A Technical Report on

Student Industrial Work Experience Scheme (SIWES)

At

I. A. EKEH ENGINEERING COMPANY

Industrial Cluster Nekede, Owerri, Imo State

By

EZEJI, GEORGE CHIBUEZE

AK16/ENG/MAE/028
Marine Engineering

SUBMITTED TO:

Mr. Anietie Udo

SIWES COORDINATOR
AKWA IBOM STATE UNIVERSITY, IKOT AKPADEN.

IN PARTIAL FULFILMENT FOR THE AWARD OF BACHELOR OF ENGINEERING

(B.ENG) DEGREE IN MARINE ENGINEERING

July 2021
 A Technical Report on
Student Industrial Work Experience Scheme (SIWES)

At

I. A. EKEH ENGINEERING COMPANY

Industrial Cluster Nekede, Owerri, Imo State

By

EZEJI, GEORGE CHIBUEZE

AK16/ENG/MAE/028
Marine Engineering

SUBMITTED TO:

Mr. Anietie Udo

SIWES CORDINATOR
AKWA IBOM STATE UNIVERSITY, IKOT AKPADEN.

IN PARTIAL FULFILMENT FOR THE AWARD OF BACHELOR OF ENGINEERING

(B.ENG) DEGREE IN MARINE ENGINEERING

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 DEDICATION

This work is dedicated to the glory of Almighty God who gave me the grace to serve and
complete my Industrial training successfully, may His name be exhalted. Amen.

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 ACKNOWLEDGEMENT

I am sincerely grateful to the Most High God, for his provision, good health and grace,
throughout the duration of my Industrial Training program.

I also acknowledge the sacrifices of my family members especially my Mother and father, Mr.
and Mrs. Sirandrea Ezeji for their immense support in prayers and material provisions for my
successful completion of this program.

I most respectfully acknowledge the assistance of the Director, I. A Ekeh Engineering Company,
Mr. I. A Ekeh for his immense supports as a friend, mentor and as a father. I want to also thanks
to the school management for keying into the Federal Government initiative to create this
program. I want to say thank you to each and every one who played a vital role to the success of
industrial training program.

May God bless you all. Amen.

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 ABSTRACT

Industrial Training is an important phase of student life. A well-planned, properly executed, and
evaluated industrial training helps a lot in developing a professional attitude. Chapter one of
this report presents the meaning, aim, and the respective organized bodies involved in the
successful implementation of the program. Chapter two present the summarized corporate
information above I. A. Ekeh Engineering Company as well as its organizational chart. Chapter
three is detailed information about the projects executed and my contributions to the success of
the projects. It also summarized my experience gained while contributing to the success of these
projects. I gained adequate experience in the area of mechanical workshop management and
planning, different types of diesel engines, manufacturer and specifications accompanying each
of these diesel engines. Their maintenance tips as well as their different components. It further
explains some of my experience in hydraulic machines and their components.

Page 5 of 39
 TABLE OF CONTENTS

COVER PAGE...............................................................................................................................1

TITLE PAGE……………………………………………………………………………………...2

DEDICATION…………………………………………………………………………………….3

ACKNOWLEDGEMENT………………………………………………………………………...4

ABSTRACT……………………………………………………………………………………….5

TABLE OF CONTENTS………………………………………………………………………….6

CHAPTER ONE..............................................................................................................................8

INTRODUCTION.........................................................................................................................8

1.1 STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

BACKGROUND.........................................................................................................................8

1.2 OBJECTIVES OF SIWES................................................................................................8

1.3 BODIES INVOLVED IN THE MANAGEMENT OF SIWES........................................9

CHAPTER TWO.........................................................................................................................10

BACKGROUND OF COMPANY/ORGANIZATION............................................................10

2.1 INTRODUCTION..........................................................................................................10

2.2 HISTORY........................................................................Error! Bookmark not defined.

2.3 STRUCTURE OF THE ORGANIZATION...................Error! Bookmark not defined.

2.4 ORGANOGRAM............................................................Error! Bookmark not defined.

CHAPTER THREE.........................................................................Error! Bookmark not defined.

WORK EXPERIENCE...................................................................Error! Bookmark not defined.

3.1 INTRODUCTION...........................................................Error! Bookmark not defined.

3.2 EXPERIENCE…………………………………………………………………………13

Page 6 of 39
CHAPTER FOUR............................................................................Error! Bookmark not defined.

4.1 RECOMMENDATION.......................................................Error! Bookmark not defined.

4.2 CONCLUSION....................................................................Error! Bookmark not defined.

REFERENCES.................................................................................Error! Bookmark not defined.

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 CHAPTER ONE

INTRODUCTION

1.1 STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

BACKGROUND

The Government’s decree No. 47 of 8th October 1971 as amended in 1990 Highlighted the
capacity building of human resources in the industry, commerce, and government through
training and retraining of workers to effectively provide the needed high-quality goods and
services in a dynamic economy as ours (Jemerigbo, 2003). This decree led to the establishment
of the Industrial Training Fund (ITF) in 1973/1974
The growing concern among our industrialists that graduates of our institution of higher learning
lack adequate practical background studies preparatory for employment in industries led to the
formation of the Students Industrial Work Experience Scheme (SIWES) by ITF in 1993/1994
(Information and Guideline for SIWES, 2002). ITF has one of its key functions; to work as a
cooperative entity with industry and commerce where students in institutions of higher learning
can undertake mid-career work experience attachment in industries that are compatible with the
area of study (Okorie 2002).
The students Industrial Work Experience Scheme (SIWES) is a skill training program designed
to expose and prepare students of Agriculture, Engineering, Environmental Science, Medical
Sciences, Pure and Applied Sciences for the industrial work situation which they are likely to
meet after graduation and also to bridge the gap existing between there theoretical knowledge
and practice. Duration of SIWES is four (4) months in Polytechnics at the end of NDI, four (4)
months in College of Education at the end of NCE II, and six (6) months in the universities at the
end of 300, 400, or 500 levels depending on the discipline (Information and Guideline for
SIWES, 2002).

