Makerere University Mechanical Engineering Student's Industrial Training Report at Kampala Capital City Authority

MAKERERE UNIVERSITY
COLLEGE OF ENGINEERING, DESIGN, ART AND

TECHNOLOGY
SCHOOL OF ENGINEERING
DEPARTMENT OF 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………………………………………. Date………………………………………
OKELLO JOB LAZARUS
i
APPROVAL
This industrial training report has been submitted by the approval of the following:
Signature………………………………… Date……………………………
TONNY SENYANGE
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 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
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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
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2.3.3 Safety precautions for the operation .................................................................................... 16
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 used to replace the pump ................................................................... 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
2.6 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 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
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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
2.8 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
2.8.5 Testing the starter ................................................................................................................. 34
2.9 Clutch adjustment ................................................................................................................... 35
2.9.1 Common faults with the clutch system, their causes and remedies ..................................... 36
2.9.2 Faults found with the clutch system..................................................................................... 37
2.9.3 Tools and equipment used to adjust the clutch .................................................................... 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
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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 structure. ...................................................................................... 7
Figure 3: Organizational Structure of the Directorate of Engineering and Technical services ...... 8
Figure 4: Recharging the battery................................................................................................... 13
Figure 5 : The removed water pump. ............................................................................................ 21
Figure 6:The unit that houses the water pump. ............................................................................. 21
Figure 7: Draining the hydraulic oil.............................................................................................. 26
Figure 8: Removing the broken leaf springs ................................................................................ 29
Figure 9: The broken leaf springs that were removed .................................................................. 29
Figure 10: Removing the tire ........................................................................................................ 32
Figure 11: Testing the voltage being received by the starter ........................................................ 35
Figure 12: The opened clutch system. .......................................................................................... 38
Figure 13: The removed pressure and clutch plates...................................................................... 38
xii
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.
1
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: 32.585832).
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: info@kcca.go.ug
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 Capital city and environments.
2
The city of Kampala faced a number of challenges, including the following that were listed in a
published report in 2011: High population, potholes, ineffective sanitation practices, traffic
congestion and increased death rates due to accidents.
Kampala was no longer reflecting a Capital city image in terms of governance and resource
allocation. It was not meeting the set standards and requirements of the central government like
sanitation, utilities and economic sector regulation.
The Parliament of Uganda, at the request of the cabinet, passed the Kampala Capital City
Authority Act in November 2010 to become effective on 1st. March .2011 that led to the birth of
KCCA. In a nutshell, the affairs of Kampala Capital city were brought under the direct
supervision of the central government of Uganda. The City Clerk, formerly the highest financial
officer in the city, was replaced by the Executive Director, who is answerable to the Minister for
Kampala. The elected mayor became the Lord Mayor, now a largely ceremonial position.
Lastly, in addition to the politically elected councilors, the expanded KCCA Council has
members from the following professional bodies, as full voting members: Uganda Institute of
Professional Engineers (UIPE), Uganda Society of Architects, Uganda Medical and Dental
Practitioners Council and Uganda Law Society (ULS).
1.3.2 Administrative divisions of Kampala
Kampala is divided into five divisions, each headed by a popularly elected mayor. The divisions
are preserved under the KCCA Act. They are: Nakawa, Makindye, Central, Kawempe and
Rubaga.
1.3.3 Mission statement of KCCA
To deliver quality services to the city
The meaning of the key words: Delivering-providing and facilitating the delivery of public
services in the city. Quality-top of the range of services offered to residents and visitors in the
city. Services-public services and innovative thinking that enables citizens and visitors realize
their individual and community goals, and City-the people, natural resources, physical
infrastructure and landscape within the defined territory of Kampala.
1.3.4 Vision statement of KCCA
To be a vibrant, attractive and sustainable city
3
The meaning of the key words: Vibrant-a healthy, economic and socially viable city. 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: Client care-we shall attend to needs of clients fairly, professionally
and in timely manner. Integrity-we shall be honest, transparent and accountable in the execution
of our work. Teamwork-we shall support and respect each other. Innovativeness-we shall use
creative approaches in addressing needs of clients. Excellence-we shall deliver a high standard
of performance that exceeds expectations of clients.
1.3.6 Services offered by KCCA
The Authority is mandated with provision of services in the city that enables residents and businesses
operating in the city to function in an environment that supports development. These services are: Health
services, Waste management, Education, Probation and social welfare, Gender mainstreaming, Youth and
community development, and Credit facilities.
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.
4
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 To provide effective and efficient Human Resource and Administration

