Graduation Internship Report

Liaoning Technical University
Undergraduate internship report

School of Mechanical Engineering
Internship name: Graduation Internship report

Profession: Student
Class: 3
Student name: Naqvi Syed Ali Zar
Student number: 20200430
Instructors: Li Jianhui
Mandate book
1. Internship tasks
a) Conduct research, collect data, and write literature reviews or research reports in combination with the
graduation project topic.
b) Corporate visits.
c) Technical talks.
2. Internship results and requirements
a) Literature review (research report), including (1) Introduction (background and related concepts).
(2) The main text (commentary). (3) Summary. (4) References.
b) 1 Copy of the internship report, including: (1) Overview of internship companies and products.
(2) Industry development status and regulations. (3) environment and sustainable development.
(4) Cost composition and project management.
3. Evaluation criteria
Serial Actual
Evaluate the content score
number score
Literature search, data search, and the use of modern
information technology tools such as computers and the
1 40
Internet to obtain information for the selected topics of the
graduation project.
Understand the implementation and implementation of
2 national and industry standards in machinery and related 20
fields in enterprises。
Mechanical design and manufacturing with an impact on
3 10
environmental and social sustainability.
Understand the cost structure of the product and analyze
4 30
the engineering management issues involved.
Score 100
Grade：（Five-stage) Instructors：

1. ABSTRACT
Industrial training is one of the requirements for the award of the Degree of Bachelor in
Mechanical Engineering. As such, students are required to write and submit reports at the end of
the training.
It consists of four chapters which altogether explain the objectives of industrial training, entail
background information about the institute, various activities carried out at the institute, general
overview of Motor Vehicle Technology, the hands-on activities and the skills acquired, challenges
faced, recommendations and conclusion.
Chapter one covers the objectives of industrial training, gives the background information about
DCVI including its core values, mission, vision, products and services provided and clientele.
Chapter two presents the general overview of Motor Vehicle Technology.
Chapter three entails all the practical activities undertaken at the workshop giving for each activity,
the different tools and equipment used, technical procedures followed, common faults, their causes
and remedies.
Chapter four covers the skills acquired, challenges faced, recommendations and conclusion.
ii
a. TABLE OF CONTENTS
1. ABSTRACT .......................................................................................................................................... ii
a. TABLE OF CONTENTS ................................................................................................................... iii
b. LIST OF TABLES .............................................................................................................................. ix
c. LIST OF FIGURES ........................................................................................................................... ix
d. LIST OF ACRONYMS USED .......................................................................................................... xi
CHAPTER ONE: GENERAL INTRODUCTION .................................................................................. 1
1.1 Background .............................................................................................................................................

1
1.2 Industrial training objectives ...................................................................................................................

1
1.2.1 General objectives ................................................................................................................................

1
1.2.2 Specific objectives ............................................................................................................................... 1
1.3 Background of Daniel Comboni Vocational Institute .............................................................................

1
1.3.1 Location of DCVI ................................................................................................................................ 2
1.3.2 Address of DCVI ................................................................................................................................. 2
1.3.3 Mission statement of DCVI ................................................................................................................. 2
1.3.4 Vision statement of DCVI.................................................................................................................... 2
1.3.5 Objectives of DCVI ............................................................................................................................. 2
1.3.6 Services offered by DCVI ....................................................................................................................

3
1.3.7 Clientele of DCVI ................................................................................................................................

3
1.3.8 Departments at DCVI .......................................................................................................................... 3

iii
1.3.9 The organizational structure of DCVI ................................................................................................. 4
1.3.10 The MVT Department ........................................................................................................................

6
1.3.11 The Motor Vehicle Workshop ........................................................................................................... 6
CHAPTER TWO: MOTOR VEHICLE TECHNOLOGY .....................................................................

7
2.1 Introduction .............................................................................................................................................

7
2.2 Vehicle Systems ...................................................................................................................................... 7
2.2.1 The Transmission System .................................................................................................................... 7
2.2.2 The Electrical System .......................................................................................................................... 8
2.2.3 The Fuel System .................................................................................................................................. 9
2.2.4 The Braking System ...........................................................................................................................

10
2.2.5 The Suspension System ..................................................................................................................... 11
2.2.6 The Steering System .......................................................................................................................... 14
2.2.7 The Intake and Exhaust Systems ....................................................................................................... 15
CHAPTER THREE: HANDS-ON ACTIVITIES CARRIED OUT .....................................................

18
3.1 Introduction ...........................................................................................................................................

18
3.2 Diagnosis and correction of failure of a car battery ..............................................................................

18
3.2.1 Common faults of the car battery, their causes and remedies ............................................................
18
3.2.2 Fault found with the battery ...............................................................................................................

19
iv
3.2.3 Tools and equipment used to recharge the battery .............................................................................
20
3.2.4 Technical procedures followed .......................................................................................................... 20
3.3 Replacement of water pump of a Cesspool truck.................................................................................. 20
3.3.1 Common faults with water pumps, their causes and remedies ..........................................................21
3.3.2 Fault found with the water pump .......................................................................................................23
3.3.3 Tools and equipment used to replace the pump .................................................................................24
3.3.4Technical procedures followed ...........................................................................................................24
3.4 Replacement of hydraulic oil of a FAW truck

...................................................................................... 25
3.4.1 Dangers involved in working with hydraulic fluids

........................................................................... 25
3.4.2 Safety precautions when dealing with hydraulic fluids

..................................................................... 26
3.4.3 Common faults with the hydraulic system

......................................................................................... 27
3.4.4 Solutions to the common faults

.......................................................................................................... 27
3.4.5 Recommendations on hydraulic systems

........................................................................................... 29
3.4.6 Faults found with the hydraulic oil

.................................................................................................... 29
3.4.7 Tools and equipment used to replace the hydraulic oil

...................................................................... 29
3.4.8 Technical procedures followed

.......................................................................................................... 29
3.5 Replacement of leaf springs of a FAW truck

........................................................................................ 30
3.5.1 Functions of the suspension of the vehicle

........................................................................................ 31
v
3.5.2 The purpose of leaf springs
................................................................................................................ 31
3.5.3 Maintenance of leaf springs

............................................................................................................... 31
3.5.4 Fault found with the leaf

springs........................................................................................................ 31
3.5.5 Safety precautions while replacing leaf springs

................................................................................. 31
3.5.6 Tools and equipment used to replace the leaf springs

........................................................................ 32
3.5.7 Technical procedures followed to replace the leaf springs

................................................................ 32
3.6 Replacement of a tire of a garbage truck

.............................................................................................. 34
3.6.1 Common tire problems and their solutions

........................................................................................ 34
3.6.2 Minimizing tire problems

.................................................................................................................. 34
3.6.3 Fault found with the tire

.....................................................................................................................35
3.6.4 Safety procedures while replacing tires

.............................................................................................35
3.6.5 Tools and equipment used to replace the tire

.....................................................................................36

..........................................................................................................36
3.7 Troubleshooting starter motor of a Toyota Pick-up

.............................................................................. 37
3.7.1 Common symptoms of a failing or bad Starter, their causes and remedies
....................................... 37
vi
3.7.2 Safety procedures while troubleshooting a starter motor
................................................................... 38
3.7.3 Tools and equipment

used.................................................................................................................. 39

.......................................................................................................... 39
3.7.5 Testing the starter

............................................................................................................................... 39
3.8 Adjusting the clutch of a garbage truck

................................................................................................ 40
3.8.1 Common faults with the clutch system, their causes and remedies
................................................... 40
3.8.2 Faults found with the clutch system

................................................................................................... 42
3.8.3Tools and equipment used to adjust the clutch ................................................................................... 43
3.9 Panel beating a Pajero Shogun ..............................................................................................................

45
3.9.1Reasons for the operation ....................................................................................................................

45
3.9.2 Tools and equipment used.................................................................................................................. 45
3.9.3 Safety precautions for the operation .................................................................................................. 45
CHAPTER FOUR: SKILLS ACQUIRED, CHALLENGES FACED RECOMMENDATIONS AND

CONCLUSION ......................................................................................................................................... 48
4.1 Introduction ...........................................................................................................................................

48
4.2 Experience gained/achievements from the training ..............................................................................48
vii
4.3 Challenges faced during the training ....................................................................................................48
4.4 Recommendations .................................................................................................................................50
4.5 Conclusion ............................................................................................................................................50
REFERENCES ..........................................................................................................................................
51
viii
b. LIST OF TABLES
Table 1: DCVI Departments and their mandates ............................................................................ 4
Table 2: Water pump troubleshooting chart ................................................................................. 21
Table 3: Clutch diagnosis/troubleshooting chart .......................................................................... 41

c. LIST OF FIGURES
Figure 1: Organizational Structure of DCVI .................................................................................................

5
Figure 2: Organizational Structure of the MVT Department ........................................................................

6
Figure 3: The Transmission System..............................................................................................................

7
Figure 4: The Electrical System ....................................................................................................................

8
Figure 5: The Fuel System ..........................................................................................................................

10
Figure 6: The Braking System ....................................................................................................................

11
Figure 7: The Suspension System ...............................................................................................................

12
Figure 8: The Front Suspension System .....................................................................................................

13
Figure 9: The Rear Suspension System ......................................................................................................

14
Figure 10: The Steering System ..................................................................................................................

15
Figure 11: The Intake System .....................................................................................................................

16
ix
Figure 12: The Exhaust System ..................................................................................................................
17
Figure 13: Recharging the battery ...............................................................................................................

20
Figure 14: The removed water pump ..........................................................................................................

24
Figure 15: The unit that houses the water pump .........................................................................................
25
Figure 16: Draining the hydraulic oil ..........................................................................................................

30
Figure 17: Removing the broken leaf springs .............................................................................................

33
Figure 18: The broken leaf springs that were removed...............................................................................

33
Figure 19: Removing the tire ......................................................................................................................

37
Figure 20: Testing the voltage being received by the starter ......................................................................
39
Figure 21: The opened clutch system .........................................................................................................

44 Figure 22: The removed pressure and clutch plates
.................................................................................... 44
Figure 23: Sanding using smooth sand paper 500 ......................................................................................

