Mechanical Engineering Internship report by Job Lazarus Okello.

MAKERERE

UNIVERSITY

COLLEGE OF ENGINEERING, DESIGN, ART AND TECHNOLOGY

SCHOOL OF ENGINEERING DEPARTMENT OF MECHANICAL MECHANICAL ENGINEERING INDUSTRIAL TRAINING REPORT AT KAMPALA CAPITAL CITY AUTHORITY

BY NAME:

OKELLO JOB LAZARUS

REG. NO. 14/U/1050 STUDENT NO. 214000258

AREPORT SUBMITTED TO MAKERERE UNIVERSITY, DEPARTMENT OF MECHANICAL ENGINEERING IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF THE DEGREE IN BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING OF MAKERERE UNIVERSITY

AUGUST, 2016

DECLARATION

I OKELLO JOB LAZARUS , do declare to the best of my knowledge, that this report is originally mine; it is a true record of the work I undertook during my industrial training at KCCA and has never been submitted for the award of a Degree in Bachelor of Science in Mechanical Engineering or any other academic qualification to Makerere University or any other University or academic institution of higher learning.

Signature………………………………………. Signature……………………………………….  

Date……………………………………… Date………………………………………

OKELLO JOB LAZARUS

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APPROVAL

This industrial training report has been submitted by the approval of the following:

Signature………………………………… Signature…………………………………

Date……………………………

TONNY SENYANGE

Signature………………………………… Signature…………………………………

Date……………………………

Dr. OLUPOT W. PETER.

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DEDICATION

This report is dedicated to my venerable mother Ms. Florence Auma who pays the greatest price for my education. May the almighty God reward you abundantly.

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ABSTRACT

Industrial training is one of the requirements for the award of the Degree in Bachelor of Science in Mechanical Engineering of Makerere University. As such, students are required to write and submit reports at the end of their training. This report is the record of the work I personally did during my industrial training at Kampala Capital City Authority (KCCA) Mechanical Yard from June to August.2016. It consists of four chapters which altogether explain the objectives of industrial training, entail  background information about KCCA, various activities carried out at the Mechanical Yard, the hands-on activities which I took part in, the SWOT analysis of the institution and the skills acquired, challenges faced, recommendations and conclusion. Chapter one covers the objectives of industrial training, gives the background information about KCCA including its core values, mission, vision, products and services provided and clientele. Chapter two entails all the practical activities undertaken at the workshop giving for each activity, the different tools and equipment used, technical procedures followed, common faults, their causes and remedies. Chapter three presents the SWOT analysis of the institution-its strengths, weaknesses, opportunities and threats. Chapter four covers the skills acquired, challenges faced, recommendations and conclusion.

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ACKNOWLEDGEMENTS

First and foremost, I would like to express my sincere gratitude and appreciation to God for His unconditional unconditional love, guidance and protection; and for making the training a success. It is entirely by His grace that I have reached this far in life in general and the academic journey in particular. Praise, glory and honor be to Him! I extend my heartfelt gratitude to the management of KCCA for granting me the valuable opportunity to train at their Engineering Department. In particular my appreciation goes to my training supervisor,  Eng. Tonny Senyange  for his  precious guidance and support rendered to me throughout the training. I also thank all the staff of the KCCA Mechanical Yard for the great ideas and thoughts shared with me during the entire training period and for their hospitality and cooperation that made it inevitable for me to acquire the much desired practical knowledge and skills in the field of Mechanical Engineering. Special thanks also go to the Mechanical Engineering Department of Makerere University and the University Administration at large for availing me with this study time so as to apply the theoretical skills learnt in class into real life problem-solving situations and understanding of the Mechanical Engineering profession at large. With great honor and in a special way, I thank my University supervisor Dr. Olupot W. Peter for his tremendous support and guidance rendered to me both during and after the training.

Sincere gratitude is also expressed to my fellow trainees with whom we shared valuable ideas; for their support, company and continued team work exhibited during the entire industrial training period. I am immensely grateful to my spiritual leaders and friends: Pr. Micheal Nyisomeh, Pr. Dickson Kanakulya, Sr. Mackrine Nyisomeh, Ms. Babirye Elizabeth Diana, Adoyo Evans Ouma, Segawa Badiru, Mr. Brian Coutinho, Mrs. Mariam Coutinho and all the brethren of Christian Missionary Fellowship International Kampala church, for their prayers, guidance and love and for pouring spiritual wisdom into my life. Most importantly, heartfelt thanks and love, to my mother Ms. Florence Auma   for her assistance, support, love, encouragement and inspiration, and for paying the greatest price for my education. Finally to all those who have supported my academic journey yet whose names are not mentioned here, I am grateful and very much appreciate all your contributions. May the ever good Lord immensely reward you all!

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TABLE OF CONTENTS

DECLARATION .............................................. ...................................................... ............................................................................... ......................... i APPROVAL ................................................................................................................................... ii DEDICATION .................................................. ...................................................... ............................................................................. ....................... iii ABSTRACT ...................................................... ............................................................................................................ ............................................................................. ....................... iv ACKNOWLEDGEMENTS ................................................. .................................................... ........................................................... ....... v TABLE OF CONTENTS ..................................................... ......................................................................................................... .......................................................... ...... vi LIST OF TABLES ..................................................... .......................................................................................................... .................................................................... ............... xi LIST OF FIGURES ..................................................................... ................................................. xii LIST OF ACRONYMS USED ..................................................... .................................................................................................... ............................................... xiii

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 KCCA background.................................................................................................................... 2 1.3.1 Location ................................................................................................................................. 2 1.3.2 Administrative divisions of Kampala .................................................................... ................ 3 1.3.3 Mission statement of KCCA ............................................... ................................................... 3 1.3.4 Vision statement of KCCA .................................................................................................... 3 1.3.5 Core values of KCCA ............................................................................................................ 4 1.3.6 Services offered by KCCA .................................................................................................... 4 vi

1.3.7 Clientele of KCCA ...................................................... .......................................................................................................... ........................................................... ....... 4 1.3.8 Directorates of KCCA............................................................................................................ 5 1.3.9 The Directorate of Engineering & Technical services ......................................................... 8 1.3.10 The KCCA Mechanical Yard............................................................................................... 9

CHAPTER TWO: HANDS-ON ACTIVITIES CARRIED OUT ................................................ 10 2.1 Introduction ................................................. ...................................................... ............................................................................ ...................... 10 2.2 Diagnosis and correction of failure of a car battery .................................................... ................................................................ ............ 10 2.2.1 Common faults of the car battery, their causes and remedies.............................................. 10 2.2.1.1 Low charge........................................................................................................................ 10 2.2.1.2 Sulphation ......................................................................................................................... 11 2.2.1.3 Wear and tear due to ageing.............................................................................................. 12 2.2.1.4 Incorrect application ......................................................................................................... 12 2.2.1.5 Low acid stratification ...................................................................................................... 12 2.2.1.6 Low acid level ................................................ ..................................................... ................................................................... .............. 12 2.2.1.7 Slipping ............................................................................................................................. 12 2.2.1.8 Overcharging..................................................................................................................... 12 2.2.1.9 Electrical faults ................................................................................................................. 13 2.2.2 Fault found with the battery ................................................ ................................................. 13 2.2.3 Tools and equipment used to recharge the battery............................................................... 13 2.2.4 Technical procedures followed ............................................................................................ 13 2.3 Diagnosis and correction of power steering faults of a Ford Ranger Double cabin ............... 14 2.3.1 Common faults with the steering system, their causes and remedies .................................. 14 2.3.2 Tools and equipment used ................................................................................................... 16 vii