Administration and Human interventions to Authority Directorates.
Resource Management.
Directorate of Physical To plan, design and manage City physical infrastructure including the
zoning, land sub division and demarcating areas for development.
Planning.
Directorate of Treasury To prepare the Institutional budget, manage and account for both
Services. 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 health and productivity of
Services and Environment. citizens; and a clean, habitable and sustainable community for the city.
Directorate of Education To provide, support, guide, coordinate, regulate and promote quality
and Social services. Education, Sports, Recreation and tourism activities to the community in
Kampala City that are geared towards individual and national
development.
To provide a comprehensive program of legal services to the Authority,

Directorate of Legal Affairs. 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 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.
To examine and evaluate the adequacy and effectiveness of the

Directorate of Internal governance, risk management, systems of internal control and the quality
Audit. of performance of KCCA when carrying out assigned responsibilities;
aimed at achieving the stated goals and objectives of the institution.
Directorate of Gender and To empower and facilitate communities, particularly the vulnerable
Community Services. groups, to realize and harness their potential for purposeful 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.
6
Figure 2: KCCA organizational structure.
7
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 OPERATIONS DEPUTY DIRECTOR

BUILDINGS MANAGER 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
8
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 well-
versed 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
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 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 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.
2.2.1 Common faults of the car battery, their causes and remedies
The following are the common faults associated with the car battery; their causes and
corrections.
2.2.1.1 Low charge

This is caused by leaving the battery in uncharged condition for a long time and also when
battery usage exceeds battery capacity.
Solution: The best solution for this problem is to recharge the battery. A jump start as well as
a trickle charger can be used for this operation. A trickle charger is most commonly used. It
delivers electricity to the battery from a power outlet in a slow, steady stream. It has an
electric cord with a plug and two jumper cables with alligator clips.
Procedures.
Before starting the recharging process, Safety must be observed. Since the battery acid is
hazardous, be sure to take adequate precautions when handling old battery terminals to
protect skin and clothing.
The following procedures are involved in charging the car battery;
a. Clean the battery terminals.
Check the terminals of the battery and clean them. Do not touch the terminals if they
are covered with a whitish powder. This is dried Sulphuric acid which can burn bare
skin and hands. Use a manual sand paper pad to wipe around the terminals or get a
10
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.
b. 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.
c. 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.
d. 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.
e. Check the battery.
After charging, check the battery to find out whether it works. Use the hydrometer to
find out the amount of electric energy in the fluid or turn on the engine. If the battery
still does not turn on, then the battery might have to get replaced.
2.2.1.2 Sulphation
If the battery is allowed to stand in a discharged state either on or off the vehicle for a long
period of time, a chemical reaction takes place which permanently impairs the performance
and life of the battery. It can be seen as a fine white/grey coating of the positive plate. This is
called sulphation.
Solution: Clean the battery terminal.
Procedures:
The following procedures can be taken to clean the battery terminal.
a. Check the battery terminals to see if there is a fine white/grey coating on the
positive plate and the non-metallic luster on the negative plate.
b. Do not touch the terminals if they are covered with a whitish powder. This is dried
sulfuric acid and it can burn bare hands.
c. Use a manual sand paper pad to wipe around the terminals or get a wet cloth and
apply a layer of baking soda (Sodium bicarbonate) to the cloth.
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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