47
Figure 24: Covering the parts that were not supposed to be sprayed ..........................................................
47
x
d. LIST OF ACRONYMS USED
ABS Antilock Brake System

AC Alternating Current
BCP Building & Concrete Practice
BOG Board of Governors
C&J Carpentry & Joinery
DCVI Daniel Comboni Vocational Institute
DIT Directorate of Industrial Training
E.I Electrical Installation
EU European Union
Fr Father
H.E His Excellency
km Kilometer
kpa kilopascal
MECP Mechanical Engineering Craft Practices
MoE&S Ministry of Education and Sports
MVT Motor Vehicle Technology
NEMA National Environment Management Authority
NGOs Non-Governmental Organizations
NOA Non-Asbestos
P.O Post Office
PPE Personal Protective Equipment
RD Road
REG. NO. Registration Number
Rev Reverend
STUDENT. NO. Student Number
UBTEB Uganda Business & Technical Examinations Board
UPDF Uganda People’s Defense Forces
xi
CHAPTER ONE: GENERAL INTRODUCTION
a. 1.1 Background
Industrial attachment is an industrial based practical training experience that prepares students for the tasks
they are expected to perform on completion of their training.
b. 1.2 Industrial training objectives

The university through its industrial training program aims at achieving a number of objectives and these
include the following;
c. 1.2.1 General objectives

To produce practical oriented graduates that meet the required job-related competences of their future
employers.
To serve as a go-between the University and the various partners who consume services and/or products of
the University.
d. 1.2.2 Specific objectives

To enable students get hands-on experience in real-life situations they are expected to work in when they
graduate.
To provide an opportunity for students to apply the principles and techniques theoretically learnt into real-
life problem-solving situations.
To provide an opportunity for students and academic staff to interact with stakeholders and potential
employers to appreciate industrial situations that will also generate information for curricula review and
improvement.
To develop an understanding of work ethics, employment demands, responsibilities and opportunities.
To enable students to bridge the gap between the theories studied in class and the practical part of the
theory.
e. 1.3 Background of Daniel Comboni Vocational Institute

Daniel Comboni Vocational Institute (DCVI) is a mixed day school with limited accommodation facilities
for students. It was founded in 1995 by the Comboni Missionaries as a private institution, in line with the
government policies and academic directives of the Ministry of Education and Sports (MoE&S). DCVI was
started in response to the needs of the local population. In spite of the troubles and insecurity at the time, it
was hoped that the Institute would be a tremendous contribution to the local population’s hopes and
legitimate aspirations to peace. The Institute aspires and hopes to provide advanced Vocational skills and
12
knowledge to technicians and craftsmen / women to meet the growing demands for skilled workers in the
public and private sectors, which is a good tool to fight poverty, hunger and neglect.
It is a registered institution and is a centre for Uganda Business & Technical Examinations Board
(UBTEB) and Directorate of Industrial Training (DIT) of the Ministry of Education and Sports.
DCVI offers five courses of two years each leading to the award of National, craft and Advanced
certificates. They are: Motor Vehicle Technology (MVT), Electrical Installation (E.I), Carpentry &
Joinery (C&J), Building and Concrete Practice (BCP) and Mechanical Engineering Craft Practices
(MECP).
1.3.1 Location of DCVI
DCVI is located in Layibi village, Techo parish, Layibi Division, Gulu Municipality on plot 61/95 Daniel
Comboni Road, 600m off Juba Road.
Email: info@combonivocational.ac.ug
Website: www.combonivocational.ac.ug
f. 1.3.3 Mission statement of DCVI
To provide advanced skills and knowledge to technicians and craftsmen and women to meet the growing
demands for skilled workers in both the public and private sectors.
1.3.4 Vision statement of DCVI

Promotion of skill-based training for self-employment.
g. 1.3.5 Objectives of DCVI

To provide technical training so as to create competent craftsmen/women and technicians.
To provide scientific, mathematical and humanitarian foundation to enable students competently handle the
technical aspects of their trades.
To create self-reliant citizens thus becoming job creators and not job seekers.
To allow young Ugandans of different religions acquire training and professional knowledge in the available
technical trades.
To equip students with communication skills that facilitates effective knowledge sharing and transfer.
To make students responsible and conscious of their roles in creating and developing the Christian society.
13
h. 1.3.6 Services offered by DCVI
The services are provided via the Production unit. The institute, through the Production unit, which is made
up of all the departments, provides services such as Repair of Customers' Vehicles, fabrication of metal
products such as doors and windows gates, among others, making of furniture out of timber for customers,
Construction of buildings, Electrical Wiring and Repair of electric motors and generators among others.
Other services in the related fields are also available.
i. 1.3.7 Clientele of DCVI

The clientele of DCVI include among others; the general public, Toyota Gulu, Gulu Archdiocese
institutions, the government of the Republic of Uganda, politicians, schools, hotels, business entities,
Government ministries, mobile service providers and telecommunication companies, UMEME, Bank of
Uganda and all other financial institutions operating within Gulu and neighboring areas, Non-Governmental
Organizations (NGOs) operating within Gulu and neighboring areas, Tourists, Health centers and hospitals,
Security institutions like the UPDF, Uganda Police, Uganda Prison and many others.
j. 1.3.8 Departments at DCVI

DCVI is made up of five Departments which altogether form the Production Unit, through which the
services of the institution are provided to its clientele. The departments and their respective mandates are
presented in Table 1 below.
DEPARTMENT MANDATE
Mechanical Engineering Craft Practices (MECP) Responsible for machining works using lathe,
milling, grinding, drilling, hydraulic press, and
shaping machines, welding and fabrication
works, and roofing among others: both within
and outside the institute.
Carpentry and Joinery (C&J) Deals in furniture like chairs, tables, doors, door
frames, cupboards, wooden beds, windows and
window frames among others.
Building and Concrete Practice (BCP) Deals in general building and construction
works and construction
materials like cement and bricks among others.
Motor Vehicle Technology (MVT) Responsible for maintenance of automobiles and

equipment like vehicles, graders, rollers,
tractors, caterpillars among others and general
automotive works.
Electrical Installation (E.I) Electrical installation works, repair and
maintenance of electrical appliances like radios,
screens, phones, cameras, refrigerators and
14
others, solar installation works, motor rewinding
and servicing, transformer rewinding and
servicing, and general electrical works both
within and outside the institute/
Table 1: DCVI Departments and their mandates
1.3.9 The organizational structure of DCVI

The institute has a Board of Governors (BOG) which meets regularly on policy issues, reviews narrative
and financial reports from the Institute’s Administration and approves yearly budget. The Administration is
headed by the Director and the Deputy Director and the Personnel
Coordinator. The three officers form the Management Committee; other members of staff in the
Administration include the Financial Assistant, Accountant, two Secretaries, Cashier and Office Assistant.
In the training area, each trade has a Head of Department; these include MECP, E.I, MVT, C&J and BCP
Departments.
Each of the above departments has teachers and support staff. The list of teachers also includes part-time
teachers for general subjects such as Entrepreneurship and English. Production Units as well have their
Heads of Departments and support staff. The above set-up constitutes the whole team of the work force in
DCVI.
The organizational structure of DCVI is as shown in Figure 1 below. During my internship, I was assigned
to the MVT Department which is under the Production Unit together with the other Departments. A
description of the activities carried out in this Department is given in section 1.3.10 of this report.
15
BOARD OF GOVERNORS
DIRECTOR
MANAGEMENT COMMITTEE
DEPUTY DIRECTOR PERSONNEL COODINATOR
HEADS OF TRAINING EXAMINATIONS FINANCIAL ASSISTANT

DEPARTMENTS SECRETARY
TEACHERS
SECRETARY ACCOUNTANT
PRODUCTION STORE
UNITS
SUPPORT
CASHIER
SUPPORT STAFF
SUPPORT STAFF
APPRENCTICE
STUDENTS DRIVER
SECURITY
KITCHEN STAFF
Figure 1: Organizational Structure of DCVI

k. 1.3.10 The MVT Department
The Department is responsible for maintenance of automobiles and equipment like vehicles, graders, rollers,
tractors, caterpillars among others and general automotive works.
At DCVI, interns are attached to the different Departments on the basis of the respective courses they
pursue. The Departments then design training programs for them. Mechanical Engineering interns are
attached to the MVT and/or MECP Departments. As such, I was attached to the MVT Department. Its
organizational structure is shown in Figure 2 below.
16
Head of Department
Motor Vehicle Technicians
Support Staff
Figure 2: Organizational Structure of the MVT Department
l. 1.3.11 The Motor Vehicle Workshop

This is the referral workshop for all auto-mobiles of DCVI and Gulu Archdiocese institutions. Vehicles and
equipment from Gulu Municipality and neighboring areas are also serviced here. It is thus responsible for
maintaining and ensuring that they are all in good mechanical and electrical working conditions. It is
located within the institute.
A number of activities are carried out in this workshop with an aim of keeping the motor vehicles and
equipment in good operating conditions. Some of these activities include; Engine overhaul, gear box
overhaul, auto-body repair, general servicing and minor repairs among others. All the activities are carried
out by experienced auto-mechanics and electricians who are wellversed with the motor vehicle internal and
external systems.
The fleet of the workshop consists of tractors, construction equipment, service vehicles, managerial vehicles
and Executive vehicles. They total up to approximately 220 in number. While training at the workshop, I
engaged in very many activities as exhaustively explained in chapter three.
CHAPTER TWO: MOTOR VEHICLE TECHNOLOGY
m. 2.1 Introduction
A motor vehicle is a self-propelled road vehicle or off-road vehicle, commonly wheeled, that does not
operate on rails, such as trains or trams and used for the transportation of passengers, or passengers and
property. The vehicle propulsion is provided by an engine or motor, usually by an internal combustion
engine, or an electric motor, or some combination of the two, such as hybrid electric vehicles and plug-in
hybrids.
17
n. 2.2 Vehicle Systems
An automobile is the result of combined work of a number of systems. Each system, though primarily
independent, is influenced by the effect of other systems interacting with it. The different systems are given
below.
o. 2.2.1 The Transmission System

Transmission system in a car helps to transmit mechanical power from the car engine to give kinetic energy
to the wheels. It is an interconnected system of gears, shafts, and other electrical gadgets that form a bridge
to transfer power and energy from the engine to the wheels. The complete set up of the system, shown in
Figure 3 below, helps to maintain the cruising speed of the car without any disturbance to the car’s
performance.
Figure 3: The Transmission System

Link to the image: (http://usciencecompendium.blogspot.com/2014/12/automobile-transmission-systempart-1.html)
p. 2.2.2 The Electrical System