2.3.3 Safety precautions for the operation .................................................................................... 16 2.3.4 Technical procedures followed ............................................................................................ 17 2.4 Replacement of water pump of a Cesspool truck ................................................................... 17 2.4.1 Common faults with water pumps, their causes and remedies ............................................ 18 2.4.2 Fault found with the water pump ................................................. ........................................ 20 2.4.3 Tools and equipment equipmen t used to replace the pump ....................................................... ................................................................... ............ 20 2.4.4 Technical procedures followed ............................................................................................ 20 2.5 Replacement of hydraulic oil of a FAW truck .................................................. ...................... 21 2.5.1 Dangers involved in working with hydraulic fluids ............................................................ 21 2.5.2 Safety precautions when dealing with hydraulic fluids ....................................................... 22 2.5.3 Common faults with the hydraulic system........................................................................... 22 2.5.4 Solutions to the common faults............................................................................................ 23 2.5.5 Recommendations on hydraulic systems ............................................................................. 24 2.5.6 Faults found with the hydraulic oil ...................................................................................... 25 2.5.7 Tools and equipment used to replace the hydraulic oil........................................................ 25 2.5.8 Technical procedures followed ............................................................................................ 25 2.6 Replacement of leaf springs of a FAW truck .................................................... .......................................................................... ...................... 26 2.6.1 Functions of the suspension of the vehicle .......................................................................... 26 2.6.2 The purpose p urpose of leaf springs ................................................. ................................................. 27 2.6.3 Maintenance of leaf springs ................................................................................................. 27 2.6.4 Fault found with the leaf springs ......................................................................................... 27 2.6.5 Safety precautions while replacing leaf springs ....................................................... ................................................................... ............ 27 2.6.6 Tools and equipment used to replace the leaf springs ......................................................... 27 2.6.7 Technical procedures followed ............................................................................................ 28 viii

2.7 Replacement of a tire of a garbage truck ................................................................................ 29 2.7.1 Common tire problems and their solutions .................................................... .......................................................................... ...................... 29 2.7.2 Minimizing tire problems .................................................................................................... 30 2.7.3 Fault found with the tire ....................................................... ....................................................................................................... ................................................ 31 2.7.4 Safety procedures while replacing tires ............................................................................... 31 2.7.5 Tools and equipment used to replace the tire....................................................................... 31 2.7.6 Technical procedures followed ............................................................................................ 31 2.8 Starter motor troubleshooting ............................................... ................................................. 32 2.8.1 Common symptoms of a failing or bad Starter, their causes and remedies ......................... 33 2.8.2 Safety procedures while troubleshooting a starter motor ............ ........................................ 33 2.8.3 Tools and equipment used ................................................................................................... 34 2.8.4 Technical procedures followed ............................................................................................ 34 2.8.5 Testing the starter .............................................. ..................................................... ................................................................... .............. 34 2.9 Clutch adjustment ................................................................................................................... 35 2.9.1 Common faults with the clutch system, their th eir causes and remedies ..................................... 36 2.9.2 Faults found with the clutch system..................................................................................... 37 2.9.3 Tools and equipment equipmen t used to adjust the clutch .................................................................... 37 2.9.4 Technical procedures followed ............................................................................................ 37

CHAPTER THREE: SWOT ANALYSIS OF KCCA ...................................................... .................................................................. ............ 39 3.1 Introduction ................................................. ...................................................... ............................................................................ ...................... 39 3.2 Strengths (S)............................................................................................................................ 39 3.3 Weaknesses (W)...................................................................................................................... 39 3.4 Opportunities (O) .................................................................................................................... 40 ix

3.5 Threats (T) .............................................................................................................................. 40 CHAPTER FOUR: SKILLS ACQUIRED, CHALLENGES FACED, RECOMMENDATIONS AND CONCLUSION ................................................ ..................................................... ................................................................... .............. 41 4.1 Introduction ................................................. ...................................................... ............................................................................ ...................... 41 4.2 Experience gained/achievements from the training .................................................... ................................................................ ............ 41 4.3 Challenges faced during the training ...................................................................................... 41 4.4 Recommendations ................................................ ..................................................... ................................................................... .............. 42 4.5 Conclusion .............................................................................................................................. 43

REFERENCES ............................................................................................................................. 44

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LIST OF TABLES

Table 1: KCCA Directorates and their mandates ........................................................................... 5 Table 2: Steering system troubleshooting chart ...................................................... ............................................................................ ...................... 15 Table 3: Water pump troubleshooting chart ................................................................................. 18 Table 4: Clutch diagnosis/troubleshooting chart .............................................................. ............ 36

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LIST OF FIGURES

Figure 1: The KCCA logo............................................................................................................... 2 Figure 2: KCCA organizational organiz ational structure. ..................................................... ...................................................................................... ................................. 7 Figure 3: Organizational Structure S tructure of the Directorate of Engineering and Technical Techn ical services ...... 8 Figure 4: Recharging the battery................................................................................................... 13 Figure 5 : The removed water pump. .................................................... ............................................................................................ ........................................ 21 Figure 6:The unit that houses the water pump. .............................................. ............................... 21 Figure 7: Draining the hydraulic oil.............................................................................................. 26 Figure 8: Removing the broken leaf springs ................................................. ............................... 29 Figure 9: The broken leaf springs that were removed .................................................................. 29 Figure 10: Removing the tire ........................................................................................................ 32 Figure 11: Testing the voltage being received by the starter ........................................................ 35 Figure 12: The opened clutch system. .......................................................................................... 38 Figure 13: The removed pressure and clutch plates. ............................................... ...................... 38

xii

LIST OF ACRONYMS USED

AC

Alternating Current

CITIE

Client care, Integrity, Teamwork, Innovativeness, and Excellence

DD

Deputy Director

DED

Deputy Executive director

E&TS

Engineering and Technical Services

ED

Executive Director

ESD

Education and Social Services Directorate

EU

European Union

KCC

Kampala City Council

KCCA

Kampala Capital City Authority

km

Kilometer

kpa

kilopascal

 NEMA

National Environment Management Authority

 NGOs

Non-Governmental Organizations

 NOA

Non-Asbestos

PH&ED

Public Health and Environment Directorate

PPE

Personal Protective Equipment

UIPE

Uganda Institute of Professional Engineers

ULS

Uganda Law Society

UPDF

Uganda People’s Defense Forces

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CHAPTER ONE: GENERAL INTRODUCTION

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.

1.2 Industrial training objectives

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

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.

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.

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1.3 KCCA background Kampala Capital City Authority (KCCA) is the legal entity, established by the Parliament of Uganda that is responsible for the operations of Kampala, the Capital city of Uganda. It replaced Kampala City Council (KCC).

1.3.1 Location The headquarters of KCCA are located on Nakasero Hill in the central business district of Kampala, immediately southwest of the Uganda Parliament Building. The main entrance to the KCCA Complex is located on Kimathi Avenue, which comes off of Parliament Avenue, few kilometers from Kampala-Jinja road alongside Sir Apollo Kagwa road. The coordinates of this  building are 0° 18' 54.00"N, 32° 35' 9.00"E (Latitude: 0.315000; Longitude: 32.58583 2). The logo of KCCA is shown in Fig 1below.

Figure 1: The KCCA logo. KCCA address.

P.O.BOX 7010 Kampala-Uganda. Tel: (+256)-0204660000 Toll free line: (+256)-0800990000. Email: [email protected]

Kampala since independence was generalized as a local government and the government act (CAP 243) did not grant any special status to recognize the Capital city status. By then it was like any other district. Service delivery and infrastructure development directly affected the quality of life of its residents and majority of the public hinged their future hopes on the activities and programs being developed within the C apital city and environments.