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 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
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.
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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 battery; 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 battery;
a. The battery terminals were checked and cleaned using a manual sand paper.
b. The cell caps were removed.
c. The charger cables were attached with the car turned off.
d. The charger was turned on for the battery to charge itself.
e. The battery was checked to find out whether it worked after charging and it
functioned properly.
The recharging operation is shown in Fig. 4 below.
Figure 4: Recharging the battery
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2.3 Diagnosis and correction of power steering faults of a Ford Ranger Double cabin
Power steering problems can make controlling the vehicle much harder especially around
curves and corners. The power steering unit of the car uses a hydraulic system that takes a lot
of the steering strain off of the driver. This system builds up pressure as the wheel is turned;
and pushes the tires to either side as the car is turned. When there are power steering
problems, the driver will instantly notice the difference as it becomes very hard to turn the
steering wheel.
2.3.1 Common faults with the steering system, their causes and remedies
The common problems associated with the power steering system; their causes and solutions
are summarized in table 2 below.
14
Table 2: Steering system troubleshooting chart
FAULT POSSIBLE CAUSE(S). REMEDY(IES).
(1) Improper tire pressures. (1) Inflate tires to recommended
(2) Loose pump drive belt. pressures.
(3) Low or incorrect fluid. (2) Tighten or replace belt.
(4) Loose, bent or poorly lubricated front end (3) Refill reservoir with proper fluid
Hard steering 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.
linkage. (6) Disassemble and inspect
(7) Air in hydraulic system. component parts. Repair or replace
(8) Low pump output or leaks in system. as necessary.
(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.
Leaking hoses 2 Damaged or improperly installed. (2) Replace or adjust O-ring in
and seals 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. (1) Adjust wheel bearings.

Tight / loose 2 Faulty shocks. (2) Replace shocks.
steering / valve 3 Worn linkage components. (3) Replace worn components.
assembly out of 4 Loose steering gear mountings or linkage (4) Tighten mountings or linkage.
points. (5) Replace and/or adjust unit.
hydraulic
5 Steering rack / box worn or improperly (6) Replace rack / box.
balance
adjusted.
6 Torsion bar bent due to impact.
1 Loose belts. (1) Replace and/or adjust belts.
2 Low fluid, air in system. (2) Refill and check for leaks.
Noises 3 Foreign matter in system. (3) Disassemble and clean system.
4 Improper lubrication. (4) Lubricate all fittings.
5 Interference in linkage. (5) Disassemble, inspect, replace or
6 Steering gear mountings loose. adjust components.
7 Incorrect adjustment or wear in rack or box. (6) Tighten mountings.
8 Wear in pump. (7) Disassemble, inspect, repair,
replace and/or adjust parts.
15
(8) Replace pump as necessary.
(1) Improper tire pressure. (1) Inflate tires to recommended
(2) Improper front end alignment. pressures.
(3) Binding brakes. (2) Align front end.
(4) Front cradler loose or accident damage. (3) Inspect replace and/or adjust
brakes.
(5) Improper rear end alignment.
(4) Straighten frame.
(6) Faulty shocks or springs.
Veer or wander (5) Inspect shocks and control arm
(7) Loose or bent front end components. torque replace and/or adjust as
(8) Play in pitman drop arm. necessary.
(9) Loose wheel bearings. (6) Replace as necessary.
(10) Pitman drop arm ball joint seizure. (7) Replace as necessary.
(8) Inspect bushings and arm. Replace
as necessary
(9) Adjust to specifications
(10) Replace arm
(1) Improper tire pressures (1) Inflate tires to recommended
(2) loose wheel bearings pressures
(3) improper front end alignment (2) adjust to specifications
Wheel oscillation (4) worn tie rods (3) align front end
(5) worn, bent or broken front end (4) track rod ends
components (5) inspect, repair or replace as
(6) tires out of round or out of balance necessary
(7) excessive lateral run out in disc brake, (6) replace or balance tires
disc or rotor (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.
c. Never use old or used seals, cotter pins, retainers or critical fasteners. Use a new seal
kit.
d. Use only approved replacement of the manufacturer.
16
e. Never check for leaks by hand, hydraulic oil under pressure can penetrate the skin and
cause severe injury.

