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INTERNSHIP EXPERIENCE AT NYALA

MOTORS S.C
AN INTERNSHIP REPORT BY:

Submitted By: ADDISU TADDESE Id no 1201292

Submitted in partial fulfillment of Requirement for

Award of

Degree of Bachelor of Science in Mechanical Engineering

SUBMITTED TO:

Department of Mechanical Engineering

Wallaga university

August 15, 2023


WALLAGA UNIVERSITY March 31, 2023

DECLARATION
I hereby declare that this internship report is an authentic record of my own works as
requirement of Industrial Training during the period from april to august for the award of
degree of B.Sc. in Mechanical Engineering, wallaga University, Addis Ababa, under the
guidance of Mr. Debala.A.

Date: August 15, 2023

Name : Addisu taddese

Id no: 1201292

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ACKNOWLEDGEMENT
First, I would like to thanks to my advisor Mr. debala for advising me in such a good manner. I
am greatly indebted to all lecturers of Mechanical Engineering department and have special
thanks to all staff members of Mechanical Engineering department for their valuable
commitment to make me interested in Mechanical Engineering. I am also grateful to wallaga
university financial assistance. My acknowledgement also extends to Nyala motors S.C because
the company for allowing me to practice my internship program which had lasted for about 4
months. During my stay, the staffs of the base service department were very encouraging, helpful
and supportive

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EXECUTIVE SUMMERY
This report is an outcome of the Internship, which was conducted during my stay in Nyala
motors S.C. This was an opportunity for me to put in practice, the theoretical knowledge I had
acquired during my study. The Internship also gave a real opportunity to gain valuable
experience to bridge the gap between study and the beginning of working lives. Moreover, the
practical exposure offered an experimental learning component that can strengthen previous
theoretical knowledge and motivated me in parsing with Mechanical Engineering. Additionally,
my experimental learning has proven to be helpful to develop my detail skills vehicle power train
and auto electrics. In this internship report, it is outlined the practical experience obtained while
working with a team of professionals which revealed the strength and weakness one had and
helped to bridge the weakness.

It also help me to make connection, to work hard, increase my practical skill it also push me to
read more also allow me understanding about work ethics and take criticism well diagnose .

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Table of Contents

Contents page
DECLARATION..............................................................................................................................I
ACKNOWLEDGEMENT..............................................................................................................II
EXECUTIVE SUMMERY............................................................................................................III
CHAPTER ONE..............................................................................................................................1
INTRODUCTION...........................................................................................................................1
1.1 Background of the company..................................................................................................1
1.1.2 Objectives of the company..............................................................................................2
1.1.3 Number of engineers, technicians and mechanics...........................................................2
1.1.4 Mission of Nyala Motors.................................................................................................3
1.1.5 Work flow........................................................................................................................3
1.1.6 Products available in Nyala Motors S.C.........................................................................3
1.1.7 Main customers or End users..........................................................................................4
1.3 Structural Organizational main activity.................................................................................4
1.4 Title and position of supervisor.............................................................................................5
1.5 Nyala Motors S.C service......................................................................................................5
1.5.1 Service operation.............................................................................................................6
1.5.2 Service reception.............................................................................................................7
1.5.3 Working bays service......................................................................................................7
1.5.4 Towing service................................................................................................................7
1.5.5 Diagnostic-tools...............................................................................................................8
1.5.6 Dealership Network.......................................................................................................11
1.5.7 New vehicle...................................................................................................................11
CHAPTER TWO...........................................................................................................................12
DETAIL OF WORKING EXPERIENCE.....................................................................................12
2.1 Summary of duties...............................................................................................................12
2.1.1 Daily duties and responsibilities....................................................................................13
2.2 Basic activities.....................................................................................................................23
2.2.1 Clutch overall................................................................................................................24
2.3 Manual transmission and transaxle......................................................................................26

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2.4 Differential...........................................................................................................................27
2.4.1 Differential Operation...................................................................................................27
2.4.2 Types of differential......................................................................................................28
2.4.3 Diagnosing differential noise........................................................................................28
2.5 Steering system....................................................................................................................29
2.5.1 Steering columns and steering linkage mechanisms.....................................................29
2.5.2 Purpose of steering system............................................................................................29
2.5.3 Types of steering system...............................................................................................30
2.6 Suspension system...............................................................................................................30
2.6.1 Types of front suspension systems................................................................................31
2.6.1 Types of rear suspension Systems.................................................................................32
2.7 Transmission system............................................................................................................33
2.7.1 Purpose of transmission system....................................................................................33
2.7.2 Types of transmission system........................................................................................33
CHAPTER THREE.......................................................................................................................35
CONCLUSION AND RECOMMENDATION............................................................................35
3.1 Conclusion...........................................................................................................................35
3.2 Comment on the training......................................................................................................35
3.3 Recommendation.................................................................................................................36
REFERENCE................................................................................................................................37
APPENDIX....................................................................................................................................38
Appendix A................................................................................................................................38
Appendix B................................................................................................................................38
Appendix C................................................................................................................................39
Appendix D................................................................................................................................39
Appendix E................................................................................................................................40

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List of table
Table 1 number of engineer and technicians...................................................................................2
Table 2 Types of front suspension systems..................................................................................31
Table 3 Types of rear suspension Systems...................................................................................32
Table 4 Kilometers classification.................................................................................................38
Table 5 Type A service activities.................................................................................................38
Table 6 Type B Service activities.................................................................................................39
Table 7 Type C Service activities..................................................................................................39
Table 8 Type D service activities.................................................................................................40