1.2 OBJECTIVES OF SIWES

The objective of SIWES among others includes:

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 i. prepare students for the industrial work situation which they are likely to meet after
graduation,
ii. provide an avenue for students in institutions of higher learning to acquire industrial
skills and experience in their approved course of study,
iii. expose students to work methods and techniques in handling equipment and
machinery not available in their institutions
iv. provide students with an opportunity to apply their knowledge in real work situation
thereby bridging the gap between theories and practices, and vi
v. enlist and strengthen employers’ involvement in the entire educational process and
prepare students for employment in industry and commerce (Information and
guideline for SIWES 2002)

1.3 BODIES INVOLVED IN THE MANAGEMENT OF SIWES

 Federal Government through the Federal Ministry of Industry, Trade, and Investment.
 Industrial Training Fund (ITF), SIWES division.
 Supervisory/Regulatory Agencies (NUC, NBTE, NCCE).
 Industry/Employers.
 Tertiary Institutions (Universities, Polytechnics, Colleges of Education), and
 Students

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 CHAPTER TWO

BACKGROUND OF COMPANY/ORGANIZATION

2.1 INTRODUCTION
I. A. Ekeh Engineering Company is a private firm founded in 1984 in kaduna and was later
moved to Owerri in 1997, and has since then be the best when it comes to caterpillar engine
maintenance and part repairs, customer’s satisfaction. Area of specialization includes epairs
and maintenance of diesel engines, transmissions, body constructs, perkins engine
maintenance and repairs, Komatsu engine maintenance, mechanical and marine engineering
training as well as engineering equipment supplies, purchase and maintenance.

I. A. Ekeh Engineering Company maintains a disciplined, trained and highly motivated team
of engineers and other management staff at all times and our key technical staffs has a very
wide knowledge and experience when it comes to diesel engine.

Major services of the company/firm

 Repairs and maintenance of caterpillar engines;

 Our services include engine overhauling e.t.c.

 Minor repairs and maintenance of Komatsu, Perkins engine

 Servicing and maintenance of CAT transmission system

 We service transmission systems, work on control valves and clutches.

 Mechanical and marine engineering training:

I. A. Ekeh Engineering Company is equipped and well-furnished mechanical engineering

workshop which we use to train I.T students and apprentice on repairs, maintenance and
servicing of engine parts.

 Engineering equipment supplies

We provide quality and standard engine parts for your engine overhauling, repairs and
maintenance.

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 MISSION

To create employment and training opportunities for professional talents in engineering

industries.

ORGANOGRAM

Director

Manager/ supervisor

Foreman Welder & Electrician Operators

Vulcanizer

I. T. Students Apprentice Wheel loader Dozer Motor Grader

operator Operator Operator

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 CHAPTER THREE
PROJECT EXECUTED, CONTRIBUTIONS AND EXPERIENCE GAINED

3.1 INTRODUCTION TO WORKSHOP TOOLBOX

I was engaged in the;

 Identification of tools and their
functions.
 Identification of bolts and nuts by
their sizes.
 Identification of different types of
spanner and their sizes

 Identifi
cation of
tools and
3.1 SERVICING OF POWERSHIFT TRANSMISSION SYSTEM their
Disassemble the transmission system

Start by:

Remove transmission system

 Put the transmission on a tool like trolley

 Remove bolts and washers that holds cover in position. Remove cover

 Remove priority valve

 Remove the three bolts that holds the pressure control valve in position. remove pressure
control valve. Remove spring.

 Loosen bolts. Remove shaft from lever.

 Move the lever away from the selector valve.

 Loosen nut. Remove the bolts that hold the directional valve in position.

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 Remove link assembly from the valve. Remove two tubes, remove directional valve.

 Remove tube, bolts that hold the selector valve in position. Remove the selector valve.

 Remove bolts and nuts that hold the transmission case to the transfer gear case. Install
two forged eyebolts in the case.

 Fasten a hoist to the case. Remove case. Case weighs 150kg

 Remove the two bushings and seals from the case. Remove tubes, bolts and locks.

 Install two forged eyebolts in bearing cage for the input shaft. Fasten a hoist to the input
shaft.

 Remove the input shaft and bearing cage as a unit. Weight of the unit is 64 kg.

 Remove bolt retainer and input flange. Remove bearing cages and as a unit from the input
shaft.

 Remove lip type seal from the bearing bearing cage.

 Remove spacer from the bearing cage. Turn the bearing cage over, remove spiral springs,
remove bearing cage.

 Remove bearing race from bearing cage, remove spiral ring that holds bearing to the input
shaft.

 Remove the three bolts that hold the clutch housing together.

 Install tooling to keep number 1 clutch piston in position in the number 1 clutch housing,
remove the other three bolt.

 Install two Forged eyebolts in number 1 clutch housing.

 Fasten a hoist to the clutch housing.

 Remove the number 1 clutch housing and piston as a unit. Weight of unit 50kg.

 Turn the number 1 clutch housing over, remove piston, rings from the piston and housing.