The following procedures were observed during the operation.
a. The vehicle was parked on a clean, dry, solid surface, the parking brake was
set, the rear wheels blocked and the transmission placed in neutral.
b. Using the hydraulic jack, the front end of the vehicle was raised until the tires
had cleared the surface.
c. The hood of the vehicle was tilted.
d. The drain pan was placed under the steering gear to catch the steering fluid.
e. The pressure and return lines from the steering gear were removed to drain the
fluid.
f. The area around the reservoir cap was wiped off with a clean towel, the bolt
was removed from canister type reservoirs and the cover was removed.
g. Using the filter wrench, the filter was removed from the canister and the filter
elements discarded.
h. The inside of the reservoir canister was wiped clean with a clean shop towel.
i. With the hoses disconnected, the steering wheel was slowly turned from full
left to full right several times to purge oil from the steering gear.
j. The pressure and return lines to the steering gear were attached and tightened.
k. A new filter element was installed in the reservoir.
l. The reservoir cap was cleaned with a solvent; the old gasket was removed
from the cap and replaced with a new gasket.
m. The reservoir was filled with new steering fluid, the reservoir cover was
installed and the bolt tightened.
n. The vehicle was started and allowed to idle.
o. The fluid level was checked and filled as needed.
p. The vehicle was steered from full left to full right several times and the fluid
level checked again and fluid was added.
q. All fittings and hoses were visually checked for external leaks. Reservoir was
not allowed to empty during start up as pump damage could result.
r. The vehicle was shut off, the drain pan removed and the vehicle was lowered
until the tires contacted the surface and removed the jack.
s. The cab was lowered.
2.4 Replacement of water pump of a Cesspool truck
The engine of a vehicle needs coolant just as much as it needs oil. Engine coolant helps
protect against high heat. It is cycled from the radiator throughout the engine, absorbing heat
from engine operation and then allowing that heat to wick away into the atmosphere at the
17
radiator. The water pump is the key to making the entire system work. It is an impeller pump,
buried under the timing belt cover on the side of the engine. The pump is operated by the
drive belt of the engine – as the belt turns, the pump turns. Blades on the pump force the
coolant to flow through the engine.
When the water pump fails or is beginning to wear out, it can lead to complete engine failure.
The water pump is the key to making the entire system work. Like any other mechanical
device, they will produce a few warning signs that they are wearing out.
2.4.1 Common faults with water pumps, their causes and remedies
Table 3 below shows common faults with water pump, their causes and remedies.
Table 3: Water pump troubleshooting chart
Fault Cause(s) Remedy(ies)

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 Contaminated Thoroughly flush the cooling system
is new, some seepage from the coolant is the main before installing the new pump and
weep hole is normal as it takes cause of weep hole refill the system with the
about ten minutes of operation leakage. recommended coolant of the
for the mechanical seal to manufacturer of the vehicle.
properly seat itself (break-in
period). More pronounced
seepage and drips from the
weep hole after this break-in
period or a large coolant bleed
mark around the weep hole are
abnormal and indicate
impending water pump failure.
Leakage from the mounting

surface. Improper water pump In case of a recently installed new
Appearance: Seepage, drips or installation or water pump, carefully remove,
large coolant bleed marks on or improper use of check and re-install the water pump.
around the mounting surface or seals/gaskets or
on the housing. sealant
Rust and corrosion. Contaminated Replace the water pump.