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Table of figure
Figure 1: company logo...................................................................................................................1
Figure 2: work flow diagram...........................................................................................................3
Figure 3: Structural Organizational main activity...........................................................................5
Figure 4: light duty vehicle shop.....................................................................................................6
Figure 5: injection tester..................................................................................................................8
Figure 6: inline type fuel injection pump........................................................................................9
Figure 7: wheel balancer................................................................................................................10
Figure 8: Driveline system.............................................................................................................13
Figure 9: component for power train.............................................................................................14
Figure 10 component for power train............................................................................................15
Figure 11: component for power train...........................................................................................16
Figure 12: components for engine.................................................................................................18
Figure 13: components for engine.................................................................................................19
Figure 14: gauges on the Dashboard.............................................................................................20
Figure 15: components for alternator............................................................................................21
Figure 16: Electronic fuel injection system...................................................................................22
Figure 17: components of clutch...................................................................................................24
Figure 18: limited slip differential (LSD)......................................................................................28
Figure 19: McPherson strut front suspension................................................................................31
Figure 20: Rear suspension............................................................................................................32
Figure 21: transfer case..................................................................................................................34

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CHAPTER ONE

INTRODUCTION
1.1 Background of the company

Figure 1: company logo

Nyala motors Share Company was established in April 1973 in line with the commercial code of
Ethiopia. It can be said that Nyala motor share company has been one of the front-runners in the
development of the privet sector in Ethiopia in the last 40 years. The continued expansion of the
company has become a trend settler to other in line a firm foundation for the success and
expansion of corporate development.

Nyala motor S.C is the sole importer and distributer of Japanese made Nissan motor
Automobiles, station wagon, pickups, forklift, UD tracks, dump tracks, cargo Tracks, Tanker
Tracks, mixers, asphalt distributing Tracks, and agricultural tractors.

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Its head quarter is located in Addis Ababa at Megenagna-Airport ring road with fully established
after sales service. In addition, Nyala motors s.c branch offices in Dire Dawa, Hawassa,
Bahirdar, Mekele, and Jimma, are dedicated to serve their esteemed customers.

1.1.2 Objectives of the company


The main objectives of the company are the following:
 To carry out all business of import/export and distribution of automotive and allied
products as well as industrial, construction and agricultural machineries;
 To engage in the supply of automotive spare parts;
 To carry out any business connected worth the above objectives;
 To perform maintenance and repair activities
 To participate in various tender geared towards the development of the country;
 To provide recurrent technical training to various customers as part of its technology
transfer objectives.

1.1.3 Number of engineers, technicians and mechanics


Engineer (mechanical) = six
We have six mechanical engineers who have taken specialized training abroad specialized in
vehicle trouble diagnosis and repairs. Conduct training to mechanics, drivers and equipment
operators and workshop management.

Number of mechanics = 55

Table 1 number of engineer and technicians


Job Description Number Qualification and experience
For heavy duty vehicles 10 Diploma graduate in auto mechanics with
construction and farm machinery experience of 3 and above years
For Nissan light duty vehicles 23 Diploma graduate in auto mechanics with
experience of 3 and above years
Auto electricians 7 Completion of grade 10 and 5 years work
experience
Body and repair men and painters 15 Completion of grade 12 and 5-10 year work
experience

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1.1.4 Mission of Nyala Motors


 Providing vehicle sales, parts, services.
 Providing vehicles service with excellence.
 Minimize servicing time with new equipped technologies

1.1.5 Work flow

Figure 2: work flow diagram

1.1.6 Products available in Nyala Motors S.C

o KICKS
o QASHQAI
o NV350 URVAN
o PATROL Y62
o NP300 NISSAN PICK UP
o X-TRAIL
o UD TRUCKS

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o VE COMMERCIAL VEHICLES
o EICHER BUS
o EICHER TRUCH
o EICHER CARGO VANS
o UNICARRIERS FORKLIFTS
o DIESEL/PETROL ENGINE
o BATTERY POWERED
o MACROPOWER BATTERY

1.1.7 Main customers or End users


The customers could be governmental or non-governmental organizations. From those I have
listed below some.
- Different vehicle owner individuals
- Governmental organizations
- Construction companies
- Agricultural based industries, etc.

1.3 Structural Organizational main activity


MME prefer to have a matrix structure, which simultaneously groups people in two ways- by the
function of which they are a member and by the product team on which they are currently
working. Even though, MME believe that a company structure has to be dynamic, the current
organizational structure is divided in to three bodies.

The first and the top executive organ of the company composed of the CEO, Directors, Internal
audit, and Legal services. This are to create the company vision, mission, value and objectives
and analyze that company objectives becomes successful.

Next to this the second organ composed of Directors, Managers and their assistants, whose
objectives are to prepare strategic plan, organize, direct, coordinate and control the overall
operation of the company.

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Figure 3: Structural Organizational main activity

1.4 Title and position of supervisor


My supervisor is the foreman and his duty is to supervise the mechanics.
1.5 Nyala Motors S.C service
Nyala Motors S.C being the National Sales company/sole distributor in Ethiopia for the world-
class products: such as NISSAN Vehicles, UD trucks, EICHER Trucks, UNICARRIERS

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Forklifts, MACROPOWER auto-battery, provides after sales services to ensure the maximum
satisfaction of its esteemed customers.
1.5.1 Service operation
The service operation of the company that has the first class accreditation from Transport
Authority of Addis Ababa Branch Office is working towards attainment of the objective of
maximizing their customer satisfaction. The type of service provided by service operation ranges
from repairs conducted at their workshop and on construction sites upon the request from their
fleet customers.

Figure 4: light duty vehicle shop

A) Pre Delivery Inspection (PDI) Service


Nyala motors provides PDI for all new vehicles before delivery to the customers. The PDI
service is guided by the manufacturer’s procedure manual developed by their respective principal
suppliers (Nissan Motors, UD trucks and EICHER trucks & buses).

B) Periodic Maintenance
Proper maintenance will ensure maximum performance, greater reliability, longer life and higher
resale value for vehicles. Hence, to ensure safety operation and optimum performance they
recommend that all Nissan vehicles, UD trucks and EICHER trucks & buses owners bring in
their vehicles to their service shops every 5,000km or three months.

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C) Component Repairs and Overhauls Service


There company service shops provide component repairs and overhauls for all sophisticated
general mechanical, electrical, electronics and mechatronics system on all Nissan vehicles, UD
trucks, EICHER trucks and buses. These services comprise of units overhauling (like engines,
manual transmission/transaxles, differential, steering system, starters, alternators …), and
diagnosis & repair of any malfunction on the vehicle by using different equipment and tools
available.