 Remove six pins and twelve springs. Install two forged eyebolts 3-inch-long in plate.
Fasten a hoist to the plate, remove the plate, weight of the plate is 54 kg.

 Remove ring gear, remove four discs and 3 plates from Number 1 clutch housing.

 Install two Forged eyebolts in number 2 clutch housing. Fasten a hoist to the clutch
housing, remove the clutch housing. Weight of the clutch housing is 91 kg.

 Remove ring gear. Remove four discs and three plates from number two clutch housing.

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 Remove piston, remove rings from the piston and the clutch housing.

 Install two forged eyebolts in number 1 carrier. Fasten a hoist to the carrier, remove the
carrier. Weight of carrier is 73kg.

 Remove shaft, gears and washers from the carrier. There is a washer on each side of the
gear.

 Turn number 1 carrier over. Remove bolts, locks, plates and remove sun gear.

 Remove dowels from the three shafts and carrier with a hammer and punch.

 Remove shafts and tubes from number one carrier. Remove gears and washers, there is a
washer on each side of the gear. Remove the bearings from the gears.

 Remove the outer bearing race from the input shaft from the number one carrier.

 Remove bolts, locks and plates. Install two forged eyebolts in number 3 clutch housing.
Fasten a hoist to the clutch housing. Remove the clutch housing, weight of the clutch
housing is 77 kg.

 Remove six pins and twelve Springs from the piston of the number four clutch.

 Remove ring gear from number 3 clutch housing. Remove three discs and two plates,
remove piston. Remove the Rings from the piston and housing.

 Install two forged eyebolts in number 4 clutch housing. Fasten a hoist to the clutch
housing, remove the clutch housing. Weight of clutch housing is 64kg. Remove 6 pins
and 12 Springs.

 Remove ring gear from number 4 clutch housing. Remove three discs and two plates,
remove piston, remove the rings from the piston and housing.

 Install two forged eyebolts in number 5 clutch housing. Fasten a hoist to the clutch
housing, remove the clutch housing. Weight of clutch housing is 54kg.

 Remove ring gear from number 5 clutch housing. Remove two discs and one plates,
remove piston, remove the rings from the piston and clutch housing.

 Remove bolts that hold number 2 carrier to the transfer gear case. Loosen bolt, install
three forged eyebolts in number 2 carrier.

 Fasten a hoist to the carrier, remove the carrier. Weight of carrier is 94kg.

 Remove spiral spring that holds the inner bearing in the carrier, remove the inner bearing,
remove retainer, put a support under the output shaft.

 Remove the snap ring that holds the output shaft to the transfer gear. Remove transfer
gear.

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 Remove the inner race and roller assemblies.

 Remove bolts that holds the bearing cages to the carrier, install three forcing screws in
bearing cage.

 Tighten the forcing screws evenly until the cages are free. Remove the bearing cages as a
unit.

 Remove spiral ring, remove bearing cage. Remove bearing from cage.

 Remove the dowel from bearing cage. Remove bearing outer race from the bearing cage.
Remove output shaft from number 2 carrier.

 Remove spacer from the output shaft, remove rings from the spacer.

 Remove shafts, gears, washers. Remove the bearings from the gears. Install three forged
bolts in the transfer gear case. Put the transfer gear case on blocks. Put a block under the
bevel pinion to prevent damage when it is removed. Weight of transfer gear case is
159kg.

 Remove bolts, locks and Washers.

 Remove the bevel pinion from the transfer gear case with a hammer and punch.

 Remove spacer from the bevel pinion. Remove the inner race and roller assembly from
the bevel pinion.

 Remove the inner race, roller assembly and gear from the transfer gear case. Remove
cover.

 Remove cap plugs and dowels that hold outer races in position in the transfer gear case.
Remove the races with a hammer and punch. Remove outer race with a hammer and a
punch.

 Wash all transmission parts (discs, plates, pins, springs, rings, keys, gears, piston, clutch
housing, transmission shaft) and keep them dry.

Assemble

Start by:

Inspection of all parts, checking of burnt disc plates, etc. make replacement of spoilt parts
and parts that are not of standard.

 Install outer race, install races, install cap plugs and dowels that hold outer races in
position in the transfer gear case.

 Install cover, install inner race, gear and roller assembly in the transfer gear case. Install
the inner race and roller assembly in the bevel pinion.

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 Install the spacer in the bevel pinion. Install the bevel pinion in the transfer gear case,
install bolts, lock and washer. Install three forged eyebolts in the transfer gear case and
install, install shaft, gears and washers, install bearings in gears.

 Lower the temperature of bearing race, install the in bearing cage. Install bolts, locks in
the bearing cage. Lower the temperature of bearing, install the bearing in bearing cage.

 Install bearing cage, install the spiral ring that holds the cages together. Fasten a hoist to
the bearing cages. Install the cages over the output shaft. Install bolts, locks that hold the
bearing cages to the carrier.

 Install the transfer gear on the output shaft. Install snap ring in its groove in the output
shaft. Install retainer, bearing and spiral ring in the transfer gear.

 Fasten a hoist to the number 2 carrier. Put the carrier in position on the transfer gear case.
Tighten bolts that hold the bearing cage to the transfer gear case. install the pistons and
rings in the clutch housings as follows;

a. Put oil on the rings

b. Install rings in pistons and housings
c. Make sure the rings are in the centers of their respective grooves. Lightly push the
pistons into positions into position in the housings.

 Fasten a hoist to the number 5 clutch housing. Install the housing on the transfer gear
case. make sure the housing is in alignment with the marks made when disassembling.
Use the long bolts as guide pins.

