. An overtensioned belt
imposes a powerful
bending force on the
shaft resulting in
shaft bending or
early shaft fracture.
Excessive vibrations
due to lack of
maintenance.
19
Cooling system
contamination
Casting Breakage
Excessive Vibration
Thermal Shock
20
The detached water pump and the unit that houses the water pump are shown in Figs. 5
and 6 below respectively.
Health problems.
People can become exposed to the chemicals in hydraulic fluids. The exposure may be due to
inhalation, ingestion, or touch. There are instances of people suffering from skin irritation or
weakness in hands while handling hydraulic fluids. There are also cases of intestinal
bleeding, pneumonia, or death through hydraulic fluid ingestion though no serious hazards
are reported with hydraulic fluid inhalation.
21
Similar to ingestion, fluids can be accidentally injected into the skin as well. This takes place
when the high-pressure hydraulic system hose is disconnected and toxic fluids are leaked and
injected into the skin. If there is a small leak in the hydraulic pipe and someone runs there
hand along it, at 2000 psi, they can easily incur an injection of hydraulic fluid and may not
even be aware that it happened until gangrene begins to set in.
b.
Fire dangers.
When working with hydraulic fluid, there is every chance that the hydraulic fluid gets heated
to high temperatures. And it is evident that most petroleum-based hydraulic fluids will burn
and thereby create explosions and burns.
c.
Environmental problems.
When the hydraulic hose or pipe leaks, the chemicals of the fluids can either stay on top of
the soil or sink into the ground. If the chemicals get mixed in a water body, they will sink to
the bottom. In fact in such cases the chemicals can stay there for more than a year. Aquatic
life can absorb the toxic hydraulic fluid, leading to illness or death to the animal or anything
higher on the food chain. For example, a hawk that eats a fish that has been contaminated by
hydraulic fluid that was mixed in water could become ill as well.
d.
Although the slimy texture of hydraulic fluids may not seem like a danger or a problem, a
spill can cause a person to slip and fall. Also when there is fluid on the hands of a person, it
can cause him to slip while climbing on a machine. It can also cause the operator to lose
steering control.
2.5.2 Safety precautions when dealing with hydraulic fluids
Certain safety precautions need to be followed when handling hydraulic fluids as discussed
below;
a. In order to avoid skin irritations, it is necessary to wash contaminated skin
immediately. It is also necessary to keep your clothing clean.
b. Always wear masks and gloves while using hydraulic fluids.
c. To avoid environmental dangers, there is a biodegradable hydraulic fluid option,
though it is more expensive.
d. To avoid fires, materials and fluids soaked in hydraulic fluid should be stored in
sealed metal containers and disposed of at proper places.
e. To check for leaks, use cardboard.
2.5.3 Common faults with the hydraulic system
Generally, improper hydraulic system operation can be traced to one of the following
deficiencies: insufficient fluid level, the presence of air in the system, contamination by
foreign material, incorrect adjustment of components, internal or external fluid leakage,
mechanical damage to components, wrong fluid type or viscosity and excessive temperatures.
22
fluids flowing in ungrounded piping or when fluid discharges on to any free surface of
the reservoir, particularly if there is free air present in the fluid.
Electrostatic discharge most often manifests itself as a clicking sound as the charge
repeatedly builds and then discharges to a surface of lower voltage through sparking. The
increased use of synthetic fluids and mineral base oils with non-metallic anti-wear
additives have resulted in fluids with low conductivity, increasing the potential for
accumulated static charge levels. In severe cases, electrostatic discharge can result in
etching, pitting or carbon deposits at the surfaces of the area where the discharge
occurred and may leave burn marks or other damage on the filter element media.
h. The foam and air entrainment inspection. As noted earlier, a darkening color of
hydraulic fluid suggests that oxidation is occurring. Oxidation rates are related directly to
high temperatures and excessive air entrainment combined with high pressure. At
atmospheric pressure and corresponding temperature, oils contain about 10%by volume
of dissolved air. At 200 psi (1400 kPa), oils can absorb about 140% by volume. The
dissolved air provides the oxygen that is necessary to promote oxidation and oxidation
rates rapidly increase as temperatures rise above 140F (60C) and hydraulic pressures
increase to their normal operating ranges. Dissolved air in oil under pressure will tend to
produce foam as pressure is released and the air comes out of solution. This free air is
now trapped inside operating cylinders and other components, which will cause erratic
and spongy operation and increased temperatures.