The electrical system, shown in Figure 4 below, consists of the battery, starter and alternator. The battery
provides juice to the starter. Then, the alternator gives that battery the energy it needs to power the car. If one of
these parts is not working properly, the car won’t start or run correctly. a Battery
Until your vehicle starts, the battery provides the car’s entire electrical current. This includes the current to the
ignition and fuel systems, which are responsible for creating the combustion necessary for the engine to function.
18
e. b Starter
While the battery supplies the power to start the vehicle, the starter is really what gets the engine going. The
battery supplies a small amount of power to the starter motor. The starter then rotates the flywheel, which turns
the crankshaft and begins the movement of the engine’s pistons. This intricate process is why it’s key to make
sure the starter works. c Alternator
When the engine is running, the alternator keeps the battery charged and the electrical system going.
The car can start with a faulty alternator, but it won’t be able to run for an extended period of time. If the
alternator requires replacement, the vehicle’s electrical system will perform erratically, its battery will discharge,
and eventually the engine will lose power.
Figure 4: The Electrical System

Link to the image: (https://repairpal.com/electrical-lights)
q. 2.2.3 The Fuel System

All internal combustion engines need three things to run:-Air, Fuel and Spark. The fuel system is critical in
storing and delivering the gasoline or diesel fuel the engine needs to run. The fuel system has the following
components:-fuel pump, fuel lines and filter as shown in Figure 5 below. A failure in any of these fuel system
components has devastating effects on the car.
f. a Fuel tank
This is basically a holding tank for the fuel. When you fill up at a gas station, the gas travels down the filler
tube and into the tank. In the tank there is a sending unit which tells the gas gauge how much gas is in the
tank. In recent years the gas tank has become a little more complicated, as it now often houses the fuel
pump and has more emissions controls to prevent vapors leaking into the air.
19
g. b Fuel pump
On newer cars the fuel pump is usually installed in the fuel tank. Older cars have the fuel pump attached to
the engine or on the frame rail between the tank and the engine. If the pump is in the tank or on the frame
rail, then it is electric and is run by the car’s battery. Fuel pumps mounted to the engine use the motion of
the engine to pump the fuel, most often being driven by the camshaft, but sometimes the crankshaft.
h. c Fuel filter
Clean fuel is critical to engine life and performance. Fuel injectors and carburetors have tiny openings
which clog easily so filtering the fuel is a necessity. Filters can be before or after the fuel pump, sometimes
both. They are most often made from a paper element, but can be stainless steel or synthetic material and
are designed to be disposable in most cases. Some performance fuel filters will have a washable mesh,
which eliminates the need for replacement.
i. d Fuel injectors
The fuel injector is basically a tiny electric valve which opens and closes with an electric signal. By
injecting the fuel close to the cylinder head, the fuel stays atomized (in tiny particles) so it will burn better
when ignited by the spark plug.
j. e Carburetors
A carburetor takes the fuel and mixes it with air. While simple in operation, they tend to need frequent
tuning and rebuilding. This is why newer cars have done away with carburetors in favor of fuel injection
20
Figure 5: The Fuel System
Link to the image: (http://www.xpertechautorepair.com/fuel_injection.html)
r. 2.2.4 The Braking System

The Vehicle’s braking system, shown in Figure 6 below, is designed to perform only one job and that is to
safely stop the vehicle. In order to achieve that, there are three key things needed:- a vehicle operator,
hydraulic pressure and friction. When the vehicle operator pushes the brake pedal down, the pedal levers
and rods actuate the power brake booster. The booster uses engine vacuum or a pump to multiply the force
from the operator’s foot to the master cylinder. Hydraulic lines connected to the master cylinder go out to a
proportioning valve or to the ABS (Antilock Brake System) module then to each either brake caliper if the
vehicle has disc brakes or to wheel cylinder if it has drum brakes. The brake fluid in the lines flows into the
calipers or wheel cylinders and the hydraulic pressure pushes the brake pads against the rotors of brake
shoes against the drums causing friction which stops the vehicle. a Disc Brakes
A disk brake system consists of a brake disk, a brake caliper and brake pads. When the brake pedal is
applied, pressurized hydraulic brake fluid squeezes the brake pad friction material against the surface of the
rotating brake disc. The result of this contact produces friction which enables the vehicle to slow down or
stop.
k. b Drum brakes
21
A drum brake system consists of hydraulic wheel cylinders, brake shoes and a brake drum. When the brake
pedal is applied the two curved brake shoes, which have a friction material lining, are forced by hydraulic
wheel cylinders against the inner surface of a rotation brake drum. The result of this contact produces
frictions which enables the vehicle to slow down or stop.
Figure 6: The Braking System

Link to the image: (https://www.pinterest.com/pin/360076932694018134/)
s. 2.2.5 The Suspension System

Suspension is the system of tires, tire air, springs, shock absorbers and linkages that connects a vehicle to its
wheels and allows relative motion between the two. Suspension systems serve a dual purpose:-contributing
to the vehicle's road-holding/handling and braking for good active safety and driving pleasure, and keeping
vehicle occupants comfortable and reasonably well isolated from road noise, bumps, and vibrations. The
suspension also protects the vehicle itself and any cargo or luggage from damage and wear. The design of
front and rear suspension of a car may be different. The suspension system of the motor vehicle, shown in Figure
7 below, is divided into front suspension and rear suspension.
22
Figure 7: The
Suspension
System
Link to the
image:
(http://www.avgnewton.com/suspension.html)
l. a The Front Suspension System
The purpose of the front suspension is to support the weight of the vehicle. Automobiles commonly use
independent front suspension whereby if one of the tires moves over a bump, the other will not be affected.
The front suspension, shown in Figure 8 below, is mainly composed of the following; ball joints, control
arms, shaft bushings, coil springs, stabilizers, shock absorbers, steering knuckle and spindle.
23
Figure 8: The Front Suspension System
Link to the image: (http://eramandeepbansal.blogspot.ug/2013/08/front-wheel-

suspensionsystem.html)
m. b The Rear Suspension System
The rear suspension system is designed to keep the rear axle and the wheels in their proper position under
the car body. The rear suspension allows, shown in Figure 9 below, each of the rear wheels to move up and
down independent of the frame so as to maintain alignment and good vehicle control. The main components
include leaf springs which are used to dampen noise and vibrations from the road to the frame of the
vehicle, and shock absorbers which are hydraulic device that help to control the up, down and rolling of the
car body
24
Figure 9: The Rear Suspension System
Link to the image:
(http://arrc.ebscohost.com/ebsco_static/repairtips/8852CH23_Rear_Suspensions.htm)
t. 2.2.6 The Steering System

The steering system, shown in Figure 10 below, converts the rotation of the steering wheel into a swiveling
movement of the road wheels in such a way that the steering-wheel rim turns a long way to move the road
wheels a short way. There are two steering systems in common use - the rack and pinion and the steering
box. On large cars, either system may be power assisted to reduce further the effort needed to move it, especially
when the car is moving slowly.
n. a The rack-and-pinion system

At the base of the steering column there is a small pinion (gear wheel) inside a housing. Its teeth mesh with
a straight row of teeth on a rack - a long transverse bar. Turning the pinion makes the rack move from side
to side. The ends of the rack are coupled to the road wheels by track rods. This system is simple, with few
moving parts to become worn or displaced, so its action is precise. A universal joint in the steering column
allows it to connect with the rack without angling the steering wheel awkwardly sideways.
25
o. b The steering-box system
At the base of the steering column there is a worm gear inside a box. A worm is a threaded cylinder like a
short bolt. Imagine turning a bolt which holding a nut on it; the nut would move along the bolt. In the same
way, turning the worm moves anything fitted into its thread. Depending on the design, the moving part may
be a sector (like a slice of a gear wheel), a peg or a roller connected to a fork, or a large nut.
The nut system has hardened balls running inside the thread between the worm and the nut. As the nut
moves, the balls roll out into a tube that takes them back to the start; it is called a recirculating-ball system.
The worm moves a drop arm linked by a track rod to a steering arm that moves the nearest front wheel. In
recirculating-ball steering, the thread between the worm and nut is filled with balls.
Figure 10: The Steering System

Link to the image: (https://repairpal.com/suspension-steering)
u. 2.2.7 The Intake and Exhaust Systems

Combustion requires air, fuel, and heat; certain ratios of all three are necessary if an engine is to operate.
The purpose of the exhaust and intake processes is to remove the burned gases at the end of the power
stroke and admit fresh charge for the next cycle.
p. a Intake System
The intake system’s job is to regulate the flow of clean, filtered air at the right temperature to the engine and
to provide vacuum to operate other devices. Most factory intake systems are designed to generate as little
noise as possible. The intake system, shown in Figure 11 below, also pulls crankcase vapors into the intake
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stream so the engine can burn them. Older carbureted engines do not have much of intake system. Usually
just an air filter mounted on top of the carburetor, which is mounted on the intake manifold, is enough for
those engines. Modern day vehicles have much more intake plumbing to accommodate smaller engine bays
which have much technology more packed into them.
Figure 11: The Intake System

Link to the image: (https://www.coolcaraircon.co.uk/how-car-air-conditioning-works/) b The Exhaust
System
The exhaust system, shown in Figure 12 below, is an assembly in a vehicle's engine that takes care of the
burnt gas that the engine produces. It consists of exhaust pipes, through which exhaust gas flow through
from one chamber to another, a header, which collects the same gas from different cylinders and directs it to
the pipes, a catalytic converter, which converts the pollutant gases produced during combustion into less
harmful substances, a muffler, which reduces engine noise, and a turbocharger, which increases engine
power. The exhaust system is vital to any vehicle because the life and performance of the vehicle's engine
depends on it. An engine cannot function well if there is back pressure trapped in it. Trapped exhaust gas
chokes an engine and stops it from doing productive work. As a result, the vehicle cannot run smoothly and
silently, or in the worst cases, will not run at all.
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Figure 12: The Exhaust System
Link to the image: (https://mechanicalserviceswi.com/auto-repair/exhaust-system) CHAPTER
THREE: HANDS-ON ACTIVITIES CARRIED OUT
v. 3.1 Introduction
During my training at DCVI, I participated in different practical activities where I applied the theoretical
knowledge and skills acquired in class into real world problem solving situations. The activities included
among others; Clutch adjustment, diagnosis and correction of battery failure, tire replacement, diagnosis and
correction of power steering faults of a car and replacement of hydraulic oil of a truck. They are detailed
below.
w. 3.2 Diagnosis and correction of failure of a car battery