Appearance: Rust and corrosion coolant, non- Thoroughly flush the cooling system
18
on the surfaces of the water compatible coolant or before installing the new pump and
pump, for example corrosion of mixing coolants of refill the system with the
the impeller fins makes the different chemistries. recommended coolant of
pump ineffective in moving the Another possible manufacturer of the vehicle
coolant. 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, non- Replace 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 Replace the water pump and make
to-side play at the shaft. Apply overload on the sure to inspect the belt drive system:
hand pressure – there should be bearing, accelerating belt, tensioner, pulleys, belt tension
no play at all. Also, rumbling or wear. A damaged and alignment.
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 Replace the water pump and make
Appearance: The shaft is bent causes excessive sure to inspect the belt drive system:
or broken. A clean break wear. An over- belt, tensioner, pulleys, belt tension
indicates an instantaneous tensioned belt and alignment.
fracture caused by sudden imposes a powerful If equipped with a water pump
overload or imbalance. If the bending force on the mounted fan, inspect the fan or fan
broken shaft is shaft resulting in clutch assembly. The fan may not be
discolored(usually blue), the shaft bending or squarely mounted on the shaft. A
damage was gradual, indicating early shaft fracture. bent or damaged fan, a worn spacer,
excessive heat build-up before Excessive vibrations or a worn or damaged fan clutch
the shaft broke. due to lack of could also be factors contributing to
maintenance. the break.
Seal leakage-dirty system Thoroughly flush a contaminated
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Cooling system system before replacing the water
contamination pump.
Check system pressure.
Use correct coolant mixture
Use distilled water where necessary.
Casting Breakage Carefully inspect pulley, belt
Excessive Vibration alignment and fan / fan clutch
assembly, replacing any bent or
worn components.
Seal leakage-clean System Take proper precautions when
filling your radiator, especially
when the engine may be very hot.
Thermal Shock 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.

a. The radiator was drained by opening the petcock valve at the bottom of the radiator.
This was done when the engine was cold.
b. The fan belt was removed, carefully noting how it was routed before removing it in
order to reinstall it correctly afterwards.
c. Any other accessories that were blocking access to the pump were removed. This
included the fan, fan shroud, timing belt cover, or any brackets.
d. The water pump was unbolted from the engine.
e. The pump mounting surface was cleaned to remove all traces of old gaskets. The
mounting surface must be clean and dry before installing the new pump.
f. The gasket was positioned on the new pump using gasket sealer or adhesive as
required, and then the new water pump was bolted to the engine.
g. The cooling system was refilled.
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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 oil or water mineral oils, synthetic fluids and
fire-resistant fluids. The primary function of a hydraulic fluid is to convey power from one
point to another. There are other important functions of hydraulic fluid such as protection of
the hydraulic machine components, lubrication of system components, transfer and
dissipation of heat, and provision of a seal to maintain pressure.
Examples of equipment that use hydraulic oil include; Excavators and backhoes, Hydraulic
brakes, Power steering systems, Transmissions and Garbage trucks.
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
bleeding, pneumonia, or death through hydraulic fluid ingestion though no serious hazards
are reported with hydraulic fluid inhalation.
21
Similar to ingestion, fluids can be accidentally injected into the skin as well. This takes place
when the high-pressure hydraulic system hose is disconnected and toxic fluids are leaked and
injected into the skin. If there is a small leak in the hydraulic pipe and someone runs there
hand along it, at 2000 psi, they can easily incur an injection of hydraulic fluid and may not
even be aware that it happened until gangrene begins to set in.
b. Fire dangers.
When working with hydraulic fluid, there is every chance that the hydraulic fluid gets heated
to high temperatures. And it is evident that most petroleum-based hydraulic fluids will burn
and thereby create explosions and burns.
c. Environmental problems.
When the hydraulic hose or pipe leaks, the chemicals of the fluids can either stay on top of
the soil or sink into the ground. If the chemicals get mixed in a water body, they will sink to
the bottom. In fact in such cases the chemicals can stay there for more than a year. Aquatic
life can absorb the toxic hydraulic fluid, leading to illness or death to the animal or anything
higher on the food chain. For example, a hawk that eats a fish that has been contaminated by
hydraulic fluid that was mixed in water could become ill as well.
d. 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 to keep your clothing clean.
b. Always wear masks and gloves while using hydraulic fluids.
c. To avoid environmental dangers, there is a biodegradable hydraulic fluid option,
though it is more expensive.
d. To avoid fires, materials and fluids soaked in hydraulic fluid should be stored in
sealed metal containers and disposed of at proper places.
e. To check for leaks, use cardboard.
2.5.3 Common faults with the hydraulic system