If hydraulic systems begin to display erratic, spongy operational behavior or cylinder
extension and retraction speeds are slower than normal or erratic in nature, there is a
good possibility that there is excessive air entrainment in the hydraulic system. The
presence of entrained air is readily apparent by the bubbly, opaque appearance of the
fluid in the reservoir.
When excessive levels of entrained air are suspected, inspect all system connections
where air may be drawn into the system. Examples are; loose pump inlet connections, the
fluid return line is broken or no longer below the oil level in the reservoir, the pump shaft
seal has failed, inadequate or broken reservoir baffle plates, suction side of circuits are
leaking or have loose connections.
Suction leaks (where air is being drawn into a component or circuit) can easily be located
by applying hydraulic oil to the connection. If the oil disappears, the troubleshooter has
located the air leak!
2.5.5 Recommendations on hydraulic systems
As hydraulic systems improve and operating pressures increase, much more attention to
predictive maintenance and reliability will be required. Two areas of concern will be a
requirement for improved filter design, selection and installation and hydraulic system
flushing techniques after a component failure has occurred.
In the first instance, more consideration will be required for improved filter installation where
increased vibration and/or higher pressure pulsation will require mitigation.
24
In the second instance, mobile filtration systems and portable hydraulic fluid purifiers will
become mandatory, if hydraulic system reliability is to be improved and maintained.
2.5.6 Faults found with the hydraulic oil
Diagnosis of the hydraulic oil of the truck, revealed the following faults that necessitated its
replacement;
a. Hydraulic oil had deteriorated. When the hydraulic oil is used for a long time, it
deteriorates and thus has to be replaced.
b. The base oil was degraded.
c. The additive package was depleted.
2.5.7 Tools and equipment used to replace the hydraulic oil
The tools and equipment used to change the hydraulic oil were; a ring spanner, box spanner,
Hammer, combination spanner, funnel, bucket, clean piece of cloth and new hydraulic oil.
2.5.8 Technical procedures followed
The following procedures were observed during the operation;
a.
b.
c.
d.
e.
f.
g.
The system was drained while the fluid was hot to keep contaminants in
suspension.
The fluid was emptied from cylinders, accumulators and lines that could not drain
properly.
The oil left in the reservoir was pumped out.
The reservoir was wipe-cleaned with lint free rags and rust and free paint were
removed.
Filter elements, strainers, and housing were cleaned.
The system was refilled with new hydraulic fluid making sure to vent high points.
The system was restored and checked for proper operation after which it
functioned.
25
Springs in general, and leaf springs in particular, help perform the first two of these
functions: they support the weight of the vehicle while absorbing bumps.
A leaf spring is usually attached to the body or frame of the vehicle at each end, while the
wheel or axle assembly is fixed to the middle of the spring. Usually each spring extends in
the same direction as the vehicle, one on each side, with attachment points at the front and
26
rear; a few suspension designs feature a single leaf spring attached at each side-a transverse
spring.
2.6.2 The purpose of leaf springs
Leaf springs are appropriate for spreading heavy loads over a large area (because they are
attached to the vehicle at the ends, which may be several feet apart) and for suspension
designs that incorporate a solid axle rather than independent suspension for each wheel
especially of heavy vehicles such as trucks.
These factors render leaf springs appropriate for trucks and other heavy vehicles but less so
for cars, as such designs tend to have undesirable effects on the handling of the vehicle. As
independent (as opposed to solid axle) rear suspensions have become increasingly common
on cars, leaf springs are now found primarily on trucks, vans, SUVs and trailers.
2.6.3 Maintenance of leaf springs
Multi-leaf springs occasionally get sticky as dirt works its way in between the leaves; the
effect can be to make the ride slightly stiffer, but this is rarely a significant problem. The
attachment points will need to be checked periodically and lubricated in some cases as
specified by the manual of the manufacturer, and regular maintenance should be carried out.
If the body of the car seems to sit too low over the wheels, this sagging is usually due to the
leaf springs having bent slightly over time, and the solution is to have them replaced.
2.6.4 Fault found with the leaf springs
Leaf springs were broken as depicted by inspection.