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The city of Kampala faced a number of challenges, including the following that were listed in a  published report in 2011: High population, potholes, ineffective sanitation practices, traffic congestion and increased death rates due to accidents. Kampala was no longer reflecting a Capital city image in terms of governance and resource allocation. It was not meeting the set standards and requirements of the central government like sanitation, utilities and economic sector regulation. The Parliament of Uganda, at the request of the cabinet, passed the Kampala Capital City Authority Act in November 2010 to become effective on 1st. March .2011 that led to the birth of KCCA. In a nutshell, the affairs of Kampala Capital city were brought under the direct supervision of the central government of Uganda. The City Clerk, formerly the highest financial officer in the city, was replaced by the Executive Director, who is answerable to the Minister for Kampala. The elected mayor became the Lord Mayor, now a largely ceremonial position. Lastly, in addition to the politically elected councilors, the expanded KCCA Council has members from the following professional bodies, as full voting members: Uganda Institute of Professional Engineers (UIPE), Uganda Society of Architects, Uganda Medical and Dental Practitioners Council and Uganda Law Society (ULS).

1.3.2 Administrative divisions of Kampala

Kampala is divided into five divisions, each headed by a popularly elected mayor. The divisions are preserved under the KCCA Act. They are: Nakawa, Makindye, Central, Kawempe and Rubaga.

1.3.3 Mission statement of KCCA

To deliver quality services to the city The meaning of the key words: Delivering-   providing and facilitating the delivery of public -top of the range of services offered to residents and visitors in the services in the city. Quality  city. Services  - public services and innovative thinking that enables citizens and visitors realize their individual and community goals, and City-  the people, natural resources, physical the infrastructure and landscape within the defined territory of Kampala.

1.3.4 Vision statement of KCCA

To be a vibrant, attractive and sustainable city 3

The meaning of the key words: Vibrant  -a healthy, economic and socially viable city. Attractive  an admirable, green, secure and hospitable city. Sustainable  -an efficient use of the environment,  protection of the biodiversity and natural ecosystem.

1.3.5 Core values of KCCA

Client care, Integrity, Teamwork, Innovativeness, and Excellence (CITIE). The meaning of key words: Cli ent care  -we shall attend to needs of clients fairly, professionally and in timely manner. Integrity  -we shall be honest, transparent and accountable in the execution of our work. Teamwork  ovativenes ss  -we shall support and respect each other. I nn ovativene -we shall use creative approaches in addressing needs of clients. Excellence- we shall deliver a high standard of performance that exceeds expectations of clients.

1.3.6 Services offered by KCCA The Authority is mandated with provision of services in the city that enables residents and businesses operating in the city to function in an environment that supports development. These services are: Health services, Waste management, Education, Probation and social welfare, Gender mainstreaming, Youth and community development, and Credit facilities.

1.3.7 Clientele of KCCA

The clientele of KCCA include among others; the general public, 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 Kampala city, Non-Government Organizations [NGOs] operating within the city, Tourists, Health centers and hospitals, Security institutions like the UPDF, Uganda Police, Uganda Prison and many others.

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1.3.8 Directorates of KCCA

KCCA is made up of ten Directorates each with its mandate as presented in table 1 below. Table 1: KCCA Directorates and their mandates DIRECTORATE

MANDATE

Directorate of Administration and Human Resource Management.

To provide effective and efficient Human Resource R esource and Administration interventions to Authority Directorates.

Directorate of Physical

To plan, design and manage manag e City physical infrastructure including the zoning, land sub division and demarcating areas for development.

Planning.

Directorate of Treasury Services.

To prepare the Institutional budget, manage and account for both expenditure and revenue for the Authority.

To design, implement and maintain infrastructure, give technical support Directorate of Engineering and control infrastructure developments in the City, in terms of defining and technical services structural designs, carrying out road works and maintenance of City (E&TS). infrastructure.

Directorate of Public Health To facilitate and provide support to ensure h ealth and productivity of Services and Environment. citizens; and a clean, habitable and sustainable community for the city.

Directorate of Education and Social services.

Directorate of Legal Affairs.

To provide, support, guide, coordinate, regulate and promote quality Education, Sports, Recreation and tourism activities to the community in Kampala City that are geared towards individual a nd national development.

To provide a comprehensive program of legal services to the Authority, supporting virtually every facet of the Authority’s work.

To review the business procedures using existing guidelines, policies and any other documentation in place. Directorate of Revenue

To come up with a revised position which is expected to enhance revenue 5

Collection.

operations in terms of data collection and analysis. To establish a clear link between the payment p ayment or collection of taxes and the provision of services for which they are meant to finance. To conduct taxpayer sensitizations, education and mobilization, policy review, decision making and ultimate Revenue collection maximization. To mobilize appropriate levels of revenue mainly from local tax base to effect service provision and address poverty in the city.

Directorate of Internal Audit.

Directorate of Gender and Community Services.

To examine and evaluate the adequacy and effectiveness of the governance, risk management, systems of internal control and the quality of performance of KCCA when carrying out assigned responsibilities; aimed at achieving the stated goals and an d objectives of the institution. To empower and facilitate communities, particularly the vulnerable groups, to realize and harness their potential for pu rposeful and sustainable development.

The organizational structure of KCCA The organizational structure of KCCA is as shown in Fig.2 below. During my internship, I was assigned to the Directorate of Engineering and Technical services. A description of the activities carried out in this Directorate is given in section 1.3.9 of this report.

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Figure 2: KCCA organizational structure.

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1.3.9 The Directorate of Engineering & Technical services

The Directorate is responsible for designing, implementation and maintenance of infrastructure, giving technical support and controlling infrastructure developments in the City, in terms of defining structural designs, carrying out road works and maintenance of City infrastructure. The Directorate guides the Authority on the urban structural design, infrastructure improvement and road network development in the City. Its various departments are illustrated in Fig. 3 below. At KCCA, interns are attached to the different Directorates on the basis of their respective courses which they pursue. The Directorates then design training programs for them. Engineering interns are attached to the Directorate of Engineering and Technical services. As an engineering student, I was attached to the Mechanical Department which is housed at the Mechanical Yard. DIRECTORATE OF ENGINEERING AND TECHNICAL SERVICES

DEPUTY DIRECTOR BUILDINGS

OPERATIONS MANAGER

DEPUTY DIRECTOR ROADS

MECHANICAL DEPARTMENT

ELECTRICAL DEPARTMENT

MECHANICAL ENGINEERS

ELECTRICAL ENGINEERS

MECHANICAL TECHNICIANS

ELECTRICAL TECHNICIANS

CASUAL WORKERS

CASUAL WORKERS

Figure 3: Organizational Structure of the Directorate of Engineering and Technical services

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1.3.10 The KCCA Mechanical Yard

The Yard is the referral workshop for all auto-mobiles of KCCA and is thus responsible for maintaining and ensuring that they are all in good mechanical and electrical working conditions. It is located on Sixth street Industrial area, Kampala. A number of activities are carried out in this workshop with an aim of keeping the motor vehicles and equipment in good operating conditions and some of which include; Engine overhaul, gear box overhaul, auto-body repair, general servicing and minor repairs. 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 Yard consists of garbage trucks, construction equipment, service vehicles, managerial vehicles and Executive vehicles. They total up to approximately 220 in number. While training at the Mechanical Yard, I engaged in very many activities as exhaustively explained in the next chapter.