Generally, improper hydraulic system operation can be traced to one of the following
deficiencies: insufficient fluid level, the presence of air in the system, contamination by
foreign material, incorrect adjustment of components, internal or external fluid leakage,
mechanical damage to components, wrong fluid type or viscosity and excessive temperatures.
22
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
locating electrostatic discharge noise at filters or reservoirs. Electrostatic charges may be
generated in hydraulic fluids by turbulence, high fluid velocities, internal fluid friction,
23
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 first instance, more consideration will be required for improved filter installation where
increased vibration and/or higher pressure pulsation will require mitigation.
24
In the second instance, mobile filtration systems and portable hydraulic fluid purifiers will
become mandatory, if hydraulic system reliability is to be improved and maintained.
2.5.6 Faults found with the hydraulic oil

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

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

The following procedures were observed during the operation;
a. The system was drained while the fluid was hot to keep contaminants in
suspension.
b. The fluid was emptied from cylinders, accumulators and lines that could not drain
properly.
c. The oil left in the reservoir was pumped out.
d. The reservoir was wipe-cleaned with lint free rags and rust and free paint were
removed.
e. Filter elements, strainers, and housing were cleaned.
f. The system was refilled with new hydraulic fluid making sure to vent high points.
g. The system was restored and checked for proper operation after which it
functioned.
25
The drainage process of hydraulic oil is shown 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 curvature also helps the spring absorb impact.
The bending of the leaves and the friction between them as they slide slightly over each other
while bending, absorb the weight of the vehicle as well as any bumps.
Leaf springs should be replaced when they are worn out, flattened out, cracked or broken.
2.6.1 Functions of the suspension of the vehicle
The suspension of the vehicle serves three major functions; they are to;
a. 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, or its own system, but either way the suspension
has to allow for movement of the wheels as the vehicle turns).
Springs in general, and leaf springs in particular, help perform the first two of these
functions: they support the weight of the vehicle while absorbing bumps.
A leaf spring is usually attached to the body or frame of the vehicle at each end, while the
wheel or axle assembly is fixed to the middle of the spring. Usually each spring extends in
the same direction as the vehicle, one on each side, with attachment points at the front and
26
rear; a few suspension designs feature a single leaf spring attached at each side-a “transverse”
spring.
2.6.2 The purpose of leaf springs
Leaf springs are appropriate for spreading heavy loads over a large area (because they are
attached to the vehicle at the ends, which may be several feet apart) and for suspension
designs that incorporate a “solid” axle rather than independent suspension for each wheel
especially of heavy vehicles such as trucks.
These factors render leaf springs appropriate for trucks and other heavy vehicles but less so
for cars, as such designs tend to have undesirable effects on the handling of the vehicle. As
independent (as opposed to solid axle) rear suspensions have become increasingly common
on cars, leaf springs are now found primarily on trucks, vans, SUVs and trailers.
2.6.3 Maintenance of leaf springs
Multi-leaf springs occasionally get “sticky” as dirt works its way in between the leaves; the
effect can be to make the ride slightly stiffer, but this is rarely a significant problem. The
attachment points will need to be checked periodically and lubricated in some cases as
specified by the manual of the manufacturer, and regular maintenance should be carried out.
If the body of the car seems to sit too low over the wheels, this sagging is usually due to the
leaf springs having bent slightly over time, and the solution is to have them replaced.
2.6.4 Fault found with the leaf springs

Leaf springs were broken as depicted by inspection.
2.6.5 Safety precautions while replacing leaf springs