2.6.5 Safety precautions while replacing leaf springs
The following precautions should be observed when replacing the leaf springs;
a. Always wear safety glasses when working carrying out the operation.
b. Wear other personal protective equipment (PPE) when necessary, for example latex
gloves or closed toe shoes.
2.6.6 Tools and equipment used to replace the leaf springs
The following tools and equipment were used to replace the leaf springs of the truck; A
ratchet, hammer, Box spanner, combination spanner (24-24), floor jack, trolley jack, lubricant
(oil); ring spanners (numbers16, 18, 19 and 30), wrenches and Jack stands.
27
n.
o.
p.
q.
r.
s.
t.
u.
The vehicle was parked on a solid, level surface to ensure that it did not roll or lean
when raised.
Using a floor jack, the rear of the vehicle was lifted up enough for the axle assembly
to hang freely.
The vehicle was secured with jack stands on both sides for safety before starting any
work.
The rear axle assembly was supported with a floor jack close to the spring.
The lower bolt was removed from the shock absorber.
The axle was lowered to relieve tension on the spring.
The U-bolts and spring retainer bracket were removed.
The parking brake cable was removed from the retainer bracket.
The rear axle was carefully lowered since leaf springs were mounted on top of the
axle.
The rear shackle bolts were loosened.
The leaf springs were supported with a jack stand and the leaf spring front and rear
eye bolts were removed.
The leaf springs were removed from the vehicle.
The front bushings of the new springs were placed into the front mounting brackets,
the front eye bolts and nuts were installed with the bolt heads towards the center of
the vehicle.
The rear bushings of the new springs were placed into the rear shackles and the rear
eye bolts and nuts were loosely installed.
The axles were adjusted to place the leaf springs center bolts into the holes on the axle
pads.
The U-bolts and retainer brackets were installed; the U-bolt nuts were snagged down
but not tightened.
The parking brake cable was reattached and the lower shock mount was attached to
the axle bracket.
Steps (d) through (q) were repeated for the other side of the truck.
The truck was lowered to the ground and all bolts torqued to the recommended
specifications.
The leaf springs repair was verified and the vehicle was aligned.
The vehicle was road-tested and found to operate well.
28
Figs 8and 9 below show the removal process of the leaf springs and the removed broken
leaf springs respectively.
29
However, if the guidelines are followed and tell-tale signs of potential problems are
looked out for; longest life possible out of tires can be got.
2.7.3 Fault found with the tire
Inspection of the tire indicated that it was worn out; that prompted its replacement.
2.7.4 Safety procedures while replacing tires
While changing tires, the following safety measures should be observed.
a. The tire levers should not be sharp. This is because the tube might get cut during the
process.
b. While changing tires, put little French chalk inside the tire. It works as a lubricant.
c. Sometimes, tire bead may get stuck on rim due to rusty rim. Do not apply extra force.
In this case, put little water on tire bead and leave it for 20 minutes and then try again.
d. Always put few amount of air inside the tube before fixing bead of tire. This air
prevents the cutting of tube and keeps it away from lever and rim.
e. While inflating tires, ensure that the tire is resting nicely on the rim flange. This
setting is very important for heavy duty vehicles especially Tractor tires.
f. After the steps to change tires have been completed, tighten the nuts and only then,
remove the jack.
g. After removing the Jack, the nuts should be tightened again for safety.
h. The wheel nuts should be checked more often in new vehicles-after every few
hundred kilometers. The reason for regular checking in case of new vehicles is that
wheel nuts might become loose due to the paint.
2.7.5 Tools and equipment used to replace the tire
A hammer, ring spanner, wrench, floor jack, trolley jack, combination spanner, box spanner
and an open spanner.
2.7.6 Technical procedures followed
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
o.
p.
The spare tire was placed on the hub, its rim aligned with wheel bolts and lug nuts
put in positions.
The nuts were tightened using the wrench in a star pattern.
The truck was lowered without applying full weight on the tire, and the nuts were
tightened further.
The truck was fully lowered to the ground.
The jacks were removed.
The nuts were tightened finally and the hubcap replaced.
The truck was road-tested and the new tire was found to function well.
The tire removal process is shown in Fig. 10 below.