D) Body and Paint Repair Service


The companies body and paint technicians carry out major and minor body & paint repairing
work in order to attain the original state of the art of the products.

E) Annual Vehicle Inspection Service


According to the Ethiopian Government Transport Authority Regulations, all vehicles are
required to undergo Annual Technical Inspection, every year, at a designated vehicles inspection
centers. Nyala Motors is one of the Designated Vehicles Inspection Centers and provides
inspection service to all Nissan vehicle and UD trucks. Temporarily it has been paused due to the
installation process of the automatic test lanes

1.5.2 Service reception


It has service reception area that is convenient and comfortable to their customers. In the service
reception, we receive customers in an orderly and professional manner that creates customer’s
confidence on their competence to meet customer expectation through convenience and quality
service.

1.5.3 Working bays service


Currently, Nyala Motors head office facility has adequate working bays for the Nissan vehicles,
UD trucks, and EICHER trucks and buses. The facility has also a well-equipped Body and Paint
Repair shop. For enhanced performance, the working bays are equipped with Auto-Lifts and
Pneumatic Tools.

1.5.4 Towing service


The company provides towing service (dragging of a car) to assist their customers in times of
accident or malfunction of vehicles.

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1.5.5 Diagnostic-tools
The company service shops use computerized diagnostic tools for Nissan vehicles and UD trucks
to diagnose electrical and electronic control systems of Nissan vehicles. The system is capable of
diagnose all electrically controlled sensors and actuators.

A) Injection tester
The fuel injectors in your vehicle are designed to spray fuel into the cylinders of your engine
where it is combined with air and compressed before being ignited by the spark plug to produce
power. As a result, an issue with one of your fuel injectors can cause your engine to run poorly,
or even fail to run at all. There are a number of issues that could cause your fuel injectors to fail.
Although some may be beyond the expertise of most home mechanics, you can often diagnose a
faulty fuel injector using injection tester.

 Test for spray volume of injector.


 Test for spray form of injector.
 Test for flow volume of various high-pressure supply pump

Figure 5: injection tester

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Figure 6: inline type fuel injection pump

B) Wheel balancer
In fact, wheels and tires are never exactly the same weight all around. The wheel's valve stem
hole will usually subtract a small amount of weight from that side of the wheel. Tires will also
have slight weight imbalances, whether from a joining point of the cap plies or a slight deviation
from perfectly round. At high speeds, even a tiny imbalance in weight can become a large
imbalance in outward force, which could cause the wheel and tire assembly to spin in a heavy
and uneven motion. This usually turns into a vibration in the car as well that could cause uneven
and damaging wear on the tires.
Maintaining proper wheel balance is a critical part of maintaining the life of the tire. Also proper
wheel balancing ensures your vehicle has a smooth and vibration free ride.

C) Wheel weight
Correcting imbalances requires attaching wheel weights to the rim. Clip-on wheel weights are
attached to the rim using a wheel weight hammer. Different types of clips are available to
accommodate the variety of wheel types and wheel covers. Aluminum wheels with a flange for
a clip-on weight may require a coated or alloy clip so they will not corrode the wheel.

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Figure 7: wheel balancer

D) Engine teste stand


After installation, it used to check engine performance before mounting on the car. A modern
engine test stand has several sensors (or transducers), data acquisition features and actuators to
control the engine state. The sensors would measure several physical variables of interest, which
typically include: Atmospheric conditions such as temperature, pressure, and humidity intake air
and fuel consumption rates, often detected using volumetric or gravimetric measurement
methods temperatures and gas pressures at several locations on the engine body such as engine
oil temperature, spark plug temperature, exhaust gas temperature, intake manifold pressure

E) Paint booth

Nyala Motors shop facility has paint booths, which are of latest design and construction, which
has enabled us to paint repaired body of their customers’ vehicles free of defects.

F) Car and component washing equipment

The company care for cleanness of its customers’ vehicles, all vehicles brought for service to
their shop shall be giving the car washing equipment and greasing service. In addition, the
company has installed component washing machine which is helped them to wash components
(like cylinder head, engine accessories) by steam before building up.

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1.5.6 Dealership Network


The company has currently five branches located at Hawassa, Dire Dawa, Bahir Dar, Mekelle
and Jimma. All branches except Mekelle are rendering the three services (vehicle sales, part sales
and maintenance/repair service).

1.5.7 New vehicle


Discover our exciting and extensive range
 Range passenger
 MICRA
 ALMERA
 SENTRA
 Range crossover
 KICKS
 NEW QASHQAI
 NEW X-TRAIL
 PATHFINDER 2017
 Range sport utility
 PATROL Y61
 PATROL Y62
 Range commercial
 NEW NV350 URVAN
 NP300 HARDBODY
 CIVILIAN

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CHAPTER TWO

DETAIL OF WORKING EXPERIENCE


2.1 Summary of duties
Nyala Motor Engineering dedicated different positions for the internship trainees; maintenance
and repair shop, service shop, heavy-duty vehicle shop, engine shop, electrical shop, body shop
and store. During my internship period at Nyala Motor Engineering, I was working on the
company-scheduled time, which is from 2:00 to 6:00 before lunch and from 7:00 to 10:30 after
lunch. The internship program was carried out from April 17 to august 15. There was
management to rotate the internship students through the mentioned positions.

During my stay at Nyala Motors Engineering spent all my training session in the workshop
section.