Battery failure is often reported and is one of the major causes of vehicle breakdowns. With modern
vehicles full of complex and sensitive electrical equipment that constantly draw current from the battery, an
ever-increasing number of mechanical faults from new and older vehicles alike are battery related.
However, the expense and inconvenience of battery failure could be heavily reduced by regular battery
maintenance. Figure 13 below shows the operation.
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x. 3.2.1 Common faults of the car battery, their causes and remedies
The following are the common faults associated with the car battery; their causes and corrections.
q. a Low charge
This is caused by leaving the battery in uncharged condition for a long time and also when battery usage
exceeds battery capacity.
Solution: The best solution for this problem is to recharge the battery. A jump start as well as a trickle
charger can be used for this operation. A trickle charger is most commonly used. It delivers electricity to the
battery from a power outlet in a slow, steady stream. It has an electric cord with a plug and two jumper
cables with alligator clips.
r. b Sulphation
If the battery is allowed to stand in a discharged state either on or off the vehicle for a long period of time, a
chemical reaction takes place which permanently impairs the performance and life of the battery. It can be
seen as a fine white/grey coating of the positive plate. This is called Sulphation.
Solution: Clean the battery terminal.
s. c Wear and tear due to ageing

As the battery is charging and discharging, the active materials within the battery plates are in motion in
order to release electricity stored by the battery. This leads to the wear and tear of the battery when used for
a long period of time.
t. Remedy: Replace the battery. d
Incorrect application
This is when the battery is not correctly applied or installed. Therefore, it cannot function properly on the
vehicle.
Remedy: Ensure that the correct battery in the right condition has been used in the right application.
u. e Low acid stratification
This is when the electrolyte on the stratified battery concentrates on the bottom causing the upper half of the
battery to be poor. Remedy: Replace the electrolyte.
v. f Low acid level
This is when the level of the acid in the battery is not enough as required.
Remedy: Refill the battery to required level.
w. g Slipping
This occurs due to incorrectly adjusted alternator charging the belt.
Remedy: Adjust the alternator to required recommendations.
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x. h Overcharging
If the alternator regulator is not set properly, an alternator voltage control circuit fails. Then the battery can
be subjected to an excessive charge. If left unchecked for a long time, the battery will overheat and will start
to evaporate the electrolyte.
Remedy: Replace regulator with another.
y. i Electrical faults
These are caused by excessive use of electric consumers for example air conditioning, long standing time
without recharge, vehicle lightings and hazard flashers left on.
Remedy: Recharge the battery; lightings and flashers should not be left on.
y. 3.2.2 Fault found with the battery
After the diagnosis, it was found that the battery had low charge. The problem was corrected by recharging
the battery.
z. 3.2.3 Tools and equipment used to recharge the battery

The following tools were used to recharge the battery; Trickle charger, Power stroke, Manual sand paper
pad and a pair of pliers.
aa. 3.2.4 Technical procedures followed
The following procedures were followed to recharge the battery;
a. The battery terminals were checked and cleaned using a manual sand paper.
b. The cell caps were removed.
c. The charger cables were attached with the car turned off.
d. The charger was turned on for the battery to charge itself.
e. The battery was checked to find out whether it worked after charging and it functioned
properly.
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Figure 13: Recharging the battery
bb. 3.3 Replacement of water pump of a Cesspool truck
The engine of a vehicle needs coolant just as much as it needs oil. Engine coolant helps protect against high
heat. It is cycled from the radiator throughout the engine, absorbing heat from engine operation and then
allowing that heat to wick away into the atmosphere at the Radiator.
The water pump is the key to making the entire system work. It is an impeller pump, buried under the
timing belt cover on the side of the engine. The pump is operated by the drive belt of the engine – as the belt
turns, the pump turns. Blades on the pump force the coolant to flow through the engine. Figures 14 and 15
below show the operation.
When the water pump fails or is beginning to wear out, it can lead to complete engine failure. The water
pump is the key to making the entire system work. Like any other mechanical device, they will produce a
few warning signs that they are wearing out.
cc. 3.3.1 Common faults with water pumps, their causes and remedies
Table 2 below shows the common faults with water pump, their causes and remedies. The water pump
experiences many faults.
z. Table 2: Water pump troubleshooting chart

FAULT POSSIBLE CAUSE REMEDY
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Weep-hole leakage. Appearance:
The internal mechanical seal of the
pump seals the shaft towards the
cooling circuit, protecting the
bearings by preventing coolant from
Thoroughly flush the cooling system
passing into the bearing assembly.
before installing the new pump and
When a water pump is new, someContaminated coolant is the main
refill the system with the
seepage from the weep hole is cause of weep hole
recommended coolant of the
normal as it takes about ten minutes
leakage
manufacturer of the vehicle
of operation for the mechanical seal
to properly seat itself (break-in
period). More pronounced seepage
and drips from the weep hole after
this break-in period or a large
coolant bleed mark around the weep
hole are abnormal and indicate
impending water pump failure.
Leakage from the mounting surface.

Improper water pump installationInorcase of a recently installed new
improper use of the seals/gaskets water
or pump, carefully remove,
Appearance: Seepage drips or large
sealant. check and reinstall the water pump.
coolant bleeds marks on or around
the mounting surface or on the
housing.
Rust and corrosion. Contaminated coolant, Replace the water pump.

noncompatible coolant or mixing
Appearance: Rust and corrosion on Thoroughly flush the cooling system
coolants of different chemistries.
the surfaces of the water pump, for before installing the new water
example corrosion of the impellerAnother possible cause may be a pump and refill the system with the
fins makes the pump ineffective in
defective pressure cap causing airrecommended coolant of the
moving the coolant. bubbles, accelerating the rust manufacturer of the vehicle.
process.
Inspect the pressure cap and replace
if defective
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Deposit build-up. Contaminated coolant, Replace the water pump.
noncompatible coolant or mixing
Appearance: Deposits, sludge and Thoroughly flush the cooling system
coolants of different chemistries.
scale build up on the inside, before installing the new pump and
clogging the water pump and refill the system with the correct
hampering proper functioning of its vehicle manufacturer’s
individual components. recommended coolant
Cavitation. Replace the water pump.

The formation of bubbles at the coolant
inlet of the pump. As the pressure Thoroughly flush the cooling system
Appearance: Vapor cavities increases in the system, the bubbles before installing the new pump and
(bubbles) in the coolant collapse implode cause harm.
refill the system with the correct
with explosive force, pock marking
vehicle manufacturer’s
the individual components of the
recommended coolant
pump. The pockmarked areas then
corrode away.
Damaged bearing. Misaligned belt causes excessive Replace the water pump and make
wear. An overtensioned belt causes
sure to inspect the belt drive system:
Appearance: With the engine off,
overload on the bearing, accelerating
belt, tensioner, pulleys, belt tension
check the condition of the bearing
wear. A damaged mechanical sealand alignment.
by looking for any side-to-side play
allows coolant to leak through the
at the shaft. Apply hand pressure –
bearings and wash away the
there should be no play at all. Also,
lubricator.
rumbling or screeching noises
coming from the water pump
indicate a worn bearing.
Damaged or broken shaft. A misaligned belt causes excessive

Replace the water pump and make
Appearance: The shaft is bent or wear. An overtensioned belt imposes
sure to inspect the belt drive system:
broken. A clean break indicates ana powerful bending force on the belt, tensioner, pulleys, belt tension
instantaneous and
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fracture caused by sudden overloadshaft resulting in shaft bending oralignment.
early shaft fracture.
or imbalance. If the broken shaft is
If equipped with a water pump
discolored (usually blue), the
Excessive vibrations due to lack ofmounted fan, inspect the fan or fan
damage was gradual, indicating
maintenance. clutch assembly. The fan may not be
excessive heat build-up before the
squarely mounted on the shaft. A
shaft broke.
bent or damaged fan, a worn spacer,
or a worn or damaged fan clutch
could also be factors contributing to
the break.
Thoroughly flush a contaminated

system before replacing the water
pump.
Seal leakage-dirty system Cooling system contamination Check the system pressure.
Use correct coolant mixture. Use
distilled water where necessary.
Carefully inspect pulley, belt

alignment and fan/fan clutch
Casting breakage Excessive vibration
assembly, replacing any bent or
worn components.
Take proper precautions when filling
your radiator, especially when the
engine may be very hot.
Allow an overhead engine to sit and
cool before adding coolant.
Seal leakage-clean system. Thermal shock Then restart engine and allow it to
run while slowly adding the
remainder.
Never start the engine without
coolant.
dd. 3.3.2 Fault found with the water pump

The water pump was worn out which could lead to complete engine failure. This prompted its replacement.
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ee. 3.3.3 Tools and equipment used to replace the pump
A new water pump, ring spanner, box spanner, combination spanner and an adjustable spanner.
aa. 3.3.4Technical procedures followed
a. The radiator was drained by opening the petcock valve at the bottom of the radiator. This was done when
the engine was cold.
b. The fan belt was removed, carefully noting how it was routed before removing it in order to reinstall it
correctly afterwards.
c. Any other accessories that were blocking access to the pump were removed. This included the fan, fan
shroud, timing belt cover, or any brackets.
d. The water pump was unbolted from the engine.
e. The pump mounting surface was cleaned to remove all traces of old gaskets. The mounting surface must be
clean and dry before installing the new pump.
f. The gasket was positioned on the new pump using gasket sealer or adhesive as required, and then the new
water pump was bolted to the engine.
g. The cooling system was refilled.
Figure 14: The removed water pump
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bb. Figure 15: The unit that houses the water pump
ff. 3.4 Replacement of hydraulic oil of a FAW truck

Hydraulic fluid is the medium by which power is transferred in hydraulic machinery. Common
hydraulic fluids are based on mineral oil or water mineral oils, synthetic fluids and fire-resistant fluids.
The primary function of a hydraulic fluid is to convey power from one point to another. There are other
important functions of hydraulic fluid such as protection of the hydraulic machine components,
lubrication of system components, transfer and dissipation of heat, and provision of a seal to maintain
pressure.
Examples of equipment that use hydraulic oil include; Excavators and backhoes, Hydraulic brakes,
Power steering systems, Transmissions and Garbage trucks. The operation is shown in Figure 16
below.
gg. 3.4.1 Dangers involved in working with hydraulic fluids