 Install ring gear in the number 5 clutch housing. Make sure the smaller outside diameter
of the ring gear is up. Install two of the longer pins for use as guide pins, install two disc
and a plate. Start with a disc.

 Remove the two long pins, install six pins and 12 Spring. Fasten a hoist to the number 4
clutch housing. Put the housing in position on the number 5 clutch housing. Make sure
the pins and springs in the number 5 clutch housing engage in their holes in the number 4
clutch housing.

 Install ring gear with its smaller outside diameter towards the top. Install two long pins
for use as guide pins. Install three discs and two plates. Start with disc.

 Remove the two long pins. Install six pins and twelve rings. Fasten a hoist to the number
3 clutch housing. Put it in position on the number 4 clutch housing, make sure the pins
and springs engage in their holes in the number 3 clutch housing.

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 Install ring gear with its smaller outside diameter towards the top, install two long pins for use as
guide pins, install three disc and two plates, starts with a disc. Remove the two long pins.

 Install plates, locks, and bolts. Lower the temperature of the bearing race for the input
shaft. Install the bearing race in the number one carrier. Install the bearings in Gears.
Install the gears, washers, and shaft in the number one carrier.

 Put the holes in the shafts in alignment with the holes in the carrier, install pins, put sun
gear in positions on the carrier. install plates, locks and bolts that holds it.

 Install tubes in shafts, turn the carrier over. install the bearings in Gears, install the gears,
washers and shaft in the carrier. make sure the balls in the shaft engage in the grooves in
the carrier.

 Install three forged eyebolts in the number one carrier. fasten a hoist to the eyebolts,
install the carrier in the number 3 clutch housing. make sure the teeth of the Sun gear
engage in the teeth of the top planetary gears for the number 2 carrier. make sure the teeth
of the lower planetary Gears of the number 1 carrier engage in the teeth of the ring gear
for the number 3 clutch.

 Repeat this steps for the other clutch housing that are remaining.

 Check to make sure the pistons are free in their clutch housing and also that the
transmission shaft is rotating properly.

 Install two bearings in the case. Install the bearings even with the top surface of the case.
Install the two seals in the case, fasten a hoist to the case, put the case in position on the
transfer gear case. Install the nuts and washers that hold the transmission case to the
transfer gear case.

 Install the bolts that hold the bearing cages of the output shaft to the transmission case. ok
put clean SAE 30 oil on seals, put the sleeves in selector valve, put the Selector valve in
position in the transmission.

 Install bowls that hold the Selector valve in position, put clean SAE 30 oil on seals for
tubes, put the tube in the transmission case and into the selector valve.

 Install the sleeve in the directional valve, put the directional valve in position in the
transmission, install the two tubes in the directional valve.

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 Install the bolts that hold the directional valve in position, put lever in position, install
shaft, tighten the bolt on lever. Install the link assembly, install seals.

 Put pressure control valve in position in the transmission, install the priority valve on the
transmission. Install the cover over the transmission hydraulic control.

End by:

Install transmission

Caution

 Put identification on each of the five clutch housings as to their order and location. The
housings must be installed in the correct order. Use caution to prevent loss of balls when
shafts are removed.

 Be extra careful when installing the pistons in the housings. Rings with damage or broken
rings can be the result of too much force been used or the pistons not being in alignment
with the housing. Make sure seal is installed with the lip of the seal towards spacer.

 Keep spacers with piston to prevent mixing at assembly. The spacers are used for the
adjustment of the pressure control valve.

Problems Associated to Transmission Failure

 Refusal to Switch Gears.

If your equipment refuses or struggles to change gears, you’re more than likely facing a
problem with your transmission system. Low transmission fluid or the wrong kind of
transmission fluid is oftentimes to blame in this situation.

 Burning Smell

When you notice a burning smell coming from your car. This odor is often an indication
that your transmission is overheating or the transmission fluid is old and burning.

 Leaking fluid

 Slipping gears

 Dragging clutch

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 Blocked or bad magnetic filters e.t.c

Solutions

 Make sure the fluid meets ISO standards before pouring it in your machine.

 Use the correct transmission oil—Caterpillar recommended fluids found in the Operation
& Maintenance Manual.

 Use Caterpillar filters—Caterpillar recommended filters found in the Operation &

Maintenance Manual.

 Cut open old filters to inspect for indications of a problem. Keep accurate records.

 Follow the proper service hours’ guidelines.

 Do not open your transmission system in a dirty environment.

 Always keep in mind proper Contamination control guidelines.

 Do not abuse your machine (application, operation, etc.).

 Transmission overhauling

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3.2 TORQUE CONVERTER (TORQUE DIVIDER)

Disassemble

Start by:
Remove engine, transmission and transfer gears

 We separate engine from transmission

 Remove the transmission control valve from the body of the transmission.

 Remove the large O-ring seal (1) from the torque converter housing.

 Fasten a hoist to the torque converter housing.

 Remove bolts that hold housings together.

 Lift torque converter housing off

 Put housing in position on the floor with the torque converter side down.

 Remove six bolts that hold the torque converter. Lift housing with a hoist off of the
torque converter.

 Put the torque converter in position on a bench. Remove retainer rings and caps.

 Turn the torque converter over and remove twelve bolts.

 Install two bolts into threaded holes and use them as forcing screws to separate converter
impeller from rotating housing.

 Remove converter impeller.

 Turn converter impeller over.

 Remove six bolts and plates.

 Use two pry bars equally spaced and pry wheel up and remove.

 After removing wheel, remove two pins.

 Remove retainer ring. Put the converter assembly in a press and press carrier out.