Among them: - - Passenger vehicle service section

- Costumer vehicle service section

- Engine overhaul workshop

-Electrical troubleshoot for both Passenger vehicle

The main workshop I had worked is mainly associated with vehicle servicing (mechanical and
electrical maintenance). I have been working all workshops except body shop due to time
shortage. I work on about four months in the light duty vehicle, under the guidance of technician
hunetaw and fikresilase, practicing service part but I had a chance to visit the whole entire of
company. Because there was no specific place for service maintenance, just repairing takes place
everywhere the vehicle parked. As a result, I could know everything, which found in each
workshop. Since there is no specific place for servicing vehicles and repair the problem they
face, we were struggling everywhere the vehicle is parked. The first eight weeks I was doing my
job with Mr hunetaw and fikresilase in the maintenance and service shop. Simply I was working
nearly on all parts of the vehicle with this intelligent mechanic. After eight weeks, then I shifted
to fuel injection pump and electric shop. Daniel was the technician of the fuel injection pump, he

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help to me to know each components and parts of the injection pump. In addition, I was working
in the electrical shop and engine shop with Mr. yohanis and sisay respectively. He can diagnosis
the alternator, starter, lighting system, accessories and electronic control module (ECU).
Under the above workshop, different tasks were performed these are-

2.1.1 Daily duties and responsibilities


Driveline system

Figure 8: Driveline system

This is the place where all parts of the vehicle, which are maintain and repair

 Checking and repairing of front and rear suspension


 Check and replace of tires
 Check and repair propeller shaft
 Check and repair gear box
 Check and repair U-joints
 Check and repair pumps such as vacuum pump, water pump
 Refilling of hydraulic oils such as brake oil, steering oil, gear box oil, engine oil

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 Check and repair air cleaners, fuel filter, oil filter


 Check and repair knuckle components like wheel hub, bearing, spacer, tie rod etc.
 Check and repair hand brake, brake pad, brake shoe

Figure 9: component for power train

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Figure 10 component for power train

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Figure 11: component for power train

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Engine maintenance
One of the most important aspects of engine maintenance is keeping the fluids the engine
requires clean and fresh. The engine is the heart of the car, and its fluids are its blood. In your
own body, your blood has kidneys and a liver to keep the blood clean -- aside from the oil filter,
a car engine can't clean its own fluids. That is why it is important to change an engine's oil
regularly, and to make sure that change happens before the oil gets too dirty. Dirty oil in the
engine is like dirty blood in your bloodstream. Things may go fine for a while, but eventually it
will lead to disaster. Even small amounts of dirty buildup over time can lesson an engine's
lifespan.

The engine's breathing also affects how long it lasts, because if an engine can't breathe well, it
has to work a lot harder. To make sure your engine can breathe properly, you need to make sure
your air filter is clean. A hot engine is also something you want to avoid -- the heat wears down
vital engine components -- so make sure your engine's cooling system is working well, too.

 Repair, maintenance and installation of crankshaft


 Repair, maintenance and installation of all bearings
 Repair, maintenance and installation of camshaft
 Repair, maintenance and installation of cylinder head and cylinder block
 Repair, maintenance and installation of differential
 Repair, maintenance and installation of valves
 Repair, maintenance and installation of gear box
 Refilling fuel
 Refilling engine, differential, transmission, steering gearbox, and clutch oils
 Cleaning overall engine

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Figure 12: components for engine

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Figure 13: components for engine

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Electrical parts maintenance


Your car's electrical system is a complex network that requires specialized diagnostic equipment
for comprehensive servicing. Our technician can access your vehicle's data with diagnostic tools
and using our strategy based diagnostic process will be able to identify the exact cause of any
electrical problems.

An automotive scan tool (scanner) is an electronic tool used to interface with, diagnose and,
sometimes, reprogram vehicle control modules.

There are many types from just as many manufacturers, one of the most familiar being the Snap-
On "brick", or MT2500/MTG2500. Snap-On, Hella Gutmann Solutions, OTC/SPX, Autel,
Launch, Vetronix/Bosch and a number of other companies produce various types of scan tools,
from simple code readers to highly capable bi-directional computers with programming
capabilities.

 Maintenance overall lighting systems


 Refill and replacement of car battery
 Air conditioning
 Maintenance of charging system
 Maintenance of starting system
 Maintenance of electronic fuel injection system. For example diagnosing electronic
control module, sensors and actuator.

Figure 14: gauges on the Dashboard

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Figure 15: components for alternator

Figure 16: Electronic fuel injection system

Body maintenance
 Body repairing
 Body painting
 Repairing vehicle seats

Tire and Wheel duties


 Tire removing and assembled
 Servicing wheel bearings and hubs
 Servicing tire pressure
 Installation the whole assembly
 When we remove tire assembly:
 Set parking brake
 Lifted up the vehicle on lift
 Remove bolts and tire
 Remove wheel-bearing, connector

Other duties
 Servicing air cleaner
 Servicing fuel tank
 Servicing carburetor

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 Servicing fuel and oil filters

Responsibilities
 Clean components of the vehicle
 Support the technician
 Clean up spills
 Cleaning grease
 Clean assembled hoses

2.2 Basic activities

 Clutch overall
 Pressure plate
 Clutch disk
 Release bearing
 5000km General service A type
 Changing engine oil
 Changing oil filter
 5000km General service B type
 Changing fuel filter
 Fuel tanker & hose lining
 10,000km General service C type
 Brake system
 Drum brake
 Disc brake
 General Service D type
 Knuckle service
 Gearbox
 Differential
 Engine over all
 Injection pump
 Suspension system

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 Steering system

2.2.1 Clutch overall


Clutch is a device used to connect and disconnect the engine and manual transmission or
transaxle. Used to connect and disconnect the driving and driven discs of a machine. The driver
can control power flow between engine and transmission or transaxle using a clutch.

A) Clutch Action
Clutch Disengaged
It is activated when the clutch pedal depressed. When the driver presses the clutch pedal, the
clutch release mechanism pulls or pushes on the clutch fork. The fork moves the release bearing
into the center of the pressure plate. Then, the pressure plate face pulls away from the clutch
disk. The clutch disc and transmission input shaft do not in turn. Finally, there is no power
transmission between the engine and drive train (drive lined). No power flow to the transaxle.
Clutch engaged it is activated when the driver releases the clutch pedal. When the driver releases
the pedal, the spring pressure inside the pressure plate pushes forward on the clutch disc.
Therefore, this locks the flywheel, disc, pressure plate and the transmission input shaft together.
Then, power starts flowing. The power (torque) transmitted from engine to the transmission
input shaft and start rotating.
Necessity of Clutch

 To connect a running engine smoothly and gradually to the drive train.