There are several dangers involved while dealing with hydraulic fluids. These include the following;
a. Health problems.
People can become exposed to the chemicals in hydraulic fluids. The exposure may be due to
inhalation, ingestion, or touch. There are instances of people suffering from skin irritation or weakness
in hands while handling hydraulic fluids. There are also cases of intestinal bleeding, pneumonia, or
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death through hydraulic fluid ingestion though no serious hazards are reported with hydraulic fluid
inhalation.
Similar to ingestion, fluids can be accidentally injected into the skin as well. This takes place when the high-
pressure hydraulic system hose is disconnected and toxic fluids are leaked and injected into the skin. If there
is a small leak in the hydraulic pipe and someone runs there hand along it, at 2000 psi, they can easily incur
an injection of hydraulic fluid and may not even be aware that it happened until gangrene begins to set in.
b. Fire dangers.
When working with hydraulic fluid, there is every chance that the hydraulic fluid gets heated to high
temperatures. And it is evident that most petroleum-based hydraulic fluids will burn and thereby create
explosions and burns. c. Environmental problems.
When the hydraulic hose or pipe leaks, the chemicals of the fluids can either stay on top of the soil or sink
into the ground. If the chemicals get mixed in a water body, they will sink to the bottom. In fact in such
cases the chemicals can stay there for more than a year. Aquatic life can absorb the toxic hydraulic fluid,
leading to illness or death to the animal or anything higher on the food chain. For example, a hawk that eats
a fish that has been contaminated by hydraulic fluid that was mixed in water could become ill as well. d.
Fluid texture problems.
Although the slimy texture of hydraulic fluids may not seem like a danger or a problem, a spill can cause a
person to slip and fall. Also when there is fluid on the hands of a person, it can cause him to slip while
climbing on a machine. It can also cause the operator to lose steering control.
hh. 3.4.2 Safety precautions when dealing with hydraulic fluids

Certain safety precautions need to be followed when handling hydraulic fluids as discussed below;
a. In order to avoid skin irritations, it is necessary to wash contaminated skin immediately. It is also
necessary to keep your clothing clean.
b. Always wear masks and gloves while using hydraulic fluids.
c. To avoid environmental dangers, there is a biodegradable hydraulic fluid option, though it is more
expensive.
d. To avoid fires, materials and fluids soaked in hydraulic fluid should be stored in sealed
metal containers and disposed of at proper places.
e. To check for leaks, use cardboard.
ii. 3.4.3 Common faults with the hydraulic system

Generally, improper hydraulic system operation can be traced to one of the following deficiencies:
insufficient fluid level, the presence of air in the system, contamination by foreign material, incorrect
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adjustment of components, internal or external fluid leakage, mechanical damage to components, wrong
fluid type or viscosity and excessive temperatures.
jj. 3.4.4 Solutions to the common faults

The following tips, tools and techniques should be considered for appropriate use to curb the faults.
a. The contaminant test. Obtain an oil sample in a clean, clear jar and let it sit overnight. Any contamination
will settle to the bottom of the container and will remain attracted to the bottom surface for viewing even
when the container is turned over.
b. The crackle test. If water is suspected but not obvious, obtain an oil sample and place two or three drops of
the oil on a hot plate. The drops will crackle, pop or sizzle if any water is present. Remember that any water
may be harmful depending upon the equipment type or process.
c. The “poor man’s” particle count. It is a simple inspection of the filter of the machine. Cut the filter open,
spread the media out on a bench and view any contaminant with a magnifying glass or microscope. Run a
magnet under the filter media. Any ferrous material will move with the magnet. This should immediately
call for a ferrographic analysis of an oil sample.
d. The color test. Any brownish or darkening discoloration of the oil which is an obvious change, suggests
that oxidation has begun. Any discoloration should be immediately investigated by sending an oil sample
for a minimum of viscosity and acid number analysis. If the viscosity has increased by 10% or more of new
oil and the acid number has increased substantially, the fluid may have reached the end of its service life and
thus replacement is required.
e. The high temperature test. Dark discoloration of the hydraulic fluid suggests that oxidation is occurring. If
high temperatures are suspected, they could be caused by external leaks which create hot spots at valves or
cylinders, plugged coolers or kinked or damaged hoses, relief valve pressure settings too high, or oil of too
high viscosity. In all cases, the use of predictive maintenance tools such as infrared thermograph or an
infrared thermometer using laser beams to instantly locate hot spots will locate the high temperature areas.
f. The internal leakage test. When a hot spot is located, such as at a cylinder barrel or servo valve, the use of
a hand held ultrasonic tester will locate the leak. During a leak, a liquid moves away from high pressure. As
it passes through the leak site, a turbulent flow is generated that has strong ultrasonic sound waves that can
be monitored. The intensity of the ultrasound will be loudest at the actual leak site. These ultrasonic sounds
cannot be heard by the human ear. Very often, external leaks will cause hot spots that will burn the hand of a
troubleshooter, so care must be taken when attempting to locate high temperature problems.
g. The excessive noise test. An ultrasonic tester can also be used to monitor conditions such as cavitation or
aeration at hydraulic pump inlets or other components, as well as locating electrostatic discharge noise at
filters or reservoirs. Electrostatic charges may be generated in hydraulic fluids by turbulence, high fluid
velocities, internal fluid friction, fluids flowing in ungrounded piping or when fluid discharges on to any
free surface of the reservoir, particularly if there is free air present in the fluid.
Electrostatic discharge most often manifests itself as a clicking sound as the charge repeatedly builds and
then discharges to a surface of lower voltage through sparking. The increased use of synthetic fluids and
mineral base oils with non-metallic anti-wear additives have resulted in fluids with low conductivity,
increasing the potential for accumulated static charge levels. In severe cases, electrostatic discharge can
38
result in etching, pitting or carbon deposits at the surfaces of the area where the discharge occurred and may
leave burn marks or other damage on the filter element media.
h. The foam and air entrainment inspection. As noted earlier, a darkening color of hydraulic fluid suggests
that oxidation is occurring. Oxidation rates are related directly to high temperatures and excessive air
entrainment combined with high pressure. At atmospheric pressure and corresponding temperature, oils
contain about 10%by volume of dissolved air. At 200 psi (1400 kPa), oils can absorb about 140% by
volume. The dissolved air provides the oxygen that is necessary to promote oxidation and oxidation rates
rapidly increase as temperatures rise above 140ºF (60ºC) and hydraulic pressures increase to their normal
operating ranges. Dissolved air in oil under pressure will tend to produce foam as pressure is released and
the air comes out of solution. This free air is now trapped inside operating cylinders and other components,
which will cause erratic and spongy operation and increased temperatures.
If hydraulic systems begin to display erratic, spongy operational behavior or cylinder extension and
retraction speeds are slower than normal or erratic in nature, there is a good possibility that there is
excessive air entrainment in the hydraulic system. The presence of entrained air is readily apparent by the
bubbly, opaque appearance of the fluid in the reservoir.
When excessive levels of entrained air are suspected, inspect all system connections where air may be
drawn into the system. Examples are; loose pump inlet connections, the fluid return line is broken or no
longer below the oil level in the reservoir, the pump shaft seal has failed, inadequate or broken reservoir
baffle plates, suction side of circuits are leaking or have loose connections.
Suction leaks (where air is being drawn into a component or circuit) can easily be located by applying
hydraulic oil to the connection. If the oil disappears, the troubleshooter has located the air leak!
kk. 3.4.5 Recommendations on hydraulic systems

As hydraulic systems improve and operating pressures increase, much more attention to predictive
maintenance and reliability will be required. Two areas of concern will be a requirement for improved filter
design, selection and installation and hydraulic system flushing techniques after a component failure has
occurred.
In the first instance, more consideration will be required for improved filter installation where increased
vibration and/or higher pressure pulsation will require mitigation.
In the second instance, mobile filtration systems and portable hydraulic fluid purifiers will become
mandatory, if hydraulic system reliability is to be improved and maintained.
ll. 3.4.6 Faults found with the hydraulic oil

Diagnosis of the hydraulic oil of the truck, revealed the following faults that necessitated its replacement;
a. Hydraulic oil had deteriorated. When the hydraulic oil is used for a long time, it deteriorates and thus
has to be replaced.
b. The base oil was degraded.
c. The additive package was depleted.
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mm. 3.4.7 Tools and equipment used to replace the hydraulic oil
The tools and equipment used to change the hydraulic oil were; a ring spanner, box spanner, Hammer,
combination spanner, funnel, bucket, clean piece of cloth and new hydraulic oil.
nn. 3.4.8 Technical procedures followed
The following procedures were observed during the operation;
a. The system was drained while the fluid was hot to keep contaminants in suspension.
b. The fluid was emptied from cylinders, accumulators and lines that could not drain
properly.
c. The oil left in the reservoir was pumped out.
d. The reservoir was wipe-cleaned with lint free rags and rust and free paint were removed.
e. Filter elements, strainers, and housing were cleaned.
f. The system was refilled with new hydraulic fluid making sure to vent high points.
g. The system was restored and checked for proper operation after which it functioned.
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Figure 16: Draining the hydraulic oil
oo. 3.5 Replacement of leaf springs of a FAW truck
The rear suspension under some vehicles is supported by a pair of leaf springs made up of multiple leaves
(strips) of spring steel. A leaf spring is a component of suspension systems of some vehicles. They are
composed of several (or occasionally just one) thin strips of metal, called leaves, arranged on top of each
other to form a single curved piece. Typically, they have three or four individual leaves that make a set of
springs. Leaf springs have a specific curvature, and this curvature and the number of leaves in the spring
pack; determine the load capacity and the ride height of the vehicle. The curvature also helps the spring
absorb impact. The bending of the leaves and the friction between them as they slide slightly over each
other while bending, absorb the weight of the vehicle as well as any bumps. Leaf springs should be replaced
when they are worn out, flattened out, cracked or broken. Figures 17 and 18 below show the operation.
pp. 3.5.1 Functions of the suspension of the vehicle

The suspension of the vehicle serves three major functions; they are to;
a. Support the vehicle

41
b. Absorb impacts from bumps, potholes, and other road irregularities
c. Allow the vehicle to turn in response to the driver’s inputs. (The steering system can be considered
part of the suspension, or its own system, but either way the suspension has to allow for movement of the
wheels as the vehicle turns).
qq. 3.5.2 The purpose of leaf springs

Leaf springs are appropriate for spreading heavy loads over a large area (because they are attached to the
vehicle at the ends, which may be several feet apart) and for suspension designs that incorporate a “solid”
axle rather than independent suspension for each wheel especially of heavy vehicles such as trucks.
These factors render leaf springs appropriate for trucks and other heavy vehicles but less so for cars, as such
designs tend to have undesirable effects on the handling of the vehicle. As independent (as opposed to solid
axle) rear suspensions have become increasingly common on cars, leaf springs are now found primarily on
trucks, vans, SUVs and trailers.
rr. 3.5.3 Maintenance of leaf springs