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 Turn the converter impeller over and remove six bolts, gear and bearing.

 Remove seal ring from the carrier if necessary.

 Remove retainer ring. Press hub from turbine and rotating housing.

 Remove turbine from rotating housing.

 Remove retaining ring from bearing.

 Remove retaining ring and then remove bearing from hub.

Assembly

 Heat bearing to maximum temperature of 275°F (135°C) and install it on hub.

 Install retaining rings.

 Put rotating housing in position on a press.

 Press hub gently into the rotating housing until movement is stopped by retaining ring.

 Put turbine in position in the rotating housing.

 Put rotating housing and turbine in position in a press. Slowly and gently press turbine
onto hub.

 Lower the temperature of bearing and install it in the converter impeller.

Install gear and bolts on the converter impeller. Tighten the bolts to a torque of 30 ± 5
N·m (22 ± 4 lb ft).

 If seal ring was removed and inspected for damage, replace it with a new one.

 Put the converter impeller and carrier in position in a press and press carrier into the
converter impeller.

 Put retaining ring in position to hold the carrier in position.

 Install wheel and install pins. Install plates and bolts.

 Connect converter impeller and rotating housing with bolts. Tighten the bolts to a torque
of 30 ± 5 N·m (22 ± 4 lb ft).

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 Turn the torque converter over and install cap and retaining ring.

 Put housing in position over the torque converter assembly and install six bolts that hold
it. Tighten the bolts to a torque of 30 ± 5 N·m (22 ± 4 lb ft).

Caution

When working on the converter proper care must be taking, tighting of the converter to its
appropriate torque must be done level by level to avoid breakage as its parts are made of cast
iron.

Problems associated to torque divider or torque converter

 Slipping.

 Shuddering.

 Overheating. ...

 Your Transmission Fluid is Contaminated. ...

 Torque Seal Damage.

Solution

What to do to fix slipping or shuddering

Your first course of action, if you notice your transmission or torque converter has started to
slip or shudder is checking your fluid level. You can't be sure the slipping or shuddering has
anything to do with your torque converter until you check your fluid levels. Remember, you
don't experience either symptom unless you have the wrong amount of fluid or the wrong
fluid in the transmission.

What to Do to Fix Overheating and Seal Damage

It's when you have a damaged torque converter seal that fluid leaks out and causes the
overheating and damage. It is the lack of fluid that causes overheating, slipping, or
shuddering. To fix the problem, you need to discover the seal that's damaged and have it
replaced.

Torque converter overhauling.

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3.3 SERVICING OF D.I NOZZLE

Disassemble

Start by:

Remove nozzle from cylinder head

 Put the nozzle in a vice, use appropriate spanner to loosen the nozzle head.

 Remove the nozzle from the vice. separate the head, stem, spring, shaft, housing, seven
hollow eye where the gas sprays through, seal.

 Wash parts with gas and use smooth Sam paper to polish nozzle eyes. Compress the
spring in a vice. Use the shaft and check the spraying eyes.

Assemble

 Put the washer in a shaft and insert it. Remove the compressed spring from the vice and
place it on the shaft.

 Put the dowel pin, replace the stem and place it back in the housing.

 Place back the head in the housing and run it down on the thread. Put the nozzle on the
vice and tighten the head appropriately.

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 Tighten the lock using Allen key, and change the seal if bad.

 Place it on a nozzle tester and check if the eyes are spraying very well.

End by:

Install in the cylinder head

Caution

Make sure the spring and dowel pins are not misplaced. Change any nozzle that does not
meet the spraying ratio

Problem associated with a failed nozzle and solution

Defective nozzle sprays little or sprays in excess or does not spray at all which will make the
equipment not to start or loosen power.

This problem will be solved by servicing the nozzle or replacing a new one

Page 24 of 39
3.4 GRINDING OF CYLINDER HEAD/TOP (3306, 3304 AND 3406 ENGINE
MODEL)

Disassemble

Start by:

Remove cylinder top

 Use valve clamp to remove valves, spring, cap and keys. Remove valve oil seal

 Wash all parts and keep them dry for inspection.

 Use sand paper to dress carbon deposits in the cylinder top.

 Change worn out parts.

 Start grinding using rough and smooth grinding paste. Grinding is done to make sure that
the valves seat well in the valve seat inserts.

Assemble

 Place the valve in the cylinder head and install valve oil seal.

 Use the valve clamp and hold the valve, spring, cap and key together.

 Use a mallet and tap on the springs to ensure a tight installation.

 Test run it with diesel fuel to make sure the fuel is not escaping through the

Problems associated to the cylinder head failure

 High oil consumption

 Bad fuel mileage
 Overheating which causes the top to crack

Solution

 Grinding of cylinder head with valves using rough and smooth grinding paste or grinding
compound

Page 25 of 39
 Changing of spoilt valves and cracked tops
 Dressing carbon around the top using sand paper in the case of a serviced top/cylinder
head
 Changing of bad seals and gasket.
 Checking on the cooling system

Page 26 of 39
FAN BELT TIGHTENER AND FAN BELT ADJUSTMENT

Remove fan belt tightener

Start by:

remove left side door.

 Remove the fan lower guard.

 Use a 19 mm Square drive wrench to release spring tension on belt and remove the belts.

 Disconnect spring at the arm assembly, disconnect Hose at the arm assembly, remove
bolts washer and plates.

 Remove arm assembly.

Install fan belt tighter

 Put arm assembly in position and install the plate washer and bolt. Connect hose
assembly to the arm assembly.