 To permit gear shifting when the vehicle is in motion.
 To allow the engine to continue running while a vehicle is temporarily halted in gear with
the clutch pedal depressed.
 To provide positive linkage capable of transmitting maximum engine power (torque).
B) Components of clutch:

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Figure 17: components of clutch

Flywheel face

A mounting place for the clutch.

The pressure plate bolts to the face of flywheel.

Flywheel face is machined to a smooth surface, where it contacts the clutch disc.

It is made of iron for good wear and heat dissipation.

Clutch disc

Consists of a splined metal hub and a round metal plate covered with friction material.
Fits between flywheel and pressure plate. Splined to the transmission input shaft.
The disc is free to slide forth and back on the shaft.
It is made of heat resistant:

- Asbestos
- Cotton fibers
- Copper wires

Rivets: used to bond the friction material to both sides of the metal parts of the disc.

Torsion spring: to absorb the torsional vibration of crankshaft and shock produced by clutch
engagement.

Groves: catted space on the friction material to aid cooling and release of the clutch disc.

Pressure plate

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- Spring- loaded device


- Locks or unlocks the clutch disc and the flywheel.

Two types of pressure plate assembly

- With coil spring type:


- With diaphragm spring type:

Pressure plate with coil spring main components:

 Coil spring: clamp the clutch disc between pressure plate face and flywheel.
 Pressure plate face: Large ring that contacts the clutch disc.
 Release levers: Allows the release bearing to move the pressure plate face.
 Pilot bearing: Support the end of transmission input shaft and Prevents the transmission
input shaft and clutch disc from wobbling when the clutch pedal released.
 Clutch Fork: Transfers motion from the release mechanism to the release bearing and
pressure plate. When the clutch fork moved by the release mechanism, it press on the
release bearing and disengage the clutch.
 Release bearing: Slides on the transmission input shaft retainer bearing.
C) Clutch service

For removing and replacing, the clutch in a vehicle is removing the driveline or drive shafts and
transmission or transaxle.

Removing the Clutch

After raising the vehicle on a hoist, clean excessive dirt, grease, or debris from around the clutch
and transmission. Then disconnect and remove the clutch linkage. Cable systems need to be
disconnected at the transmission.

On rear-wheel-drive vehicles, remove the driveline and transmission because the engine is
somewhat supported by the transmission mounts. It is necessary to support the engine with a tall
jack stand. In some cases, the bell housing is removed with the transmission. In other cases, it is
removed after the transmission is removed.

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On front-wheel-drive vehicles with transaxles, any parts that interfere with transaxle removal
must be removed first. These parts might include drive axles, parts of the engine, brake and
suspension system, or body parts.

2.3 Manual transmission and transaxle


These are vital links in the power train of any modern vehicle. The purpose of the transmission
or transaxle is to use gears of various sizes to give the engine a mechanical advantage over the
driving wheels. Gears in the transmission or transaxle housing alter the torque and speed of this
power input before passing it on to other components in the drive train. Without the mechanical
advantage the gearing provides, an engine can generate only limited torque at low speeds.

Without sufficient torque, moving a vehicle from a standing start would be impossible. In any
engine, the crankshaft always rotates in the same direction. If the engine transmitted its power
directly to the drive axles, the wheels could be driven only in one direction. Instead, the
transmission or transaxle provides the gearing needed to reverse direction so the vehicle can be
driven backward. There is also a neutral position that stops power from reaching the drive
wheels.

2.4 Differential
The differential is a geared mechanism located between the driving axles of a vehicle. It rotates
the driving axles at different speeds when the vehicle is turning a corner. It also allows both axles
to turn at the same speed when the vehicle is moving in a straight line.

The differential serves to establish a state of balance between the forces between the drive
wheels and allows the drive wheels to turn at different speeds when the vehicle changes
direction.

The differential allows the drive wheels to rotate at different speeds when negotiating a turn or
curve in the road and redirects the engine torque from the drive shaft to the rear drive axle shafts.

2.4.1 Differential Operation


The amount of power delivered to each driving wheel by differential is expressed as a
percentage. When the vehicle moves straight ahead, each driving wheel rotates at 100% of the
differential case speed. When the vehicle is turning, the inside wheel might be getting 90% of the

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differential case speed. At the same time, the outside wheel might be getting 110% of the
differential case speed.

Pinion gear transfers torque to the ring gear. As the ring gear turns, it turns the differential case
and the pinion shaft. The differential pinion gears transfer torque to the side gears to turn the
driving axle shafts.

The differential pinion gears determine how much torque goes to each driving axle, depending
on the resistance an axle shaft or wheel has while turning. The pinion gear rotates on the pinion
shaft. When this rotary motion is transferred to the ring gear, the torque flow changes direction
and becomes parallel to the axle shafts and wheels.

2.4.2 Types of differential

 Open Differential
 Limited-Slip Differential
 Locking Differential

Figure 18: limited slip differential (LSD).

Because the ring gear is bolted to the differential case, the case must rotate with the ring gear.
The pinion gear shaft mounted in the differential case must also rotate with the case and the ring
gear. Because the pinions are meshed with both side gears, the side gears rotate and turn the axle
shafts. The ring gear, differential gears, and axle shafts turn together without variation in speed
as long as the vehicle is moving in a straight line.

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2.4.3 Diagnosing differential noise


When turning corners or rounding curves, the problem might be damaged differential pinion
gears and pinion shaft. This damage is caused when the inside diameter of the differential
pinions and the outside diameter of the differential pinion shaft are scored and damaged. The
damage is usually caused by allowing one driving wheel to revolve at high speeds while the
opposite wheel remains stationary.

Another gear noise that is common in differentials is the chuckle. A chuckle is a low sound that
occurs when gears are worn to the point where there is excessive clearance between the pinion
gear and the ring gear. Chuckle sounds occur most often in the decelerating mode, particularly
below 40 mph (65 km/h). As the vehicle decelerates, the chuckle also slows and can be heard all
the way to a stop.