32
2.8.1 Common symptoms of a failing or bad Starter, their causes and remedies
They include the following:
a. Grinding noise. When the starter drive gear is worn out or not engaging properly, they
will often produce a grinding noise that is similar to the one that is heard if engine is
started and then accidentally the starter is hit again. If the grinding symptom is
ignored, it may also result in damage to the engine flywheel. It should be diagnosed
immediately upon detection.
b. Freewheeling. Freewheeling occurs when the engine is cranked and simply a whining
noise is heard from the starter without the engine cranking. When this occurs, it
means the starter gear is not engaging with the flywheel. This is a bad situation that
could result in the need for a starter replacement. If this is occurring, the vehicle
should be serviced as soon as possible.
c. Smoke. Seeing smoke is cause for immediate concern, and can indicate a few
different problems with the starter or starting circuit. Smoke usually indicates that too
much power is being drawn through the electrical supply to a starter, either because
the starter is shorted, has been operated too long without a rest or there is a connection
problem. Smoke might also be accompanied by a burning smell. If smoke is seen, the
vehicle should be serviced by a professional as soon as possible.
d. Oil soak. The starter is often located around the bottom of the engine and is
vulnerable to soaking from leaks from the engine oil or other drive train fluids. An
oil-soaked starter likely has a short life remaining. Consider correcting the leak and
replacing the starter before a malfunction occurs.
e. Malfunctioning solenoid. The solenoid transmits electrical current from the battery to
the starter motor when the key is turned in the ignition of the vehicle and also pushes
the starter drive into the flywheel to allow cranking. Without the solenoid, the starter
does not work. If the key is turned to the crank position and nothing happens, try
jiggling the transmission gear shift lever first. If the engine still will not crank, there
might be something wrong with the solenoid.
f. When you turn the key to crank the engine, nothing happens. The engine does not turn
over.
g. When the key is turned to crank the engine and all that is heard is one loud click. The
engine does not turn over; or when the key is turned to crank the engine and the
engine turns over very but very slowly and then stops.
h. When the battery is good but the car fails to start.
2.8.2 Safety procedures while troubleshooting a starter motor
While troubleshooting a starter motor, certain safety measures need to be observed. They
include the following:
33
a. If you have to lift up the car or truck to access the starter motor: Use jack-stands to
support the car or truck off the ground, and use safety glasses while working
underneath the vehicle.
b. You will need a helper to crank the engine as you perform some of the tests, and to
help you perform the very important Voltage Drop Test.
c. When jumpering 12 Volts to the S-terminal wire (circuit) make sure you do not shortto-ground your jumper wire.
2.8.3 Tools and equipment used
Spanners (Open, fixed, adjustable, combination and box), safety glasses, jack stands,
a voltmeter, pair of pliers, screwdriver, jack, and multi-meter.
2.8.4 Technical procedures followed
a.
b.
c.
d.
34
35
2.9.1 Common faults with the clutch system, their causes and remedies
They are summarized in table 4 below.
Table 4: Clutch diagnosis/troubleshooting chart
Faults
Slipping.
Grabbing or
Chattering.
Possible causes
a. Improper linkage
adjustment.
b. Improper pedal travel.
c. Loose linkage.
d. Faulty pilot bearing.
e. Faulty driven disc.
f. Fork off ball stud.
g. Clutch disc hub binding on
clutch gear spline.
h. Clutch disc warped or bent.
i. Loose pivot rings in cover
assembly.
Remedy(ies)
a. Adjust linkage.
b. Trim bumper stop and adjust
linkage.
c. Replace as necessary.
d. Replace bearing.
e. Replace disc.
f. Install fork onto stud. Lightly
lubricate fingers at release
bearing.
g. Repair or replace clutch gear
and/or disc.
h. Replace disc (run out should
not exceed 0.020).
i. Replace plate and cover
assembly.
a. Adjust linkage to
specifications.
b. Install new disc and correct
leak at its source.
c. Replace disc.
d. Replace pressure plate or
flywheel.
e. Replace pressure plate. (Be
sure lash is checked before
replacing plate.)
f. Make 30 to 40 normal starts.
Caution: Do not overheat.
g. Allow to coolcheck lash.
a. Install new disc and correct
leak.
b. Replace transmission clutch
gear.
c. Tighten or replace mountings.
d. Replace pressure plate or
flywheel.
e. Sand off if superficial, replace
burned or heat checked parts.