Multi-leaf springs occasionally get “sticky” as dirt works its way in between the leaves; the effect can be to
make the ride slightly stiffer, but this is rarely a significant problem. The attachment points will need to be
checked periodically and lubricated in some cases as specified by the manual of the manufacturer, and
regular maintenance should be carried out. If the body of the car seems to sit too low over the wheels, this
sagging is usually due to the leaf springs having bent slightly over time, and the solution is to have them
replaced.
ss. 3.5.4 Fault found with the leaf springs
The leaf springs were broken as depicted by inspection. This necessitated their removal and replacement.
tt. 3.5.5 Safety precautions while replacing leaf springs
The following precautions should be observed when replacing the leaf springs;
a. Always wear safety glasses when working carrying out the operation.
b. Wear other personal protective equipment (PPE) when necessary, for example latex gloves or closed
toe shoes.
uu. 3.5.6 Tools and equipment used to replace the leaf springs
The following tools and equipment were used to replace the leaf springs of the truck;
A ratchet, hammer, Box spanner, combination spanner (24-24), floor jack, trolley jack, lubricant (oil); ring
spanners (numbers16, 18, 19 and 30), wrenches and Jack stands.
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vv. 3.5.7 Technical procedures followed to replace the leaf springs
a. The vehicle was parked on a solid, level surface to ensure that it did not roll or lean when raised.
b. Using a floor jack, the rear of the vehicle was lifted up enough for the axle assembly to hang freely.
c. The vehicle was secured with jack stands on both sides for safety before starting any work.
d. The rear axle assembly was supported with a floor jack close to the spring.
e. The lower bolt was removed from the shock absorber.
f. The axle was lowered to relieve tension on the spring.
g. The U-bolts and spring retainer bracket were removed.
h. The parking brake cable was removed from the retainer bracket.
i. The rear axle was carefully lowered since leaf springs were mounted on top of the axle.
j. The rear shackle bolts were loosened.
k. The leaf springs were supported with a jack stand and the leaf spring front and rear eye bolts were
removed.
l. The leaf springs were removed from the vehicle.
m. The front bushings of the new springs were placed into the front mounting brackets, the front eye bolts and
nuts were installed with the bolt heads towards the center of the vehicle.
n. The rear bushings of the new springs were placed into the rear shackles and the rear eye bolts and nuts were
loosely installed.
o. The axles were adjusted to place the leaf springs center bolts into the holes on the axle pads.
p. The U-bolts and retainer brackets were installed; the U-bolt nuts were snagged down but not tightened.
q. The parking brake cable was reattached and the lower shock mount was attached to the axle bracket.
r. Steps (d) through (q) were repeated for the other side of the truck.
s. The truck was lowered to the ground and all bolts torqued to the recommended specifications.
t. The leaf springs repair was verified and the vehicle was aligned.
u. The vehicle was road-tested and found to operate well.
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cc. Figure 17: Removing the broken leaf springs
Figure 18: The broken leaf springs that were removed
44
ww. 3.6 Replacement of a tire of a garbage truck
Tires are often the most neglected components on vehicles, but better care should be taken of them, our
lives on the ride depend on them. They support the overall weight of the vehicle and thus must be in good
conditions to function properly. They are one of the most important components of the vehicle. The tire
tread area making contact with the road is relatively small– only about the size of the palm of the hand - so
if tires are worn or damaged it can seriously affect the safety and handling of the vehicle. Figure 19 below
shows the operation.
xx. 3.6.1 Common tire problems and their solutions

Tires wear abnormally as the result of excessive sharp braking or rapid acceleration. The guide below for
what to look out for will help when inspecting tires:
a. Illegal wear. When a tire is worn, it needs replacing immediately. Any tire in this condition has been
used far beyond the legal tread depth limit.
b. Misalignment. A misaligned tire will be worn noticeably more on one side than the other. For
example, a tire aligned inwards will wear more on the outside than the inside. If the tire is aligned outwards
the inner shoulders of the tire wear more than the outer shoulders. Any tire in this state should be replaced
immediately.
c. Camber wear. Cambered wheels result in increased wear on the outer edge of a tire.
Cambering occurs due to poor fitting and this significantly reduces the lifespan of a tire. Wheels should be
repaired.
d. Emergency braking. If an emergency stop is performed, the tire wears enormously in an isolated area
and can lead to deflation. If an emergency stop maneuver has recently been executed, check the tires for
isolated damage.
e. Cuts and tears. Observe the sidewalls of the tires. Sharp objects such as nails, glass or metal can
cause a cut or tear in the tire. If a cut or tear is spotted it can render your tire unserviceable. Tires in this
state should be replaced immediately.
f. Impact damage. If a vehicle hits an object at high speed such as a kerb, a bulge may be visible in the
side wall of the tires. The area of the bulge or egg highlights the location of casing damage. The damage
should be diagnosed and fixed immediately.
yy. 3.6.2 Minimizing tire problems

Tires are the only point of contact that the vehicle has with the road and as such, they need to be in good
working condition at all times to ensure the safety of the users. To minimize tire problems and thus
maximize the life of tires and achieve optimal performance from the vehicle, observe the following:
a. Ensure that tires are correctly inflated. Driving with incorrect tire pressures can affect handling and
braking of a vehicle, particularly in wet conditions, and can seriously compromise safety of users. In some
cases, tires are over-inflated which inhibits vehicle handling and causes excessive wear on the centre strip of
a tire. Driving on severely under-inflated tires can cause heat build-up and eventually a premature failure.
Check tire pressure regularly and before every long trip.
b. Observe the load capacity. Do not exceed the load capacity relative to the load index of the tires.
Overloading a vehicle increases strain upon the tires which raises temperatures, causes rapid wear and
45
significantly heightens the risk of receiving impact damage that leads to premature failure. Consult the
vehicle handbook to find pressures should there be need to fully load the vehicle.
c. Manage the speed of the car. Driving at very high speeds over long and short distances causes tire
temperatures to increase, which in some cases can lead to tire damage. If tires are not correctly inflated,
driving at high speeds also increases the likelihood of sudden tire failure and rapid loss of air. To maximize
the life of tires, observe speed limits and avoid aggressive acceleration/deceleration.
d. Make use of spare tires. If any damage to a tire or wheel is seen, replace tire with spare tire and have
tires checked by a professional.
e. Inspect the tires. It may not always be noticed if one of the tires has been damaged. Inspect tires
regularly for wear and any damage to avoid any sudden problems. Also, have a professional inspect the tires
every year.
Note: Unfortunately many tire problems are unavoidable. Tires can be checked regularly but still fall foul of
an errant nail, piece of metal or a pesky pothole. However, if the guidelines are followed and tell-tale signs
of potential problems are looked out for; longest life possible out of tires can be got.
3.6.3 Fault found with the tire

Inspection of the tire indicated that it was worn out; this prompted its removal and replacement.
zz. 3.6.4 Safety procedures while replacing tires

While changing tires, the following safety measures should be observed.
a. The tire levers should not be sharp. This is because the tube might get cut during the process.
b. While changing tires, put little French chalk inside the tire. It works as a lubricant.
c. Sometimes, tire bead may get stuck on rim due to rusty rim. Do not apply extra force. In this case, put little
water on tire bead and leave it for 20 minutes and then try again.
d. Always put few amounts of air inside the tube before fixing bead of tire. This air prevents the cutting of
tube and keeps it away from lever and rim.
e. While inflating tires, ensure that the tire is resting nicely on the rim flange. This setting is very important for
heavy duty vehicles especially Tractor tires.
f. After the steps to change tires have been completed, tighten the nuts and only then, remove the jack.
g. After removing the Jack, the nuts should be tightened again for safety.
h. The wheel nuts should be checked more often in new vehicles-after every few hundred kilometers. The
reason for regular checking in case of new vehicles is that wheel nuts might become loose due to the paint.
aaa. 3.6.5 Tools and equipment used to replace the tire

A hammer, ring spanner, wrench, floor jack, trolley jack, combination spanner, box spanner and an open
spanner.
46
bbb. 3.6.6 Technical procedures followed
a. The truck was parked on a flat surface.
b. The parking brake was applied and the truck put in to park position.
c. Rocks were placed in front of the front and back tires.
d. The jacks were placed under the frame near the tire that was to be replaced.
e. The jacks were raised until they were supporting but not lifting the car.
f. The hubcap was removed and the nuts loosened by turning them counterclockwise.
g. The jacks were pumped to lift the tire off the ground.
h. The nuts were removed by turning them counterclockwise until they loosed.
i. The tire was then removed.
j. The spare tire was placed on the hub, its rim aligned with wheel bolts and lug nuts put in positions.
k. The nuts were tightened using the wrench in a star pattern.
l. The truck was lowered without applying full weight on the tire, and the nuts were tightened further.
m. The truck was fully lowered to the ground.
n. The jacks were removed.
o. The nuts were tightened finally and the hubcap replaced.
p. The truck was road-tested and the new tire was found to be functioning well.
47
Figure 19: Removing the tire
ccc. 3.7 Troubleshooting starter motor of a Toyota Pick-up
Before an engine starts, it must first be cranked. Turning the engine over draws air and fuel into the
cylinders and compresses the mixture so it can be ignited to provide power. Cranking the engine also
generates the ignition and crankshaft position sensor signals that are needed to fire the spark plugs and
operate the fuel injectors. Cranking the engine is achieved with the help of the starter.
So if a starter fails to crank the engine or turns too slowly, the engine will not start. Unfortunately, starting
problems are not always simple to diagnose. Sometimes the starter motor is blamed for a hard starting or
no-start condition that is not the fault of the starter. As a result, some starters are replaced unnecessarily.
One way to avoid such predicaments is to bench-test old starters to make sure they are defective before they
are replaced by new ones. After removing your old starter, you can test the current draw and cranking speed
of the starter. Figure 20 below shows the operation.
3.7.1 Common symptoms of a failing or bad Starter, their causes and remedies They include
the following:
a. Grinding noise. When the starter drive gear is worn out or not engaging properly, they will often
produce a grinding noise that is similar to the one that is heard if engine is started and then accidentally the
starter is hit again. If the grinding symptom is ignored, it may also result in damage to the engine flywheel.
It should be diagnosed immediately upon detection.
48
b. Freewheeling. Freewheeling occurs when the engine is cranked and simply a whining noise is heard
from the starter without the engine cranking. When this occurs, it means the starter gear is not engaging
with the flywheel. This is a bad situation that could result in the need for a starter replacement. If this is
occurring, the vehicle should be serviced as soon as possible.
c. Smoke. Seeing smoke is cause for immediate concern, and can indicate a few different problems with
the starter or starting circuit. Smoke usually indicates that too much power is being drawn through the
electrical supply to a starter, either because the starter is shorted, has been operated too long without a rest
or there is a connection problem. Smoke might also be accompanied by a burning smell. If smoke is seen,
the vehicle should be serviced by a professional as soon as possible.
d. Oil soak. The starter is often located around the bottom of the engine and is vulnerable to soaking
from leaks from the engine oil or other drive train fluids. An oil-soaked starter likely has a short life
remaining. Consider correcting the leak and replacing the starter before a malfunction occurs.
e. Malfunctioning solenoid. The solenoid transmits electrical current from the battery to the starter
motor when the key is turned in the ignition of the vehicle and also pushes the starter drive into the flywheel
to allow cranking. Without the solenoid, the starter does not work. If the key is turned to the crank position
and nothing happens, try jiggling the transmission gear shift lever first. If the engine still will not crank,
there might be something wrong with the solenoid.
f. When the key is turned to crank the engine, nothing happens. The engine does not turn over.
g. When the key is turned to crank the engine and all that is heard is one loud click. The engine
does not turn over; or when the key is turned to crank the engine and the engine turns over very but very
slowly and then stops.
h. When the battery is good but the car fails to start.
ddd. 3.7.2 Safety procedures while troubleshooting a starter motor