2.5 Steering system


Steering systems are essential to provide vehicle safety, steering quality, and steering control!
Steering system problems can cause the steering to pull to one side when driving straight ahead,
excessive steering effort, wheel shimmy, or excessive steering wheel free-play. These problems
all reduce vehicle safety and increase driver fatigue. Therefore, steering systems must be
properly maintained.

2.5.1 Steering columns and steering linkage mechanisms


The steering column connects the steering wheel to the steering gear. The steering wheel is
connected to the steering shaft, and this shaft extends through the center of the steering column.
The lower end of the steering shaft is connected through a universal joint or flexible coupling to
the shaft from the steering gear. The steering shaft is supported on bearings in the steering
column. Some steering columns are designed to collapse or move away from the driver, if the
driver is thrown against the steering wheel in a collision. Some steering columns are designed so
the driver can tilt the steering wheel downward or upward to provide increased driver comfort
and facilitate entering and exiting the driver’s seat.

2.5.2 Purpose of steering system


• Provides precise control of the front-wheel direction.

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• Maintain the correct amount effort needed to turn the wheels.

• Absorb most of the shock going to the steering wheel as the tires meet bumps and holes in the
road.

Requirements of the steering system

1. Excellent maneuverability

2. Proper steering effort

3. Smooth recovery

4. Minimum transmission of shock from road surface.

2.5.3 Types of steering system

A) Recirculating Ball Steering Gears


Some vehicles are equipped with a recirculating ball steering gear, where in the steering shaft is
attached to a worm gear in the steering gear. A ball nut with internal grooves is mounted over the
worm gear. Ball bearings are mounted between the worm gear and ball nut grooves to reduce
friction and provide reduced steering effort. Outer grooves on the ball nut are meshed with
matching teeth on the sector shaft. The lower end of the sector shaft is splined to the pitman arm.
When the steering wheel is turned, the ball nut moves upward or downward on the worm gear,
which rotates the sector shaft to provide the desired steering action. Recirculating ball steering
gears can be manual-type with no hydraulic assist, or power-type with hydraulic assist from the
power steering pump.

A) Rack and Pinion Steering Gears


Rack and pinion steering gears and linkages are more compact than recirculating ball steering
gears and parallelogram steering linkages. Therefore, rack and pinion steering gears are usually
installed on smaller, front-wheel drive vehicles. Rack and pinion steering gears transfer more
road shock from the front wheels to the steering gear and steering wheel, because the tie rods are
connected directly to the rack in the steering gear. In a rack and pinion steering gear, a toothed
rack is mounted on bushings in the rack housing. The rack teeth are meshed with teeth on a
pinion gear mounted near one end of the gear. The pinion gear is mounted on bearings in the

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gear housing. The steering shaft from the steering column is attached to the upper end of the
pinion gear. When the steering wheel is turned, the rotation of the pinion gear moves the rack
inward or outward to provide the desired steering action. Rack and pinion steering gears can be
manual-type or power assisted.

2.6 Suspension system


The suspension system must provide proper steering control and ride quality. Performing these
functions is extremely important to maintain vehicle safety and customer satisfaction. For
example, if the suspension system allows excessive vertical wheel oscillations, the driver may
lose control of the steering when driving on an irregular road surface. This loss of steering
control can result in a vehicle collision and personal injury. Excessive vertical wheel oscillations
transfer undesirable vibrations from the wheel(s) to the passenger compartment, which causes
customer dissatisfaction with the ride quality. The suspension system and frame must also
position the wheels and tires properly to provide normal tire life and proper steering control.

2.6.1 Types of front suspension systems


The front suspension systems are extremely important to provide proper wheel position, steering
control, ride quality, and tire life. The suspension systems must supply proper ride quality to
maintain customer satisfaction and reduce driver fatigue, as well as provide proper wheel and tire
position to maintain directional control. When driving Proper wheel position, also ensures
normal tire tread life.

Table 2 Types of front suspension systems


Type Usage Cost and Weight Package Control

McPherson Strut Small FWD Cars Light & Not expensive Compact Ok

SLA or Double Luxury Cars Heavier & expensive Not compact Good
Wishbone
Solid Axle with Heavy Trucks Heavy & not expensive Compact Minimum
Leaf Springs

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Figure 19: McPherson strut front suspension

2.6.1 Types of rear suspension Systems

If a solid axle connects the rear wheels of a car, then the suspension is usually quite simple-
based on either a leaf spring or a coil spring. In the former design, the leaf springs clamped
directly to the drive axle. The ends of the leaf springs attach directly to the frame, and the shock
absorber is attached at the clamp that holds the spring to the axle. For many years, American car
manufacturers preferred this design because of its simplicity.

The same basic design can be achieved with coil springs replacing the leaves. In this case, the
spring and shock absorber can be mounted as a single unit or as separate components. When they
are separate, the springs can be much smaller, which reduces the amount of space the suspension
takes up.

Table 3 Types of rear suspension Systems


Type Usage Cost and Weight Package Control

Twist Beam Small FWD Cars Light & Not expensive Compact Ok

Multi-Link Luxury Cars Heavier & expensive Not compact Good

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Hotchkiss Trucks Heavy & not expensive Compact Minimum

Figure 20: Rear suspension

2.7 Transmission system


A power transmission system, which provides controlled application of the power. Often the
term transmission refers simply to the gearbox that uses gears and gear trains to provide speed
and torque conversions from a rotating power source to another device.

2.7.1 Purpose of transmission system


 To provide high torque at the time of starting, hill climbing, accelerating and pulling a
load.

 Obtained by the set of gears called a transmission or gear set.

 The gear set enclosed in a metal box called a gearbox.

 Vehicle speed can be changed with the help of gearbox keeping the engine speed same
with certain limit.