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CHAPTER TWO: HANDS-ON ACTIVITIES CARRIED OUT

2.1 Introduction Introduction

During my training at the KCCA Mechanical Yard, 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; diagnosis and correction of battery failure, tire replacement, diagnosis and correction of power steering faults of a car and replacement replac ement of hydraulic oil of a truck.

2.2 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 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. maintenance.

2.2.1 Common faults of the car battery, their causes and remedies

The following are the common faults associated with the car battery; their causes and corrections.

2.2.1.1 Low charge

This is caused by leaving the battery in uncharged condition for a long time and also when  battery usage exceeds battery capacity. Solution: The best solution for this problem is to recharge the battery. A jump start as well as a trickle charger can be used for this operation. A trickle charger is most commonly used. It delivers electricity to the battery from a power outlet in a slow, steady stream. It has an electric cord with a plug and two jumper cables with alligator clips. Procedures.

Before starting the recharging process, Safety must be observed. Since the battery acid is hazardous, be sure to take adequate precautions when handling old battery terminals to  protect skin and clothing. The following procedures are involved in charging the car battery; a. Clean the battery terminals. Check the terminals of the battery and clean them. Do not touch the terminals if they

b.

c.

d.

e.

wet cloth and apply a layer of baking soda (Sodium bicarbonate) to the cloth. Care should be taken not to allow the solution to make contact with skin and clothing. Rub the terminals down with the removal system, and ensure that they are ready to receive the wires. Remove the cell caps. On many batteries, there is a series of small caps, these caps are known as cell caps, and they have to be removed before a battery charger can be used, otherwise gases created by charging will not be able to escape into the atmosphere. Attach the charger cables. Make sure that the car is turned off and then attach the cables or wires to the battery terminals. The charger has two wires; the one which has to be connected to the red or positive terminal and the other which is connected to the negative terminal. Make sure that the two wires do not touch each other. This is because the wires spark when they touch; causing ignition of the hydrogen gas that surrounds the battery. This could cause nasty burns and serious injuries or even cause an explosion. Turn on the charger. Once both terminals are connected, connect the charger to the electric outlet. Turn on the current and the battery will charge itself. Leave the charger on for sufficient amount of time. Turn off the charger and check the reading on it. If the reading is less than an Ampere, then you can unplug the charger. Check the battery. After charging, check the battery to find out whether it works. Use the hydrometer to find out the amount of electric energy ene rgy in the fluid or turn on the engine. If the battery still does not turn on, then the battery might have to get replac ed.

2.2.1.2 Sulphation

If the battery is allowed to stand in a discharged state either on or off the vehicle for a long  period of time, a chemical reaction takes place which permanently impairs the performance and life of the battery. It can be seen as a fine white/grey coating of the positive plate. This is called sulphation. Solution: Clean the battery terminal. Procedures:

The following procedures can be taken to clean the battery terminal. a. Check the battery terminals to see if there is a fine white/grey coating on the  positive plate and the non-metallic luster on the negative plate.  b. Do not touch the terminals if they are covered with a whitish powder. This is dried sulfuric acid and it can burn bare hands. c. Use a manual sand paper pad to wipe around the terminals or get a wet cloth and

d. Take care not to allow the solution to make contact with skin and clothing. Rub the terminals down with the removal system.

2.2.1.3 Wear and tear due to ageing

As the battery is charging and discharging, the active materials within the battery plates are in motion in order to release electricity stored by the battery. This leads to the wear and tear of the battery when used for a long period of time. Remedy:

Replace the battery.

2.2.1.4 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.

2.2.1.5 Low acid stratification 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.

2.2.1.6 Low acid level

This is when the level of the acid in i n the battery is not enough as required. Remedy: Refill the battery to required level.

2.2.1.7 Slipping

This occurs due to incorrectly adjusted alternator charging the belt. Remedy: Adjust the alternator to required recommendations.

2.2.1.8 Overcharging 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.

2.2.1.9 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.

2.2.2 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.

2.2.3 Tools and equipment used to recharge the battery

The following tools were used to recharge the batter y; Trickle charger, Power stroke, Manual sand paper pad and a pair of pliers.

2.2.4 Technical procedures followed

The following procedures were followed to recharge the batter y; a.  b. c. d. e.

The battery terminals were checked and cleaned cle aned using a manual sand paper. The cell caps were removed. The charger cables were attached with the car turned off. The charger was turned on for the battery to charge i tself. The battery was checked to find out whether it worked after charging and it functioned properly. The recharging operation is shown in Fig. 4 below.

Figure 4: Recharging the battery

2.3 Diagnosis and correction of power steering faults of a Ford Ranger Double cabin

Power steering problems can make controlling the vehicle much harder especially around curves and corners. The power steering unit of the car uses a hydraulic system that takes a lot of the steering strain off of the driver. This system builds up pressure as the wheel is turned; and pushes the tires to either side as the car is turned. When there are power steering  problems, the driver will instantly notice the difference as it becomes very hard to turn the steering wheel.

2.3.1 Common faults with the steering system, their causes and remedies

The common problems associated with the power steering system; their causes and solutions are summarized in table 2 below.

Table 2: Steering system troubleshooting chart FAULT

Hard steering

Leaking hoses and seals

Tight / loose steering / valve assembly out of hydraulic  balance

 Noises

POSSIBLE CAUSE(S).

REMEDY(IES).

(1) Improper tire pressures. (1) Inflate tires to recommended  pressures. (2) Loose pump drive belt. (2) Tighten or replace belt. (3) Low or incorrect fluid. (3) Refill reservoir with proper fluid (4) Loose, bent or poorly lubricated front end check for leaks.  parts. (4) Tighten or replace parts: (5) Improper front end alignment. Lubricate all fittings. (6) Partial seizure in steering column or (5) Align front end. (6) Disassemble and inspect linkage. component parts. Repair or replace (7) Air in hydraulic system. as necessary. (8) Low pump output or leaks in system. (7) Bleed system. Refill and check (9) Obstruction in lines. for leaks. (10) Pump valves sticking or out of (8) Disassemble pump. Check for adjustment. worn or damaged parts. Check for (11) Steering rack / box worn out. leaks in the system. (9) Clean or replace lines. (10) Replace or adjust valves. (11) Re-engineer. 1 Too much fluid in pump reservoir. (1) Remove oil to proper level. 2 Damaged or improperly installed. (2) Replace or adjust O-ring in 3 Loose pump fittings or studs.  pump reservoir. 4 Defective pump and seals. (3) Re-torque to specifications. 5 Cracks in hose or splits in fittings. (4) Replace. (5) Replace hose assembly. 1 Loose wheel bearings. 2 Faulty shocks. 3 Worn linkage li nkage components. 4 Loose steering gear mountings or linkage  points. 5 Steering rack / box worn or improperly adjusted. 6 Torsion bar bent due to impact.

(1) Adjust wheel bearings. (2) Replace shocks. (3) Replace worn components. (4) Tighten mountings or linkage. (5) Replace and/or adjust unit. (6) Replace rack / box.

1 Loose belts. 2 Low fluid, air in system. 3 Foreign matter in system. 4 Improper lubrication. 5 Interference in linkage. 6 Steering gear mountings loose. 7 Incorrect adjustment or wear in rack or box.

(1) Replace and/or adjust belts. (2) Refill and check for leaks. (3) Disassemble and clean system. (4) Lubricate all fittings. (5) Disassemble, inspect, replace or adjust components. (6) Tighten mountings.

(8) Replace pump as necessary.

Veer or wander

Wheel oscillation

(1) Improper tire pressure. (2) Improper front end alignment. (3) Binding brakes. (4) Front cradler loose or accident damage. (5) Improper rear end alignment. (6) Faulty shocks or springs. (7) Loose or bent front end components. (8) Play in pitman drop arm. (9) Loose wheel bearings. (10) Pitman drop arm ball joint seizure.