While troubleshooting a starter motor, certain safety measures need to be observed. They include the
following:
a. If you have to lift up the car or truck to access the starter motor: Use jack-stands to support the car or
truck off the ground, and use safety glasses while working underneath the vehicle.
b. You will need a helper to crank the engine as you perform some of the tests, and to help you perform
the very important Voltage Drop Test.
c. When jumpering 12 Volts to the S-terminal wire (circuit) make sure you do not short-toground your
jumper wire.
eee. 3.7.3 Tools and equipment used
Spanners (Open, fixed, adjustable, combination and box), safety glasses, jack stands, a voltmeter, pair of
pliers, screwdriver, jack, and multi-meter.
fff. 3.7.4 Technical procedures followed

a. The state of charge of the battery was determined.
b. The ignition switch was checked if it was sending power to the solenoid.
c. The starter motor was checked if the problem lied in itself
d. The solenoid was tested to see if it was working.
49
ggg. 3.7.5 Testing the starter
a. The battery was tested first, using a multi-meter.
b. The starter motor was tested if it was receiving 12 Volts on its battery circuit.
c. The starter motor was tested if it was receiving the start signal from the ignition switch.
d. The starter battery and ground circuits were voltage-drop-tested.
e. Using a jumper-wire, 12 volts was applied to the Start signal wire.
f. The engine was turned by hand to eliminate a locked-up engine or a locked-up AC compressor.
Figure 20: Testing the voltage being received by the starter
hhh. 3.8 Adjusting the clutch of a garbage truck

If the clutch is maintained properly, it can be good for the life of the vehicle. Most modern vehicles with
manual transmissions have self-adjusting clutches that require no adjustment, but models without self-
adjustment should be properly adjusted. Figures 21 and 22 below show the operation.
3.8.1 Common faults with the clutch system, their causes and remedies They are
summarized in Table 3 below.
50
Table 3: Clutch diagnosis/troubleshooting chart
FAULT POSSIBLE CAUSES REMEDY
1. Improper linkage adjustment. 1. Adjust linkage.
2. Improper pedal travel. 2. Trim bumper stop and adjust linkage.
3. Loose linkage. 3. Replace as necessary.
4. Faulty pilot bearing. 4. Replace bearing.
5. Faulty driven disc. 5. Replace disc.
6. Fork off ball stud. 6. Install fork onto stud. Lightly lubricate
7. Clutch disc hub binding on clutch fingers at release bearing.
gear spline. 7. Repair or replace clutch gear and/or
8. Clutch disc warped or bent. disc.
9. Loose pivot rings in cover assembly.8. Replace disc (run out should not
exceed
0.020″).
9. Replace plate and cover assembly.
ls to Release (Pedal pressed to floor).
ft lever does not move freely in and
of reverse gear.
1. Improve adjustment (no lash). 1. Adjust linkage to specifications.
2. Oil soaked driven disc. 2. Install new disc and correct leak at its
3. Worn facing or facing torn from source.
disc. 3. Replace disc.
4. Warped pressure plate or flywheel.4. Replace pressure plate or flywheel.
Slipping. 5. Weak diaphragm spring. 5. Replace pressure plate. (Be sure lash is
6. Driven plate not seated in. checked before
7. Driven plate overheated. replacing plate.)
6. Make 30 to 40 normal starts. Caution:
Do not overheat.
7. Allow to cool–check lash.
1. Oil on facing. Burned or glazed facings. 1. Install new disc and correct leak.
2. Worn splines on clutch gear. 2. Replace transmission clutch gear.
3. Loose engine mountings. 3. Tighten or replace mountings.
4. Warped pressure plate or flywheel. 4. Replace pressure plate or flywheel.
5. Burned or smeared resin on fly wheel 5.
or Sand off if superficial, replace burned
pressure plate. or heat checked parts.
Grabbing or Chattering.
51
1. Weak retracting springs.
2. Release fork loose on ball stud or in
bearing groove.
3. Oil in driven plate damper.
4. Driven plate damper spring failure.
1. Replace pressure plate.
2. Check ball stud and retainer.
3. Replace driven disc.
Rattling-Transmission Click 4. Replace driven disc.
1. Improper adjustment. No lash.
2. Release bearing binding on
transmission bearing retainer.
3. Insufficient tension between clutch
fork spring and ball stud.
4. Fork improperly installed.
5. Weak linkage return spring. 1. Adjust linkage.
2. Clean, re-lubricate, check for burrs,
and nicks among others.
3. Replace fork.
Throw-out bearing noise with 4. Install properly.
clutch fully engaged 5. Replace spring.
1. Worn release bearing.
2. Fork off ball stud (heavy clicking).
Noisy3. Pilot bearing loose in crankshaft.
1. Replace bearing.
2. Install properly and lubricate fork fingers
at bearing.
1. Lubricate and free up linkage and release
bearing.
2. Replace pressure plate.
3. Adjust linkage to get proper lash, make sure
proper pedal stop
1. Bind in linkage or release bearing. (bumper) is installed.
2. Springs weak in pressure plate.
Pedal stays on floor when released 3. Springs being over traveled.
1. Lubricate and free linkage.
1. Bind in linkage. 2. Replace driven plate.
Hard pedal effort 2. Driven plate worn.
3.8.2 Faults found with the clutch system

Inspection of the clutch system revealed the following faults that prompted the operation.
a. The clutch was getting worn out.

b. There was difficulty shifting-the shifter was not moving freely.
52
3.8.3Tools and equipment used to adjust the clutch
The following tools and equipment were used to carry out the operation
A drive ratchet, socket, large screwdriver, drop Light, piece of wood, floor pads, fan and an extension cord
iii. 3.8.4 Technical procedures followed
a. The parking brake was engaged, the gear shifter put in neutral, and the clutch pedal pressed to the
floor.
b. The access opening for the clutch assembly was located under the truck just behind the oil pan. A torch
light was used to see where the adjustment plate was.
c. With the clutch pedal depressed, a large flathead screwdriver was used as a lever to rotate the flywheel
assembly till the adjustment plate was at the bottom and fully accessible.
d. Using a socket, only the left-hand bolt which secures the retaining strap was removed.
e. The retaining strap was removed and set aside.
f. Using a wrench, the adjusting bolt on the splined shaft was rotated clockwise (handle towards the side
of the driver) until the proper amount of clutch adjustment was achieved.
g. Reassembling was done and the car was road-tested and found to be functioning properly.
53
Figure 21: The opened clutch system
Figure 22: The removed pressure and clutch plates
54
3.9 Panel beating a Pajero Shogun
Panel beating refers to repairing vehicle bodies back to their factory state after having been damaged. This
work is done by an auto-body mechanic called the panel beater. The process is a highly labor intensive,
involving various techniques to remove dents, shape panels to match the original contours then smooth,
resurface and spray paint the damaged areas.
Spraying a car involves applying to the body of the car, a jet of vapor or tiny drops of coating or paint to
make the car look good. The operation is shown in Figures 23 and 24 below.
3.9.1Reasons for the operation

The operation was carried out in order to:
1. Remove the dents developed during the damage.
2. Prepare the body of the car for spray painting.
3. Bring back the body of the vehicle to the factory state.
3.9.2 Tools and equipment used

Hand hammer, body file, rough sand paper, wooden piece, filler paste, pad, hardener, spot putty, spraying
gun, primer, wooden holder, smooth sand paper, water, undercoat duke metallic paint, undercoat duke silver,
thinner, clear coating, Hacksaw blade, Detergents, ring spanners 14 combined, papers and cellotape.
3.9.3 Safety precautions for the operation

The following are the safety measures that should be observed during the operation:
Always use correct spanners when removing the body parts of the vehicle that
is to be panel-beaten and/or sprayed.
Great care should be taken when using the hammer to bring back the shape of the body of the vehicle in
such a way that the body is not further damaged.
Carefully use the body file as it may hurt the user and also cause further damages to the part being filed.
Always wear protective gears during the operation.
Ensure that the vehicle is properly parked.
The following procedures were observed during the operation.