 Connect spring to the arm assembly with pin, washer and cotter pin. Use 19mm square
drive wrench to release spring tension on the arm assembly.

 Install fan belt, install fan lower guard.

 Put lubrication on fan belt tighter bearings through fittings

Fan belt adjustment:

 Wind the belt over the fan blades and around the crankshaft pulley. Insert the ½-inch
breaker bar into the tension adjuster and push it to the left. Wind the belt behind the
adjuster, under the idler pulley and over the alternator pulley.

 Remove the ½-inch breaker bar and allow the tension adjuster to pull the slack from the
belt. The belt should be properly seated in the groove of each pulley. Start the engine and
then check for proper alignment by observing the motion of the pulleys and the belt.

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FUEL INJECTOR PUMP (3306 ENGINE MODEL)

remove fuel injector pump

Start by:

Remove fuel injection pump housing and governor

 Put the pump housing in position on a tool,

 Remove cover from the pump housing.

 Loosen the bushing from the pump housing.

 Remove the fuel injection pump from the housing. The sleeve on the plunger will slide
off the lever as the pump is removed.

Install fuel injection pumps

 Put the fuel injection pump in the bore in the pump housing so sleeve is engaged with
lever.

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 Tighten the bushing for the fuel pump with wrench to a torque of 70 ± 5 lb.ft. (95 ± 7
N·m).

 Install cover (3) and make sure the spring is in the correct position in the cover.

 Remove pump housing from tool.

End by:

Install fuel injection pump housing and governor

Disassemble Fuel Injection Pumps

Start by:

Remove fuel injection pumps

 Remove bushing and seal from bonnet.

 Remove ring from the bonnet and barrel. Remove check valve and spring from the
bonnet.

 Remove spring and washer. Remove plunger and sleeve.

Assemble Fuel Injection Pumps

 Install sleeve, plunger, spring and washer on barrel.

 Install the check valve and spring in the bonnet. Connect the barrel and bonnet and install
the ring. Install the seal and bushing on the bonnet.

End by:

Install fuel injection pumps

Caution

 Do not loosen screws. If the screws are loosened, the fuel pump adjustment will be
changed.

 Keep the plunger and sleeve with their respective barrel for installation. Do not use
plunger, sleeves or barrels with other plungers, sleeves or barrels.

 Be sure the sleeve and plunger are installed in their original barrel. Make sure the large
hole in the plunger is up.

Problems

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 An abrupt loss of engine power is a somewhat obvious sign of a fuel injector failure. If
the fuel injector is clogged, the fuel supply will be irregular too. When the fuel level
fluctuates drastically, the high and low rpm's will cause the engine to move in surges
rather than slow and gradual movements.

 If a clogged fuel injector continually struggles to disperse fuel to the engine, a time will
come when it misses the fuel supply completely and the engine will misfire. The misfire
will easily be felt while driving, and often requires immediate repair by trained
automotive repair specialists. As the engine misfires, the engine can quickly overheat and
pre-ignite the fuel mixture.

 A damaged fuel injector will not only cause issues with driving, but the effects will
persist even as the engine idles. Instead of a smooth engine idle, it will be rough and
irregular when the fuel supply is abrupt.

 Reduced fuel efficiency is another signal of a damaged fuel injector. Such damage can
cause fuel to be wasted by leaking from the body or by supplying excessive fuel when the
internal springs are damaged

 Injector timing issues

Solutions

 Correct fuel injector pump timing

 Injector pump overhauling.

SERVICING OF OIL PUMP (3306 CAT DIESEL ENGINE)

how to disassemble

Start by:

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Remove oil pan/sump

 Use a support for oil pump and remove bolt.

 The weight of oil pump is 18kg
 Remove oil pump
 Remove the bolt and pull pipe assembly out of the pump body.
 Loosen bolt that holds the pump drive gear, leave a gap of 3.2mm between bolt and
washer.
 Use tool to remove the oil pump drive gear from the oil pump shaft.
 Remove bolt, washer, gear and key. Remove cover.
 Remove body assembly from spacer assembly and body assembly.
 Inspect bearings in body assembly and make a replacement necessary.
 Use appropriate tool and arbor press to push bearings from body.
 Remove pump scavenge section drive year and driven gear
 Remove spacer assembly.
 Inspect bearings in spacer assembly. Make a replacement if necessary.
 Use appropriate tool and an arbor press to push bearings from spacer assembly.
 Remove pump driven shaft assembly and drive shaft assembly from body.
 Remove retainer from body assembly.
 Remove spacer, spring and plunger from body assembly.
 Inspect bearings in body assembly and make replacement if necessary.
 Use appropriate tool and an arbor press to push bearings from body assembly
 Washing of all parts and keeping them dry.

ASSEMBLE OIL PUMP:

Start by:

Inspection of all part and making replacement where necessary.

 Make sure all of the parts are clean and free of dirt and foreign materials. Put clean engine
oil on the parts at time if necessary.
 Install bearings using short extension until the bearings are even with the outside surface
of main pump body. Install bearings so the junctions in the bearings are 30 0±150 from the
centre line of the bearing bores and towards the oil pump outlet passage.
 Install plunger in pump body. The plunger must move freely in its bore in pump body.
 Install spring and spacer.
 Install retainer, hold spring in compression with retainer and install the bolts which hold
the retainer.
 Install drive shaft assembly and pump driven shaft assembly in pump body.
 Install the bearings in spacer and ensure that the oil holes and bore are in alignment.
 Install your spacer over the shaft assemblies, install spacer with the cavity toward outside.
 Install scavenge pump gears on the shaft assemblies.
 Install bearings in the pump body and ensure that everything is in proper alignment.