2.7.2 Types of transmission system

 Manual Transmission

 Sliding Mesh Gear box

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 Constant Mesh Gear box

 Synchromesh Gear box

 Automatic Transmission
 Semi-automatic (fluid coupling)
 Fully automatic

Figure 21: transfer case

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CHAPTER THREE

CONCLUSION AND RECOMMENDATION


3.1 Conclusion
During internship period, we successfully built on the foundations of classroom knowledge by
using the practical skills gained during our internship. We built on our knowledge of automotive
engineering on a detailed basis, successfully learning and acquiring the skills to maintain service
and diagnose vehicular problems. Besides the technical and practical skills and know gained, I
personally also gained the necessary work ethics and commitment that should make me
successful in the part of my life succeeding my graduation., I think I used the internship period
as a way to gaining real life experiences I couldn’t gain in the class room.

Generally, this internship is a good program of transmitting knowledge, improving practical


skill, upgrading theoretical knowledge, improving interpersonal communication skill, improving
team playing skills, improving leadership skills, understanding about work ethics related issue
and improving our entrepreneurship skills. Finally, this internship the best way to get
knowledge’s in multidirectional therefore this program should continue in the next generation.

3.2 Comment on the training


The overall objective of the Field Internship program is to enable students to practice necessary
skills that improve their abilities and to supply the public and private organizations with the
students that might fit their field of interest, skills, and training for possible future placement. In
addition, allow us the opportunity to apply our knowledge and skills in a professional setting
while still in school. It is also an excellent opportunity to see how the theories learned in classes
are integrated into the practical world.

In my view, the intern program is the essential thing for the student to involve with the working
world. I am totally changed after the internship regarding to

 Gains practical knowledge


 Career related experience
 Opportunity to explore career avenues

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 Upgrading practical skill


 Communication skill
 Valuable work experience for their resumes
 Potential to earn academic credit
 Increased self-confidence
 Enhances conventional classroom learning methods
 Letter of recommendation from departments supervisor

3.3 Recommendation
I recommend the company

 Have to fulfill safety to the workers specially dust cover for nose.
 Should arrange the layout, because of the workspace may happen hazard.
 Workers and the working tools are not balanced. They have to provide full tools for each
worker.
 Should give repair for machine, which is not functioning and give maintenance for the
machine, which is working.
 To install air sucker to suck the car smock b/c of the smock from the service room is very
dangers to the worker
 Finally, we recommend them they should manufacture the handy packer machine
inserting the grease to the wheel bearing.

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REFERENCE
1) Anne Winkle and Bonnie Hart, 4th edition, Report Writing Style Guide for Engineering
Students.
2) Nyala Motors Engineering, 2010, Maintenance Schedule for periodic services, Vol 1.

3) Nyala Motors Engineering, 2010, Maintenance Schedule for periodic services, Vol 2.

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APPENDIX
Appendix A
Table 4 Kilometers classification
Type of
Specific kilometers( in 1000Kms)
service
A 5,15,25,35,45,55,65,75,85,105,115,125,135,145,155,165,175,185,195
B 10,30,50,70,90,110,130,150,170,190
C 20,60,100,120,160,200
D 40,80,140,180

Appendix B
Table 5 Type A service activities

No Components to be checked or repair Maintenance code


1 Brake pad, disc and drums I
2 Steering pump I
3 Front and rear suspension I
4 Brake and clutch fluids I
5 Engine oil with filter R
6 Air cleaner element I
7 Fuel system/ Fuel lines I
8 Any external leakage I
9 Drive belts I
10 Drive shaft grease I
11 Tightening bolt and nuts I

KEY: - I= Inspect,
R= Replace

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Appendix C
Table 6 Type B Service activities

No Components to be checked or repair Maintenance code


1 Brake pad, disc and drums I
2 Steering links center arms I
3 Braking pedal I
4 Ball joint and dust cover I
5 Brake pipe and hoses I
6 Brake fluid I
7 Power steering fluid I
8 Engine oil with filter R
9 Fuel filter and lines R
10 Air cleaner element I
11 Spark plugs I
12 Oil and water leakage I
13 Front and rear suspension I
14 Battery and its connection I
15 All lights, horn, wiper and washer I

KEY: - I= Inspect
R= Replace

Appendix D
Table 7 Type C Service activities

No Components to be checked or repair Maintenance code


1 Brake pad, disc, drums and hand break cables I
2 Steering links center arms I
3 Valve clearance I
4 Spark plugs (gasoline) I

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5 Ball joint I
6 Brake, clutch and power steering oils I
7 Engine oil with filter R
8 Fuel filter (diesel) R
9 Air filter element ( diesel) R
10 Drive belt I
11 Air filter (gasoline) I
12 Front and rear suspension I
13 Differential oil I
14 Any external leakage I
15 Exhaust pipes and mountings I
16 Tighten bolt and nut I
17 Battery and battery connection I
18 All lights, horn, wiper and washer I

KEY: - I= Inspect
R= Replace

Appendix E
Table 8 Type D service activities

No Components to be checked or repair Maintenance code


1 Brake pad, disc, drums and hand break cables I
2 Steering knuckle I
3 Brake disc and drum I
4 Differential and gear oil R
5 Brake pedal I
6 Brake pipes and hoses I
7 Any external leakage I
8 Brake fluid, clutch fluid and power steering fluid R
9 Valve clearance I

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10 Engine oil with filter R


11 Fuel filter element R
12 Spark plugs (gasoline) R
13 Drive belts I
14 All lights, horn, wiper and washer I
15 Front and rear suspension I
16 Air filter elements (diesel) R
17 Radiator coolant I
18 Tighten all bolts and nuts. I
19 Battery and it’s connection I
20 Ball joints and bush I
21 Fuel line and connection (diesel) I

KEY: - I= Inspect
R= Replace

Part 2
Project

Design and Development of Hydraulic Bearing Puller and Pusher

ABSTRACT: Now a day’s hydraulic system plays very important role in almost all the
application in automobile industries, small service center, aircraft industries are used where
precision is required. Traditional method of bearing removal or installation is hammering but
unnecessary hammering causes several damages to the bearing as well as shaft due to which
chances of failure of bearing may possible. The modification is to give less human effort,
simplify the operation without damaging shaft and bearing. The hydraulic bearing puller and
pusher work on the principle of Pascal’s law.