(1) Inflate tires to recommended  pressures. (2) Align front end. (3) Inspect replace and/or adjust  brakes. (4) Straighten frame. (5) Inspect shocks and control arm torque replace and/or adjust as necessary. (6) Replace as necessary. (7) Replace as necessary. (8) Inspect bushings and arm. Replace as necessary (9) Adjust to specifications specifications (10) Replace arm

(1) Improper tire pressures (2) loose wheel bearings (3) improper front end alignment ali gnment (4) worn tie rods (5) worn, bent or broken front end components (6) tires out of round or out of balance (7) excessive lateral run out in disc brake, disc or rotor

(1) Inflate tires to recommended  pressures (2) adjust to specifications (3) align front end (4) track rod ends (5) inspect, repair or replace as necessary (6) replace or balance tires (7) reface or replace brake disk or rotor

2.3.2 Tools and equipment used

An open spanner, a hammer, ring spanner, wrenches, floor jack, trolley jack, combination spanner and box spanner.

2.3.3 Safety precautions for the operation

The following are the safety measures that should be observed when diagnosing and correcting power steering faults of a car. a. Always follow the procedures of the manufacturer of the vehicle, for lifting and  blocking.  b. Clean up all oil spills to avoid slips and falls.  Never use old or used seals, cotter pins, retainers or critical fasteners. Use a new seal

e.  Never check for leaks by hand, hydraulic oil under pressure can penetrate the skin and cause severe injury.

2.3.4 Technical procedures followed

The following procedures were observed during the operation. a. The vehicle was parked on a clean, dry, solid surface, the parking brake was set, the rear wheels blocked and the transmission transmi ssion placed in neutral.  b. Using the hydraulic jack, the front end of the vehicle was raised until the tires had cleared the surface. c. The hood of the vehicle was tilted. d. The drain pan was placed under the steering gear to catch the steering fluid. e. The pressure and return lines from the steering gear were removed to drain the fluid. f. The area around the reservoir cap was wiped off with a clean towel, the bolt was removed from canister type reservoirs and the cover was removed. g. Using the filter wrench, the filter was removed from the canister and the filter elements discarded. h. The inside of the reservoir canister was wiped clean with a clean shop towel. i. With the hoses disconnected, the steering wheel was slowly turned from full left to full right several times to purge oil from the steering gear.  j. The pressure and return lines to the steering ste ering gear were attached and tightened. tighte ned. k. A new filter element was installed in the reservoir. l. The reservoir cap was cleaned with a solvent; the old gasket was removed from the cap and replaced with a new gasket. m. The reservoir was filled with new steering fluid, the reservoir cover was installed and the bolt tightened. n. The vehicle was started and allowed to idle. o. The fluid level was checked and filled as needed.  p. The vehicle was steered from full left to full right several times and the fluid level checked again and fluid was added. q. All fittings and hoses were visually checked for external leaks. Reservoir was not allowed to empty during start up as pump damage could result. r. The vehicle was shut off, the drain pan removed and the vehicle was lowered until the tires contacted the surface and removed the jack. s. The cab was lowered.

2.4 Replacement of water pump of a Cesspool truck

The engine of a vehicle needs coolant just as much as it needs oil. Engine coolant helps

radiator. The water pump is the key to making the entire system work. It is an impeller pump,  buried under the timing belt cover on the side of the engine. The pump is operated by the drive belt of the engine  –   as the belt turns, the pump turns. Blades on the pump force the coolant to flow through the engine. When the water 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 the y are wearing are wearing out.

2.4.1 Common faults with water pumps, their causes and remedies

Table 3 below shows common faults with water pump, their causes a nd remedies. Table 3: Water pump troubleshooting chart

Fault Weep hole leakage. Appearance: The internal mechanical seal of the pump seals the shaft towards the cooling circuit, protecting the  bearings by preventing coolant from passing into the bearing assembly. When a water pump is new, some seepage from the weep hole is normal as it takes about ten minutes of operation for the mechanical seal to  properly seat itself (break-in  period). More pronounced seepage and drips from the weep hole after this break-in  period or a large coolant bleed mark around the weep hole are abnormal and indicate impending water pump failure. Leakage from the mounting surface. Appearance: Seepage, drips or large coolant bleed marks on or around the mounting surface or on the housing.

Cause(s)

Remedy(ies)

Contaminated coolant is the main cause of weep hole leakage.

Thoroughly flush the cooling system  before installing the new pump and refill the system with the recommended coolant of the manufacturer of the vehicle.

Improper water pump installation or improper use of seals/gaskets or sealant

In case of a recently installed new water pump, carefully remove, check and re-install and re-install the water pump.

on the surfaces of the water  pump, for example corrosion of the impeller fins makes the  pump ineffective in moving the coolant.

compatible coolant or  before installing the new pump and mixing coolants of refill the system with the different chemistries. recommended coolant of Another possible manufacturer of the vehicle cause may be a defective pressure Inspect the pressure cap and replace cap causing air if defective.  bubbles, accelerating the rust process. Deposit build-up. Contaminated Appearance: Deposits, sludge coolant, nonReplace the water pump. and scale build up on the inside, compatible coolant or Thoroughly flush the cooling system clogging the water pump and mixing coolants of  before installing the new pump and hampering proper functioning different chemistries. refill the system with the correct of its individual components. vehicle manufacturer’s recommended coolant. Cavitation. The formation of Appearance: Vapor cavities  bubbles at the (bubbles) in the coolant coolant inlet of the Replace the water pump. collapse with explosive force,  pump. As the Thoroughly flush the cooling system  pock marking the individual  pressure increases in  before installing the new pump and components of the pump. The the system, the refill the system with the correct  pockmarked areas then corrode  bubbles implode and vehicle manufacturer’s away. cause harm. recommended coolant. Damaged bearing. Misaligned belt Appearance: With the engine causes excessive off, check the condition of the wear. An over bearing by looking for any side- tensioned belt causes to-side play at the shaft. Apply overload on the hand pressure –  pressure –  there  there should be  bearing, accelerating no play at all. Also, rumbling or wear. A damaged screeching noises coming from mechanical seal the water pump indicate a worn allows coolant to  bearing. leak through the  bearings and wash away the lubricator. Damaged or broken shaft. A misaligned belt Appearance: The shaft is bent causes excessive or broken. A clean break wear. An overindicates an instantaneous tensioned belt fracture caused by sudden imposes a powerful overload or imbalance. If the  bending force on the  broken shaft is shaft resulting in discolored(usually blue), the shaft bending or damage was gradual, indicating early shaft fracture. excessive heat build-up before Excessive vibrations

Replace the water pump and make sure to inspect the belt drive system:  belt, tensioner, pulleys, belt pulleys, belt tension and alignment.

Replace the water pump and make sure to inspect the belt drive system:  belt, tensioner, pulleys, belt pulleys, belt tension and alignment. If equipped with a water pump mounted fan, inspect the fan or fan clutch assembly. The fan may not be squarely mounted on the shaft. A  bent or damaged fan, a worn spacer, or a worn or damaged fan clutch

Cooling system contamination

Casting Breakage Excessive Vibration

Seal leakage-clean System

Thermal Shock

system before replacing the water  pump. Check system pressure. Use correct coolant mixture Use distilled water where necessary. Carefully inspect pulley, belt alignment and fan / fan clutch assembly, replacing any bent or worn components. Take proper precautions when filling your radiator, especially when the engine may be very hot. Allow an overheated engine to sit and cool before adding coolant. Then, restart engine and allow it to run while slowly adding the remainder.  Never start the engine without coolant.