Rattling-Transmission
Click
Throw-out bearing
noise with clutch fully
engaged
Noisy
a. Adjust linkage.
b. Clean, re-lubricate, check for
burrs, and nicks among others.
c. Replace fork.
d. Install properly.
e. Replace spring.
a. Replace bearing.
b. Install properly and lubricate
fork fingers at bearing.
a. Lubricate and free up linkage
and release bearing.
b. Replace pressure plate.
c. Adjust linkage to get proper
lash, make sure proper pedal
stop (bumper) is installed.
a. Lubricate and free linkage.
b. Replace driven plate.
b. The access opening for the clutch assembly was located under the truck just behind
the oil pan. A torch light was used to see where the adjustment plate was.
c. With the clutch pedal depressed, a large flathead screwdriver was used as a lever to
rotate the flywheel assembly till the adjustment plate was at the bottom and fully
accessible.
d. Using a socket, only the left hand bolt which secures the retaining strap was removed.
e. The retaining strap was removed and set aside.
f. Using a wrench, the adjusting bolt on the splined shaft was rotated clockwise (handle
towards the side of the driver) until the proper amount of clutch adjustment was
achieved.
g. Reassembling was done and the car was road-tested and found to be functioning
properly.
The opened clutch system is shown in Fig.12 below.
40
d. While making inquiries from the senior mechanics on the work being done, different
reactions would be received from different people; some were welcoming while others
were tough. So most of the research and inquiries were made with the friendly mechanics
and more efforts were made to befriend everyone at the workshop.
e. Delay of some spare parts of the vehicles which made some work not to be completed in
time.
f. Most of the work needed use of heavy tools and machine components which made the
work difficult, tiresome and time consuming. In such cases, help was sought from other
people in the workshop to help especially with lifting the heavy machine components and
tools.
g. Inadequate tools and equipment like spanners, cylinder head resurfacing machine,
crankshaft regrinding machine, and water jet cleaner which is used to clean the radiator;
caused delay of the work hence creating work backlogs.
h. Unfavorable weather conditions like heavy rainfall often disrupted activities at the
workshop. In such cases, operations were carried out under an erected temporary
structure, which could only accommodate small vehicles.
i. Relating theoretical knowledge to practical situations was a great setback.
j. Limited time to share knowledge with all engineers due to a tight schedule at the
workshop.
k. Inadequate financial support to cater for my daily expenses like transport, meals and
others.
l. Limited working space due to congestion at the Mechanical Yard.
m. Inadequate safety guards during operation of some machines like air compressor which
blows dust from air cleaner.
n. Lack of well scheduled training program and an immediate person who is responsible for
the affairs of the trainees. This made trainees not to fully exploit some of the most
important engineering aspects of the institution as there was no serious monitoring and
also access to some of the sections was either not easy or prohibited without the
permission of a supervisor.
o. There was poor sanitation at the Mechanical yard. For toilets were shared equally by both
male and female workers. This could put the health of workers at risk.
4.4 Recommendations
Following what transpired during the industrial training especially the challenges I encountered,
I recommend the following to KCCA Mechanical yard.
a.
Proper waste management should be frequently carried out at the Yard. Rubbish
should be collected together and either burnt or disposed off to keep the yard clean
every time.
42
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
4.5 Conclusion
The internship was a fruitful experience. Through the application of the theoretical knowledge
into real-life problem solving situations, I gained a lot of experience especially in the automotive
field. I also got insight into professional practice, learnt how life can be fruitful as well as
challenging under employment; and how to face and deal with these challenges.
It was also a great opportunity for developing personal networking activities and making
contacts with influential people; which is of great value to me as far as my career is concerned.
The training also enabled me to discover my strengths and weaknesses. This further helped me to
identify areas to improve on.
In a nutshell, I achieved most of my learning objectives from the training.
43
REFERENCES
Anon., 2001. A New Methodology for Engine Diagnostics and Control Utilizing Synthetic
Engine Variables: Theoretical and Experimental Results, Transactions of the ASME. Journal of
Dynamic Systems, Measurement, and Control, Volume 123.
Gao, Y. & Randall, R. B., n.d. Reconstruction of diesel engine cylinder pressure using a time
domain smoothing technique, Mechanical Systems and Signal Processing. 5 ed. s.l.:s.n.
Senyange, T., 2016. Eng. [Interview] (July-August 2016).
Srinivasan, S., n.d. Automotive mechanics. 2nd ed. s.l.:s.n.
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