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 Put scavenge section body in position over the shaft assemblies and against pump body.
Install the two bolts to hold the pump together.
 Install cover on scavenge pump section cover.
 Install key in the oil pump drive shaft and install gear.
 Install bolt and washer to hold the drive gear. Tighten bolt to a torque of 55±7
End by:

Install oil pump

Caution:

Be sure the dowels in the oil pump body are engaged with the holes in the block. Also be sure
the oil drive gear is correctly engaged with the crankshaft gear before the bolts are installed.
Failure to do so can cause damage to the oil pump.

Problems associated with failed/bad oil pumps

 Noise from the valve train (lifters, push rod, scales and valve guides).
 Strange noises from the lifters
 Reduced oil pressure/low oil pressure
 Hotter engine and a noising oil pump
Causes of failing oil pump:

 Engine sludge and dirt which could have mixed with the oil can block oil flow and cause
friction between gear teeth and generate too much heat.
 Contamination could have been introduced to the system during installation and block oil
flow.
Solutions:

 Engine oil servicing and ensure all components are kept clean during installation
 Engine overhauling in case of transferred debris
 Importance of oil pump overhauling
 To get normal oil pressure and for swift function of the engine parts.

Page 32 of 39
TURBOCHARGER

Disassemble

Start by:

Remove turbocharger

 Put the turbocharger in position on tool group, put marks on the three housings of the
turbocharger for correct installation and alignment at assembly.
 Put marks on the clamps for correct installation and alignment at assembly. Loosen
clamp and remove compressor housing and clamp from the cartridge assembly.
 Remove heat shield from the cartridge housing. Loosen clamp and remove cartridge
assembly from turbine housing.
 Put the end of the turbine shaft in tooling e.g. plier, use a universal joint and socket of
the correct size to remove the nut that holds compress wheel on the turbine shaft.
 Use a press to push the turbine shaft out of compressor wheel and the cartridge
housing. Remove compressor wheel from the cartridge housing.
 Remove shroud from turbine shaft
 Remove seal ring from turbine shaft.
 Bend the tabs of the locks from bolts and remove the bolts.
 Remove backplate assembly from the cartridge housing. Make a note of the position
of the coil holes in the backplate assembly and cartridge housing for correct alignment
at assembly.
 Push spacer out of its bore in backplate.
 Remove seal rings from spacer. Remove O-ring seal.
 Remove thrust collar from the cartridge housing.
 Remove thrust bearing from the cartridge housing.
 Use tool like pin plier to remove snap ring from the cartridge.
 Use tool like pin plier to remove last snap ring.
ASSEMBLING OF TURBOCHARGER

 Make sure all of the oil passages in the turbocharger cartridge housing, backplate
assembly and bearings are clean and free of dirt and foreign material.
 Put clean engine oil on all parts of the cartridge at assembly.
 Use tool like pin plier to install snap ring 1 in the turbine end of the cartridge housing.
 Install washer and bearing. Use too like pin plier to install snap ring to hold the
washer and bearing in position.
 Use tool like pin plier to install snap ring in the cartridge housing.

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  Install washer. Push bearing into the cartridge housing until washer makes contact
with snap ring.
 Install thrust bearing over the dowels in the cartridge housing. Make sure the grooves
in bearing are towards the outside.
 Put thrust collar in position on the thrust bearing with the counterbore for the spacer
up.
 Install O-ring seal in the groove of the cartridge housing.
 Install seal rings on spacer so the gaps in the rings are 1800 apart.
 Install spacer in backplate assembly.
 Make sure the oil passage in the cartridge housing and the oil passage in the backplate
assembly are in alignment. Put backplate assembly in position on the cartridge
housing. Make sure the spacer fits correctly in the counterbore of the thrust collar.
 Install the locks and bolts to hold backplate assembly to the cartridge housing and
tighten bolts to torque of 10± 1Nm. Bend the tabs of the locks on the bolts.
 Put the turbine shaft in position in tooling. Put 6V2055 high vacuum grease in the
groove for seal ring. Install seal ring on turbine shaft.
 Install shroud on turbine shaft.
 Install the cartridge housing on the turbine shaft while the space in the backplate is
held in position. Make sure the seal ring on the turbine shaft is fitted correctly in the
cartridge housing.
 Put compressor wheel in position on the turbine shaft.
 Put a small amount of oil on the turbine shaft threads and the compressor wheel face
that will be under the nut.
 Put the cartridge housing in a vise.
 Install turbine housing on tool group.
 Install the heat shield on the cartridge housing.
 Install the clamp and compressor housing on the cartridge in the correct position.
End by:

Install turbocharger

CAUTIONS:

 To prevent a bent shaft, do no put a side force on the turbine shaft when the
compressor wheel not is loosened.
 Do no put a side force on the turbine shaft when the nut is tightened or a bent shaft
will be the result
PROBLEM ASSOCIATED TO THE TURBOCHARGER FAILURE:

 Power loss.
 Worn or excessive clearance caused by low oil, contaminated oil and dirt injection.
 Whistling caused by an air or gas leak.
 Sluggish or seized turbocharger resulting from oil breakdown and degradation.
 Damaged blade caused by contamination from dirt or other particles entering the
turbine or compression housing.

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SOLUTION:

 Use the proper synthetic oil recommended by the manufacturer.

 Install a quality oil filter and change at recommended intervals.
 Frequently sample the oil for contamination and additive depletion.
 Repair any air leaks and sources from contamination injection.
 Idle the engine for two to three minutes to cool down the turbocharger bearings before
shutting off the engine, and thus the (cooling) oil supply.