2.4.2 Fault found with the water pump

The water pump was worn out which could lead to complete engine failure. This prompted its replacement.

2.4.3 Tools and equipment used to replace the pump

A new water pump, ring spanner, box spanner, combination spanner and an adjustable spanner.

2.4.4 Technical 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 install ing 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.

The detached water pump and the unit that houses the water pump are shown in Figs. 5 and 6 below respectively.

Figure 5 : The removed water pump.

Figure 6: The unit that houses the water pump.

2.5 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 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 protecti on 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  brakes, Power steering systems, Transmissions systems, Transmissions and Garbage and Garbage trucks.

2.5.1 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

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.

2.5.2 Safety precautions when dealing with hydraulic fluids

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

2.5.3 Common faults with the hydraulic system

Generally, improper hydraulic system operation can be traced to one of the following deficiencies: insufficient fluid level, the presence of air in the system, contamination by

2.5.4 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 thermography 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

fluids flowing in ungrounded piping or when fluid discharges on to any free surface of the reservoir, particularly if there is free air present in the fluid. Electrostatic discharge most often manifests itself as a clicking sound as the charge repeatedly builds and then discharges to a surface of lower voltage through sparking. The increased use of synthetic fluids and mineral base oils with non-metallic anti-wear additives have resulted in fluids with low conductivity, increasing the potential for accumulated static charge levels. In severe cases, electrostatic discharge can result in etching, pitting or carbon deposits at the surfaces of the area where the discharge occurred and may leave burn marks or other damage on the filter element media. h. The foam and air entrainment inspection. As noted earlier, a darkening color of hydraulic fluid suggests that oxidation is occurring. Oxidation rates are related directly to high temperatures and excessive air entrainment combined with high pressure. At atmospheric pressure and corresponding temperature, oils contain about 10%by volume of dissolved air. At 200 psi (1400 kPa), oils can absorb about 140% by volume. The dissolved air provides the oxygen that is necessary to promote oxidation and oxidation rates rapidly increase as temperatures rise above 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!

2.5.5 Recommendations on hydraulic systems

As hydraulic systems improve and operating pressures increase, much more attention to  predictive maintenance and reliability will be required. Two areas of concern will be a requirement for improved filter design, selection and installation and hydraulic system flushing techniques after a component failure has occurred.

In the second instance, mobile filtration systems and portable hydraulic fluid purifiers will  become mandatory, if hydraulic system reliability is to be improved and and maintained.

2.5.6 Faults found with the hydraulic oil

Diagnosis of the hydraulic oil of the truck, revealed the following faults that necessitated its replacement; a. Hydraulic oil had deteriorated. When the hydraulic oil is used for a long time, it deteriorates and thus has to be replaced.  b. The base oil was degraded. c. The additive package was depleted.

2.5.7 Tools and equipment used to replace the hydraulic oil

The tools and equipment used to change the hydraulic oil were; a ring spanner, box spanner, Hammer, combination spanner, funnel, bucket, clean piece of cloth and new hydraulic oil.

2.5.8 Technical procedures followed

The following procedures were observed during the operation; a.  b. c. d. e. f. g.

The system was drained while the fluid was hot to keep contaminants in suspension. The fluid was emptied from cylinders, accumulators and lines that could not drain  properly. The oil left in the reservoir was pumped out. The reservoir was wipe-cleaned with lint free rags and rust and free paint were removed. Filter elements, strainers, and housing were cleaned. The system was refilled with new hydraulic fluid making sure to vent high points. The system was restored and checked for proper operation after which it functioned.

The drainage process of hydraulic oil is shown s hown in Fig. 7 below.

Figure 7: Draining the hydraulic oil. 2.6 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 leafs in the spring pack; determine the load capacity and the ride height of the vehicle. The cur vature 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.

2.6.1 Functions of the suspension of the vehicle

The suspension of the vehicle serves three major functions; they are to; Support the vehicle  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, s uspension, or its own system, but either way the suspension has to allow for movement of the wheels as the vehicle turns). a.

Springs in general, and leaf springs in particular, help perform the first two of these functions: they support the weight of the vehicle while absorbing bumps. A leaf spring is usually attached to the body or frame of the vehicle at each end, while the

rear; a few suspension designs feature a single leaf spring attached at each side-a side-a “transverse” spring.

2.6.2 The purpose of leaf springs

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

2.6.3 Maintenance of leaf springs

Multi-leaf Multi-leaf springs occasionally get “sticky” as dirt works its way in between the leaves; the effect can be to make the ride slightly stiffer, but this is rarely a significant problem. The attachment points will need to be checked periodically and lubricated in some cases as specified by the manual of the manufacturer, and regular maintenance should be carried out. If the body of the car seems to sit too low over the wheels, this sagging is usually due to the leaf springs having bent slightly over time, and the solution is to have them replaced.

2.6.4 Fault found with the leaf springs

Leaf springs were broken as depicted by inspection.

2.6.5 Safety precautions while replacing leaf springs

The following precautions should be observed when replacing the leaf springs; a. Always wear safety glasses when working carrying out the operation.  b. Wear other personal protective equipment (PPE) when necessary, for example latex gloves or closed toe shoes.

2.6.6 Tools and equipment used to replace the leaf springs

The following tools and equipment were used to replace the leaf springs of the truck; A ratchet, hammer, Box spanner, combination spanner (24-24), floor jack, trolley jack, lubricant (oil); ring spanners (numbers16, 18, 19 and 30), wrenches and Jack stands.

2.6.7 Technical procedures followed

a.  b. c. d. e. f. g. h. i.  j. k. l. m.

n. o.  p. q. r. s. t. u.

The vehicle was parked on a solid, level surface to ensure that it did not roll or lean when raised. Using a floor jack, the rear of the vehicle was lifted up enough for the axle assembly to hang freely. The vehicle was secured with jack stands on both sides for safety before starting any work. The rear axle assembly was supported s upported with a floor jack close to the spring. The lower bolt was removed from the shock absorber. The axle was lowered to relieve tension on the spring. The U-bolts and spring retainer bracket were rem oved. The parking brake cable was removed from the retainer bracket. The rear axle was carefully lowered since leaf springs were mounted on top of the axle. The rear shackle bolts were loosened. The leaf springs were supported with a jack stand and the leaf spring front and rear eye bolts were removed. The leaf springs were removed from the vehicle. The front bushings of the new springs were placed into the front mounting brackets, the front eye bolts and nuts were installed with the bolt heads towards the center of the vehicle. The rear bushings of the new springs were placed into the rear shackles and the rear eye bolts and nuts were loosely installed. The axles were adjusted to place the leaf springs center bolts into the holes on the axle  pads. The U-bolts and retainer brackets were installed; the U-bolt nuts were snagged down  but not tightened. The parking brake cable was reattached and the lower shock mount was attached to the axle bracket. Steps (d) through (q) were repeated for the other side si de of the truck. The truck was lowered to the ground and all bolts torqued to the recommended specifications. The leaf springs repair was verified verifie d and the vehicle was aligned. The vehicle was road-tested and found to operate well.

Figs 8and 9 below show the removal process of the leaf springs and the removed broken leaf springs respectively.

Figure 8: Removing the broken leaf springs springs

Figure 9: The broken leaf springs that were removed

2.7 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   only about the size of the palm of the hand - so if tires are worn or damaged it can seriously affect the safety safet y and handling of the vehicle.

2.7.1 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.

Emergency braking. If an emergency stop is performed, the tire wears enormously in d. Emergency 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 immediatel y.

2.7.2 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 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 c hecked 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.