KEYWORDS: Bearing puller, Bearing pusher, Pascal’s law, Hydraulic jack, Principle of
hydraulics, CAD model.

I. INTRODUCTION

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In hydraulic bearing puller and pusher is a special arrangement which will be attached to a
hydraulic jack, bearing clamp and shaft clamp respectively. First we use hydraulic jack. There
after the hydraulic jack is connected to the bearing clamp with the help of pusher arrangement.
Then the shaft clamp is attached with the help of stud rod which is connected to the jack plate. In
order to maintain geometrical precision and the surface integrity of ball and roller bearing
raceways and rolling elements , it is mandatory that care in storage , handling and installation be
observed. The hydraulic bearing puller and pusher perform both pulling and pushing operation
safely and without harming bearing surfaces. The Hydraulic Bearing Puller and Pusher was
developed by Rakesh Y. Suryawanshi in which [1] the machine is a arrangement of for removing
as well as installing bearing on the shaft. Hydraulic pulling consists of adjustable mechanical jaw
puller inbuilt with the hydraulic jack. When pump operated, plunger comes outside. Then
mechanical jaws adjusted bellow the bearing and again operate the pump.

II. OBJECTIVES

By using hydraulic bearing puller equal and consistent force is applied so that bearing can easily
removed from the shaft without damaging surface finish of the shaft. Same as in mounting the
bearing on the shaft in reverse fashion.

 Less human effort is required.


 Time is reduced.
 Bearing and shaft are not damage during mounting and removal.
 Overall production is increased.

III. DISCRIPTION

1. Hydraulics’:

The word hydraulics’ concerned with study of behaviour of water at rest and at motion i.e.
behaviour of liquids. Hydraulics’ includes properties, advantages and applications of liquids. The
two main scientists give the direction to forward, one is Daniel Bernoulli and another is Blasé
Pascal. Bernoulli's conducted an experiment on fluid flow and gives fluid flow equation to the
world and at same period Pascal developed science of hydraulics.

2. Pascal’s law :

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A1*F1 = A2*F2

Fig. 1 Pascal’s law [2]

Pascal's law (also Pascal's principle or the principle of transmission of fluid-pressure) is a


principle in fluid mechanics states that a pressure change occurring anywhere in a confined
incompressible fluid is transmitted throughout the fluid such that the same change occurs
everywhere. The law was established by French mathematician Blaise Pascal in 1647–48.

According to Pascal’s Law, Pressure or intensity of pressure at a point in a static fluid will be
equal in all directions. In order to understand how hydraulic system depends over Pascal’s law,
we will consider following case. As we can see in above figure, area A2 is larger as compared to
area A1 hence it will require less force to lift the heavy load.

3. Bearing installation and removal basics :

 Mechanical Removal, Installation And Methods


 Thermal Removal, Installation & Methods

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Figure :2 manual methode figure :3 termal methode

IV. WORKING AND DESIGN

Hydraulic puller and pusher perform both the operation i.e. removal of bearing and installation
respectively. Hydraulic pulling consists of bearing clamp with the hydraulic jack. When jack
operated, plunger comes outside. Then bearing clamp goes upward direction and bearing is
installed on shaft. During operation, hydraulic jack applies continuous pressure on shaft with the
help of pusher pin and remove bearing from shaft.

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2. Design Consideration:

 Load capacity of Hydraulic Jack (W) = 5 ton (50 KN)


 Operating Pressure (p) = 80 Kgf
 Lift Range (L) = 15 cm
 Man effort put on handle (e) = 20Kg
 Permissible tensile stress of mild steel (6t) = 120 N/mm2
 No. of stroke for lifting load (n) = 150
 Factor of safety = 5
 Permissible shear stress of mild steel (τ) = 20 N/mm2
 Permissible comp. stress of mild steel (6c) = 20 N/mm2
 Permissible comp. stress of cast iron (6c) = 120 N/mm2
 Permissible shear stress of cast iron (τ) = 35 N/mm2

Design of Hydraulic Jack: 1)

 The material of hydraulic jack is cast iron and having capacity of 5 ton. Material used for handle
and jack plate is mild steel.
 Outer diameter of jack (Do) = 50 mm
 Inner diameter of jack (Di) = 20 mm
 Oil capacity in reservoir at bottom of jack = 200 ml
 Handle attached to jack (l*b*t) = (280 mm*10 mm*8 mm)
 Vertical stud rod attach to both sides diagonally to the jack plate (l) = 500 mm

Design of bearing clamp: 2)

 Puller plate dimension (l*b*t) = (150 mm*90 mm*8 mm)


 Upper hole on bearing clamp = 52 mm
 boring height on bearing clamp = 5 mm
 Hole on bearing clamp = 25 mm

Design of Shaft Clamp: 3)

Material used for shaft clamp is mild steel. During pushing operation of bearing, shaft clamp
plays very important role i.e. to hold the shaft.

 Diameter of shaft ( D) = 50 mm

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 Shaft clamp Dimension (l*b*t) = ( 180 mm*90 mm*10 mm)


 Central hole on clamp plate of diameter = 50 mm
 slot on clamp plate for vertical stud of diameter = 36 mm
 Slot diameter = 12 mm

Design of pushing Arrangement: 4)

The material used for pusher is mild steel. Pusher is made like C frame having horizontal stripes
on which two vertical strips welded at the end of horizontal strips . The two horizontal loads
welded on vertical strips.

 Horizontal strip dimension ( l*b*t) = ( 150 mm*25 mm*8mm)


 Horizontal load strips dimension ( l*b*t) = ( 45 mm*28 mm*12mm)

Design of pusher pin 5)

The material used for pusher is mild steel it is use for puss shaft in bearing removing process.

 Diameter of pin (D) = 15 mm

V. CONCLUSION

In order to remove and installed bearing safely, to make modification in traditional method. The
modification made in installing and easy removing bearing. The purposes of modification are
Simplicity of operation, removing and installation of bearing done without damaging bearing
surface, compact, portable, well suited, low cost, Multifunctional ,safe ,versatile.

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