ENGINE OVERHAULING (3306 MODEL CAT ENGINE)

DISASSEMBLING

Start by:

Remove Engine Block

 Remove the air cleaner housing by loosening the bolts/nuts.

 Remove turbocharger, remove exhaust manifold.
 Remove fuel lines, nozzles/valve covers.
 Remove rocker arm group. Remove cylinder head.
 Remove the kick starter
 Remove sump, oil pan, oil pump, lifters.
 Remove the injector
 Check the cylinder liners to make sure they are still good for use.

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  Check for seals (O-ring seal, mechanical seal) and make sure they are good. Make a
replacement in the case of a bad seal.
 Remove the crankshaft pulley, crankshaft, flywheel.
 Remove the crankshaft.
 Remove and disassemble all engine components and let the engine block to be free.
 Wash the engine block and blow it dry.
 Wash all engine parts and keep them dry to avoid rusting.

ASSEMBLING:

 Inspecting all the parts and seals carefully to make sure they are still of correct
standard. Make a replacement in the case of any bad one.
 After changing the cylinder liners O-ring seal and changing bad liners, we install the
cylinder lines using sleeve presser.
Bedding of the crankshaft

 First the engine block is turned upside down with gloves on.
 We then use compressed air to make sure the block is completely free of dirt, debris,
water, etc.
 We fix the upper main bearings in the block appropriately and we put small amount of
lubricant like a high quality oil so that the crankshaft can seat properly. We install the
crankshaft and lubricate the upper part where the bottom bearings and main cap will
be installed.
 We install the thrust bearings.
 We install the main cap which has the main bearings.
 We use a rubber mallet to hit the main cap so that it will fit well.
 We then adjust the bolts to their correct torque as specified by the manufacturer.
 We install the camshaft and its thrust bearing, valve lifter and lubricate.
Piston installation

 We first change the piston rings, oil rings and possibly bad piston crown.
 Install piston. Make sure it is a key to camshaft for 3306 and 3304 engine model.
 Install the oil pump and ensure its in tit perfect position with the crankshaft teeth.
 Remove dirt from bolt holes and tighten sump, etc.
 Install the timing gear that connects the crankshaft and camshaft.

Cylinder head/top installation

 Grinding the cylinder top with rough grinding paste.

 Smoothen it with smooth grinding paste.
 Install valves.

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  Install valve oil seal, spring, cap and key using valve clamp.
 Hit the cap on the valve with a mallet to check if the valves are in their correct seat.
 Install top cylinder gasket.
 Install cylinder top and make sure they are placed correctly in the dowel to the hole on
the cylinder top.
Install push rods after checking for straightness. The push rods are meant to seat on the
valve lifters.
Install the rocker arm assembly after checking it.
Place the rocker arm on the push rods and install the head bolts correctly and place
them in their correct torque.
Set the clearance of the first rocker arm and the last one (clearance between the arm
and head bolt).
Set the tappet clearance or valve lash adjustment (40mm thickness inlet and 70mm
thickness outlet) using feeler gauge.
Install valve cover with gasket.
Install exhaust manifold with their gasket/shims.
Install fuel pump (injector). Install water pump.
Install pulley, banjo and make sure you install their appropriate.
PROBLEMS ASSOCIATED WITH A BAD ENGINE (3306)

 Poor lubrication
 Failing oil pump
 Oil deposits and debris.
 Inadequate fuel and air compression.
 Leaking engine coolant
 Blocked engine radiators.
 Prolonged engine deterioration.
 Power loss
 Over heating
 Smoking engine
 Noises
SOLUTION

 Power loss:
This could be due to worn out governors and bad fuel pump that do not deliver the
accurate quantity of fuel.
Solution:
 Check for seals and change bad governors.
 Check valve lash adjustment.
 In the case of smoking engine:

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 - Blue smoke emitting from exhaust pipes means that your engine is burning engine
oil.
Solution:
 Check for oil leaks especially around and inside the combustion engine.
 Check worn valves or piston rings and make changes where necessary

- Grey engine smoke indicates a failed turbocharger.

Solution:
 Check turbocharger.

- White engine smoke indicates condensation building up in the exhaust.

- Black smoke indicates faulty fuel injector, sensors or maybe an issue with fuel
pressure regulator

 For overheating:
- Inspect coolant level
- Check the cooling system
- Inspect radiator: check fins and open up blocked fins using appropriate tools
- Inspect fan and fan shroud: check loose drive bolts
- Check for damage to the fan blades
- Look for leaks

Page 38 of 39
 CHAPTER FOUR

CONCLUSION AND RECOMMENDATION

CONCLUSION

During the course of my industrial training with I. A. EKEH ENGINEERING, I was

exposed to several experience ranging from identification of tools, engine components to
servicing, repairs and maintenance of caterpillar engines and parts.

I. A. EKEH ENGINEERING COMPANY made me appreciate the works of engineering,

the company made me see the practical aspect of engineering.

RECOMMENDATION

 The program should be improved to be able to cater for both the sick ones who could
not meet up the program.
 Financial support programme should be created to assist the student undergoing the
programme in accommodation and at least transportation.
 Proper sensitization should be given to student before embarking on this programme.

CHALLENGES

 The major challenge I encountered was insufficient fund in terms of transportation

and accommodation.
 The company director does not allow taking photograph during working hours. So I
found it difficult to take photographs why working.

REFERENCE

https://www.google.com/search?q=caterpillar+service+manual

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