However, if the guidelines are followed and tell-tale signs of potential problems are looked out for; longest life possible out of tires can be got.

2.7.3 Fault found with the tire

Inspection of the tire indicated that it was worn out; that prompted its replacement.

2.7.4 Safety procedures while replacing tires

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

2.7.5 Tools and equipment used to replace the tire

A hammer, ring spanner, wrench , floor jack, trolley jack, combination spanner, box spanner and an open spanner.

2.7.6 Technical procedures followed

a.  b. c. d. e. f. g.

The truck was parked on a flat surface. The parking brake was applied and the truck put in to park position. Rocks were placed in front of the front and back tires. The jacks were placed under the frame near the tire that was to be replaced. The jacks were raised until they were supporting but not lifting the car. The hubcap was removed and the nuts loosened by turning them counterclockwise. The jacks were pumped to lift the tire off the ground.

 j. k. l. m. n. o.  p.

The spare tire was placed on the hub, its rim aligned with wheel bolts and lug nuts  put in positions. The nuts were tightened using the wrench in a star pattern. The truck was lowered without applying full weight on the tire, and the nuts were tightened further. The truck was fully lowered to the ground. The jacks were removed. The nuts were tightened finally and the hubcap replaced. The truck was road-tested and the new tire was found to function well. The tire removal process is shown s hown in Fig. 10 below.

Figure 10: Removing the tire 2.8 Starter motor troubleshooting

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 cr ankshaft 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.

2.8.1 Common symptoms of a failing or bad Starter, their causes and remedies

They include the following: a. Grinding noise. When the starter drive gear is worn out or not engaging properly, they will often produce a grinding noise that is similar to the one that is heard if engine is started and then accidentally the starter is hit again. If the grinding symptom is ignored, it may also result in damage to the engine  flywheel. It  flywheel. It should be diagnosed immediately upon detection.  b. Freewheeling. Freewheeling occurs when the engine is cranked and simply a whining noise is heard from the starter without the engine cranking. When this occurs, it means the starter gear is not engaging with the flywheel. This is a bad situation that could result in the need for a starter replacement.  replacement.  If this is occurring, the vehicle should be service be serviced d 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 th ere is a connection  problem. Smoke might also be accompanied by b y a burning smell. If smoke is seen, the vehicle should be serviced 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 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 sti ll will not crank, cr ank, there might be something wrong with the solenoid. f. When you turn the key to crank the engine, nothing happens. The engine does not turn over. g. When the key is turned to crank the engine and all that is heard is one loud click. The engine does not turn over; or when the key is turned to crank the engine and the engine turns over very but very slowly and then stops. h. When the battery is good but the car fails to start.

2.8.2 Safety procedures while troubleshooting a starter motor

While troubleshooting a starter motor, certain safety measures need to be observed. They include the following:

a. If you have to lift up the car or truck to access the starter motor: Use jack-stands to support the car or truck off the ground, and use safety glasses while working underneath the vehicle.  b. You will need a helper to crank the engine as you perform some of the tests, and to help you perform the very important Voltage Drop Test. c. When jumpering 12 Volts to the S-terminal wire (circuit) make sure you do not shortto-ground your jumper wire.

2.8.3 Tools and equipment used

Spanners (Open, fixed, adjustable, combination and box), safety glasses, jack stands, a voltmeter, pair of pliers, screwdriver, jack, and multi-meter.

2.8.4 Technical procedures followed

a.  b. c. d.

The state of charge of the battery batter y was determined. The ignition switch was checked if it was sending power to the solenoid. The starter motor was checked if the problem lied in itself. The solenoid was tested to see if it was working.

2.8.5 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. The testing process of the voltage being received by the starter is shown in Fig. 11  below.

Figure 11: Testing the voltage being received by the starter

2.9 Clutch adjustment

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.

2.9.1 Common faults with the clutch system, their causes and remedies

They are summarized in table 4 below. Table 4: Clutch diagnosis/troubleshooting chart Faults

Fails to Release (Pedal  pressed to floor). Shift lever does not move freely in and out of reverse gear.

Slipping.

Grabbing or Chattering.

Possible causes

a. Improper linkage adjustment.  b. Improper pedal travel. c. Loose linkage. d. Faulty pilot bearing. e. Faulty driven disc. f. Fork off ball stud. g. Clutch disc hub binding on clutch gear spline. h. Clutch disc warped or bent. i. Loose pivot rings in cover assembly.

a. Improve adjustment (no lash).  b. Oil soaked driven disc. c. Worn facing or facing torn from disc. d. Warped pressure plate or flywheel. e. Weak diaphragm spring. f. Driven plate not seated in. g. Driven plate overheated.

a. Oil on facing. Burned or glazed facings.  b. Worn splines on clutch gear. c. Loose engine mountings. d. Warped pressure plate or flywheel.

Remedy(ies) a. Adjust linkage.  b. Trim bumper stop and adjust adjust linkage. c. Replace as necessary. d. Replace bearing. e. Replace disc. f. Install fork onto stud. s tud. Lightly lubricate fingers at release  bearing. g. Repair or replace clutch gear and/or disc. h. Replace disc (run out should not exceed 0.020″). i. Replace plate and cover assembly.

a. Adjust linkage to specifications.  b. Install new disc and correct leak at its source. c. Replace disc. d. Replace pressure plate or flywheel. e. Replace pressure plate. (Be sure lash is checked before replacing plate.) f. Make 30 to 40 normal starts. Caution: Do not overheat. g. Allow to cool –   – check check lash. a. Install new disc and correct leak.  b. Replace transmission clutch gear. c. Tighten or replace mountings. d. Replace pressure plate or flywheel.

Rattling-Transmission Click 

Throw-out bearing noise with clutch fully engaged

 Noisy

Pedal stays on floor when released

Hard pedal effort

a. Weak retracting springs.  b. Release fork loose on ball stud or in bearing groove. c. Oil in driven plate damper. d. Driven plate damper spring failure. a. Improper adjustment. No lash.  b. Release bearing binding on transmission bearing retainer. c. Insufficient tension between clutch fork spring and ball stud. d. Fork improperly installed. e. Weak linkage return spring. a. Worn release bearing.  b. Fork off ball stud (heavy clicking). c. Pilot bearing loose in crankshaft. a. Bind in linkage or release  bearing.  b. Springs weak in pressure  plate. c. Springs being over traveled. a. Bind in linkage.  b. Driven plate worn.

a. Replace pressure plate.  b. Check ball stud and retainer. c. Replace driven disc. d. Replace driven disc.

a. Adjust linkage.  b. Clean, re-lubricate, check for  burrs, and nicks among others. c. Replace fork. d. Install properly. e. Replace spring.

a. Replace bearing.  b. Install properly and lubricate fork fingers at bearing. a. Lubricate and free up linkage and release bearing.  b. Replace pressure plate. c. Adjust linkage to get proper lash, make sure proper pedal stop (bumper) is installed. a. Lubricate and free linkage.  b. Replace driven plate.

2.9.2 Faults found with the clutch system

a. The clutch was getting worn out.  b. There was difficulty shifting-the shifter was not moving freely.

2.9.3 Tools and equipment used to adjust the clutch

A drive ratchet, socket, large screwdriver , drop Light ,  piece of wood , floor pads, f an an and an extension cord

2.9.4 Technical procedures followed

The parking brake was engaged, the gear shifter put in neutral, and the clutch pedal

 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. r emoved. e. The retaining strap was removed and set aside. asid e. f. Using a wrench, the adjusting bolt on the splined shaft was rotated clockwise (handle towards the side of the driver) until the proper amount of clutch adjustment was achieved. g. Reassembling was done and the car was road-tested and found to be functioning  properly. The opened clutch system is shown in Fig.12 below.