dd. The vehicle was parked on a clean, dry, solid surface, the parking brake was applied.
ee. The dents on the body parts of the vehicle were identified by visual inspection, where the damaged
parts are surveyed using the eyes, and feeling inspection where the hands are gently moved on the surface to
feel the dented parts.
55
ff. The vehicle was properly cleaned with water and dried with a piece of cloth.
gg. The hand hammer and piece of cloth were used to bring back the shape of the body of the vehicle that
was damaged, taking care not to disorganize the permanently designed marks on the body surface of the
vehicle.
hh. The damaged parts were filed off; properly making sure that the outer coating is also filed. This was
done using the body file.
ii. The filler paste was mixed with the hardener in appropriate proportion with the hardener and then the
mixture was applied on the body parts that had been filed. The filler paste was applied using pads.
jj. The parts were left to dry and then were again slightly filed with the body file and then sanded
properly using rough sand paper to smoothen the body surfaces.
kk. Spot putty was then applied using a pad so as to fill in the scratches developed during filing and
sanding processes.
ll. The parts were left to dry and then were sanded properly with smooth sand paper 500. While doing so,
water was applied frequently. The parts were then again left to dry.
mm. The parts that were not supposed to be sprayed were covered using pieces of papers and mended with
masking tape.
nn. Using spraying gun, the primer was then applied to the body surfaces, to prevent rusting from
occurring. It was then left to dry.
oo. The body was then sprayed with undercoat duke silver using a spraying gun. It was then left to dry
after which it was sprayed with undercoat metallic.
pp. Clear coating was then sprayed to the body surface. The clear coating was mixed with hardener and
thinner to make the body surface to shine brightly and look newer.
Figure 23: Sanding using smooth sand paper 500
56
Figure 24: Covering the parts that were not supposed to be sprayed
CHAPTER FOUR: SKILLS ACQUIRED, CHALLENGES FACED
RECOMMENDATIONS AND CONCLUSION
4.1 Introduction
This chapter covers the skills acquired from the field attachment training, challenges faced at work,
recommendations and conclusion.
4.2 Experience gained/achievements from the training
From the industrial training, I acquired a number of skills and knowledge through the application of the
theoretical knowledge learnt in class into the practical operations which led to an improvement and
widening of my engineering knowledge. All activities were carried out while taking note of all the safety
precautions necessary to prevent accidents and produce the desired results accurately and in time while
using the right tools and following the correct procedures.
The following were the achievements from the training.
a. Maintenance of vehicles and equipment.
b. Exposure to the demands and challenges of the workplace.
c. Appreciation of the professional and therefore better work ethics.
d. Improved confidence in problem-solving.
e. How to relate to different categories of people likely to be met in real-life situation.
f. Opportunity to meet and work with potential employers.
g. Gained first-hand experience working as an engineering professional.
57
h. I learnt how to work with other engineering professionals and the value of teamwork in engineering.
i. I was able to increase my technical, interpersonal and communication skills, both oral and written.
4.3 Challenges faced during the training
During the training, a number of challenges were faced as given below.
a. Most technical words used in motor vehicle work were not familiar to me but more research and
inquiries were made from the senior mechanics and through reading of vehicle manuals to get acquainted
with them.
b. In the earlier days of the training, several accidents and injuries were sustained for example cuts on
fingers and legs; however with time, vigilance on work was increased which reduced on injuries.
c. Language barrier. The language used at the work place was not familiar to me but usually requested
them to kindly translate for me and also efforts were made to learn the key words normally used while
carrying out operations.
d. While making inquiries from the senior mechanics on the operations being carried out, different
reactions would be received from different people; some were welcoming while others were tough. So most
of the research and inquiries were made with the friendly mechanics and serious efforts were made to
befriend everyone at the workshop.
e. Delay of some spare parts of the vehicles which made some work not to be completed in time.
f. Most of the work needed use of heavy tools and machine components which made the work difficult,
tiresome and time consuming. In such cases, help was sought from other people in the workshop to help
especially in lifting the heavy machine components and tools.
g. Inadequate tools and equipment like spanners, cylinder head resurfacing machine, crankshaft
regrinding machine, and water jet cleaner which is used to clean the radiator; caused delay of the work
hence creating work backlogs.
h. Unfavorable weather conditions like heavy rainfall often disrupted activities at the workshop. In such
cases, operations were carried out under an erected structure, which however could only accommodate
small vehicles.
i. Relating theoretical knowledge to practical situations was a great setback. However, through
continuous research and persistent inquiries from the workshop technicians, it became easy.
j. Limited time to share knowledge with all engineers and technicians due to tight schedules at the
workshop.
k. Inadequate financial support to cater for my daily expenses like transport, meals and others.
l. Limited working space due to congestion in the workshop.
m. Inadequate safety guards during operation of some machines like air compressor which blows dust
from air cleaners.
n. Lack of well-designed training program and an immediate person who is responsible for the affairs of
the trainees. This made trainees not to fully exploit some of the most important engineering aspects of the
institution as there was no serious monitoring and also access to some of the sections was either not easy or
prohibited without the permission of a supervisor.
o. There was poor sanitation at the workshop. For example, toilets were shared equally by both male and
female workers. This is risky to the health of workers.
58
p. Too much bureaucracy which led to delay of work in the workshop as sometimes spare parts and other
materials could not be accessed in time.
4.4 Recommendations
Following what transpired during the industrial training especially the challenges I encountered, I
recommend the following to the management of DCVI.
a. Proper waste management should be frequently carried out at the workshop. Rubbish should be collected
together and either burnt or disposed off to keep the workshop clean every time.
b. There should be a well-designed training program for trainees and an immediate person responsible for their
affairs.
c. All the necessary tools should be availed and close supervision carried out by registering all the tools and
the corresponding workers using them so that in case of any tool loss, the particular worker is responsible
and replaces them.
d. More safety gadgets should be acquired especially for air compressing and panel beating
e. More air compressors should be acquired so that more air filters can be cleaned within a short time.
f. Cleaning air filters should be carried out from an open space where there is free circulation of air to protect
the person carrying out the operation from dust and other harmful fumes.
g. Scraps should be removed from working areas to give more working space as well as for safety purposes.
h. There should be a scrap yard where scraps are collected and stored.
i. Management should consider expanding the workshop so as to accommodate the ever-increasing volume of
work at the workshop.
j. Training duration should be extended since the mechanical engineering field is a very wide one and
therefore cannot be fully exhausted within the allocated weeks of training.
k. Materials should be acquired timely and availed immediately upon requisition, to avoid delay in carrying
out work in the workshop.
l. In a bid to improve sanitation of workers at the workshop, I recommend that male and female workers
should use separate toilets.
jjj. 4.5 Conclusion
The internship was a fruitful experience. Through the application of the theoretical knowledge into real-life
problem-solving situations, I gained a lot of experience especially in the automotive field. I also got insight
into professional practice, learnt how life can be fruitful as well as challenging under employment; and how
to face and deal with these challenges. It was also a great opportunity for developing personal networking
activities and making contacts with influential people; which is of great value to me as far as my career is
concerned. The training also enabled me to discover my strengths and weaknesses. This further helped me
to identify areas to improve on. In a nutshell, I achieved most of my learning objectives from the training.
REFERENCES
Anon., 2001. A New Methodology for Engine Diagnostics and Control Utilizing ‘Synthetic’
Engine Variables: Theoretical and Experimental Results, Transactions of the ASME. Journal of Dynamic
Systems, Measurement, and Control, Volume 123.
59
Gao, Y. & Randall, R. B., n.d. Reconstruction of diesel engine cylinder pressure using a time domain
smoothing technique, Mechanical Systems and Signal Processing. 5 ed. s.l.:s.n .
Rachkara, P., 2017. Eng. [Interview] (July-August 2017).
Srinivasan, S., n.d. Automotive mechanics. 2nd ed. s.l.:s.n.

Anon., 2017. [Online]
Available at: https://repairpal.com/electrical-lights
Available at: http://www.xpertechautorepair.com/fuel_injection.html
Available at: http://www.avgnewton.com/suspension.html
Available at: http://eramandeepbansal.blogspot.ug/2013/08/front-wheel-suspension-system.html
Available at: http://arrc.ebscohost.com/ebsco_static/repairtips/8852CH23_Rear_Suspensions.htm
Available at: https://repairpal.com/suspension-steering
Available at: https://www.coolcaraircon.co.uk/how-car-air-conditioning-works/)
Available at: https://mechanicalserviceswi.com/auto-repair/exhaust-system
Anon., 2017. Automobile-transmission-system. [Online]
Available at: http://usciencecompendium.blogspot.com/2014/12/automobile-transmissionsystem-part-1.html
60

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Liaoning Technical University

Undergraduate internship report

Internship name: Graduation Internship report

Grade： （Five-stage) Instructors：

Chapter two presents the general overview of Motor Vehicle Technology.

a. TABLE OF CONTENTS ................................................................................................................... iii

b. LIST OF TABLES .............................................................................................................................. ix

c. LIST OF FIGURES ........................................................................................................................... ix

d. LIST OF ACRONYMS USED .......................................................................................................... xi

CHAPTER ONE: GENERAL INTRODUCTION .................................................................................. 1

1.1 Background .............................................................................................................................................

1.2 Industrial training objectives ...................................................................................................................

1.2.1 General objectives ................................................................................................................................

1.2.2 Specific objectives ............................................................................................................................... 1

1.3 Background of Daniel Comboni Vocational Institute .............................................................................

1.3.1 Location of DCVI ................................................................................................................................ 2

1.3.2 Address of DCVI ................................................................................................................................. 2

1.3.3 Mission statement of DCVI ................................................................................................................. 2

1.3.4 Vision statement of DCVI.................................................................................................................... 2

1.3.5 Objectives of DCVI ............................................................................................................................. 2

1.3.6 Services offered by DCVI ....................................................................................................................

1.3.7 Clientele of DCVI ................................................................................................................................

1.3.8 Departments at DCVI .......................................................................................................................... 3

1.3.10 The MVT Department ........................................................................................................................

1.3.11 The Motor Vehicle Workshop ........................................................................................................... 6

CHAPTER TWO: MOTOR VEHICLE TECHNOLOGY .....................................................................

2.1 Introduction .............................................................................................................................................

2.2 Vehicle Systems ...................................................................................................................................... 7

2.2.1 The Transmission System .................................................................................................................... 7

2.2.2 The Electrical System .......................................................................................................................... 8

2.2.3 The Fuel System .................................................................................................................................. 9

2.2.4 The Braking System ...........................................................................................................................

2.2.5 The Suspension System ..................................................................................................................... 11

2.2.6 The Steering System .......................................................................................................................... 14

2.2.7 The Intake and Exhaust Systems ....................................................................................................... 15

CHAPTER THREE: HANDS-ON ACTIVITIES CARRIED OUT .....................................................

3.1 Introduction ...........................................................................................................................................

3.2 Diagnosis and correction of failure of a car battery ..............................................................................

3.2.2 Fault found with the battery ...............................................................................................................

3.2.4 Technical procedures followed .......................................................................................................... 20

3.3 Replacement of water pump of a Cesspool truck.................................................................................. 20

3.3.2 Fault found with the water pump .......................................................................................................23

3.3.3 Tools and equipment used to replace the pump .................................................................................24

3.3.4Technical procedures followed ...........................................................................................................24

3.4 Replacement of hydraulic oil of a FAW truck

3.4.1 Dangers involved in working with hydraulic fluids

3.4.2 Safety precautions when dealing with hydraulic fluids

3.4.3 Common faults with the hydraulic system

3.4.4 Solutions to the common faults

3.4.5 Recommendations on hydraulic systems

3.4.6 Faults found with the hydraulic oil

3.4.7 Tools and equipment used to replace the hydraulic oil

3.4.8 Technical procedures followed

3.5 Replacement of leaf springs of a FAW truck

3.5.1 Functions of the suspension of the vehicle

3.5.3 Maintenance of leaf springs

3.5.4 Fault found with the leaf

3.5.5 Safety precautions while replacing leaf springs

3.5.6 Tools and equipment used to replace the leaf springs

3.5.7 Technical procedures followed to replace the leaf springs

3.6 Replacement of a tire of a garbage truck

3.6.1 Common tire problems and their solutions

3.6.2 Minimizing tire problems

3.6.3 Fault found with the tire

Grade：（Five-stage) Instructors：