.

Figure 12: The opened clutch system. The removed pressure and clutch plates are shown s hown in Fig. 13 below.

CHAPTER THREE: SWOT ANALYSIS OF KCCA

3.1 Introduction

SWOT analysis (alternatively SWOT matrix) is an acronym for strengths, weaknesses, opportunities, and threats-and is a structured planning structured planning method that evaluates those four elements of an organization and may ma y provide a basis for decision-making and problem-solving.

3.2 Strengths (S)

a. Massive physical and financial resources owned by the institution. KCCA is well endowed with workshop tools, labor and also financial assistance from the government.  b. The Authority has experienced and skilled human resources. These ease service delivery and hence improve the efficiency of the Authority. c. High level of accountability and transparency in the institution. This makes management and supervision in the Authority much easier. d. Expertise and experience in management. The Authority employs highly trained and qualified personnel that deliver quality services. e. Increased revenue collection in the city. This provides finances for running the day-today activities of the Authority. f. Good reputation for innovation. g. The Authority has a broad spectrum of researchers. This has improved the level of creativity and innovations in KCCA. h. Teamwork at the institution. The Authority uses a Functional Organization structure under which high levels of teamwork are observed.

3.3 Weaknesses (W)

a. The Mechanical Yard workshop lacks special equipment like lathe machines, drill machines and also even the available machines and tools are in bad conditions.  b. High cost of operations incurred by the institution. This arises from the many personnel employed, the expensive equipment used, and other costs of management. c. The Authority is understaffed. That is there is limited manpower compared to the amount of work to be done by the Authority. d. Bureaucracy and long channels of communication within the institution. This cuts across procurement processes and also requisition for funds from the government. This derails the quality of the services delivered by the Authority. e. Poor logistical support to workers. This lowers motivation among workers and hence leading to poor quality service delivery. 39

f. Financial mismanagement. This is associated with embezzlement of funds by some offices hence causing delays in service delivery by the authority.

3.4 Opportunities (O)

a. The government of Uganda is emphasizing infrastructure development in the city. This is in line with the key objectives of the Authority and hence eases its work.  b. Government is injecting more money in purchase and maintenance of vehicles for the institution. c. The institution being a government property can obtain more land for its expansion. d. Increasing level of economic activities in the city. This has increased avenues for collecting revenue that runs the Authority’s budgets. e. There is certain level of cooperation with the national institutions like National Drug Authority, NEMA, government ministries and other institution that help in delivering quality services. f. There are increasing donations from donors, other institutions and friends of KCCA to support their activities. For example, on 26-Jul-2016 , Inter Aid Uganda donated to KCCA health facilities medical equipment worth 400m Uganda shillings to support Kisenyi, Kitebi and Kawaala Health Centres. g. Good law enforcement agencies that work together on crime and drugs for example the Uganda Police and the Uganda People’s Defense Forces among others. These help to maintain law and order in the city.

3.5 Threats (T)

a. Reduction on foreign aid by donors; most of government vehicles are bought using funds from foreign aid. These facilitate service delivery in the Authority.  b. Delay by the government to release money; this has always delayed work. c. Unstable political environment. Political demonstrations and protests in the city derail the operations of the Authority. d. Encroachment on KCCA assets by the public for example land which limits the Authority’s ability to expand. e. Insecurity in the city. f. Low level of awareness of the public about the activities of the Authority. This makes it hard for the Authority to run some of its programs due to opposition from the public.

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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.  b. c. d. e. f. g. h. i.

Maintenance of vehicles and equipment. Exposure to the demands and challenges of the workplace. Appreciation of the professional and therefore better work ethics. Improved confidence in problem-solving. How to relate to different categories of people likely to be met in real-life situation. Opportunity to meet and work with potential employers. Gained first-hand experience working as an en gineering professional. I learnt how to work with other engineering professionals and the value of team work in engineering. 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.  b. In the early days of the training, several accidents and injuries were sustained for example cuts on fingers but with time, vigilance on work was increased which reduced on injuries. c. 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. 41

d. While making inquiries from the senior mechanics on the work being done, different reactions would be received from different people; some were welcoming while others were tough. So most of the research and inquiries were made with the friendly mechanics and more efforts were made to befriend everyone ever yone at the workshop. e. Delay of some spare parts of the vehicles veh icles which made some work not to be completed in time. f. Most of the work needed use of heavy tools and machine components which made the work difficult, tiresome and time consuming. In such cases, help was sought from other  people in the workshop to help especially with lifting the heavy machine components co mponents and tools. g. Inadequate tools and equipment like spanners, cylinder head resurfacing machine, crankshaft regrinding machine, and water jet cleaner which is used to clean the radiator; caused delay of the work hence creating work backlogs. h. Unfavorable weather conditions like heavy rainfall often disrupted activities at the workshop. In such cases, operations were carried out under an erected temporary structure, which could only accommodate small vehicles. i. Relating theoretical knowledge to practical situations was a great setback.  j. Limited time to share knowledge with all engineers due to a tight schedule at the workshop. k. Inadequate financial support to cater for my daily expenses like transport, meals and others. l. Limited working space due to congestion at the Mechanical Yard. m. Inadequate safety guards during operation of some machines like air compressor which  blows dust from air cleaner. n. Lack of well scheduled training program and an immediate person who is responsible for the affairs of the trainees. This made trainees not to fully exploit some of the most important engineering aspects of the institution as there was no serious monitoring and also access to some of the sections was either not easy or prohibited without the  permission of a supervisor. o. There was poor sanitation at the Mechanical yard. For toilets were shared equally by both male and female workers. This could put p ut the health of workers at risk.

4.4 Recommendations

Following what transpired during the industrial training especially the challenges I encountered, I recommend the following to KCCA Mechanical yard. a.

Proper waste management should be frequently carried out at the Yard. Rubbish should be collected together and either burnt or disposed off to keep the yard clean every time. 42

 b. c.

d. e. f.

g. h. i.  j. k. l.

There should be a well-designed training program for trainees and an immediate  person responsible for their affairs. 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 worker is responsible and replaces them. More safety gadgets should be acquired especially for air compressing. More air compressors should be acquired so that more air filters can be cleaned within a short time. 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. Scraps should be removed from working areas to give more working space as well as for safety purposes. There should be a scrap yard where scraps are collected and stored. Management should consider expanding the workshop so as to accommodate the ever increasing number of vehicles and equipment at KCCA. Training duration should be extended since the mechanical engineering field is a very wide one and therefore cannot be fully exhausted within the 10 weeks of internship. Materials should be acquired timely and availed immediately upon requisition, to avoid delay in carrying out work in the workshop. In a bid to improve sanitation of the workers at the Mechanical yard, I recommend that male and female workers should use separate sepa rate toilets.

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.

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REFERENCES

Anon., 2001. A New Methodology for Engine Diagnostics and Control Utilizing ‘Synthetic’ Engine Variables: Theoretical and Experimental Results, Transactions of the ASME. Journal ASME.  Journal of of  Dynamic Systems, Measurement, and Control, Volume 123. Gao, Y. & Randall, R. B., n.d. Reconstruction n.d.  Reconstruction of diesel engine cylinder pressure using a time domain smoothing technique, Mechanical Systems and Signal Processing. 5 ed. s.l.:s.n. Senyange, T., 2016. Eng. 2016. Eng. [Interview] (July-August 2016). Srinivasan, S., n.d. Automotive n.d. Automotive mechanics. 2nd ed. s.l.:s.n.

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