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

The following tools and equipment were used to replace the leaf springs of the truck; A
ratchet, hammer, Box spanner, combination spanner (24-24), floor jack, trolley jack, lubricant
(oil); ring spanners (numbers16, 18, 19 and 30), wrenches and Jack stands.
27
a. The vehicle was parked on a solid, level surface to ensure that it did not roll or lean
when raised.
b. Using a floor jack, the rear of the vehicle was lifted up enough for the axle assembly
to hang freely.
c. The vehicle was secured with jack stands on both sides for safety before starting any
work.
d. The rear axle assembly was supported with a floor jack close to the spring.
e. The lower bolt was removed from the shock absorber.
f. The axle was lowered to relieve tension on the spring.
g. The U-bolts and spring retainer bracket were removed.
h. The parking brake cable was removed from the retainer bracket.
i. The rear axle was carefully lowered since leaf springs were mounted on top of the
axle.
j. The rear shackle bolts were loosened.
k. The leaf springs were supported with a jack stand and the leaf spring front and rear
eye bolts were removed.
l. The leaf springs were removed from the vehicle.
m. The front bushings of the new springs were placed into the front mounting brackets,
the front eye bolts and nuts were installed with the bolt heads towards the center of
the vehicle.
n. The rear bushings of the new springs were placed into the rear shackles and the rear
eye bolts and nuts were loosely installed.
o. The axles were adjusted to place the leaf springs center bolts into the holes on the axle
pads.
p. The U-bolts and retainer brackets were installed; the U-bolt nuts were snagged down
but not tightened.
q. The parking brake cable was reattached and the lower shock mount was attached to
the axle bracket.
r. Steps (d) through (q) were repeated for the other side of the truck.
s. The truck was lowered to the ground and all bolts torqued to the recommended
specifications.
t. The leaf springs repair was verified and the vehicle was aligned.
u. The vehicle was road-tested and found to operate well.
28
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 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 about the size of the palm of the hand - so if tires are worn or damaged it can
seriously affect the safety and handling of the vehicle.
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.
29
d. Emergency braking. If an emergency stop is performed, the tire wears enormously in
an isolated area and can lead to deflation. If an emergency stop maneuver has recently
been executed, check the tires for isolated damage.
e. Cuts and tears. Observe the sidewalls of the tires. Sharp objects such as nails, glass
or metal can cause a cut or tear in the tire. If a cut or tear is spotted it can render your
tire unserviceable. Tires in this state should be replaced immediately.
f. Impact damage. If a vehicle hits an object at high speed such as a kerb, a bulge may
be visible in the side wall of the tires. The area of the bulge or egg highlights the
location of casing damage. The damage should be diagnosed and fixed immediately.
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 by a professional.
e. Inspect the tires. It may not always be noticed if one of the tires has been damaged.
Inspect tires regularly for wear and any damage to avoid any sudden problems. Also,
have a professional inspect the tires every year.
Note: Unfortunately many tire problems are unavoidable. Tires can be checked
regularly but still fall foul of an errant nail, piece of metal or a pesky pothole.
30
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.

a. The truck was parked on a flat surface.
b. The parking brake was applied and the truck put in to park position.
c. Rocks were placed in front of the front and back tires.
d. The jacks were placed under the frame near the tire that was to be replaced.
e. The jacks were raised until they were supporting but not lifting the car.
f. The hubcap was removed and the nuts loosened by turning them
counterclockwise.
g. The jacks were pumped to lift the tire off the ground.
h. The nuts were removed by turning them counterclockwise until they loosed.
i. The tire was then removed.
31
j. The spare tire was placed on the hub, its rim aligned with wheel bolts and lug nuts
put in positions.
k. The nuts were tightened using the wrench in a star pattern.
l. The truck was lowered without applying full weight on the tire, and the nuts were
tightened further.
m. The truck was fully lowered to the ground.
n. The jacks were removed.
o. The nuts were tightened finally and the hubcap replaced.
p. The truck was road-tested and the new tire was found to function well.
The tire removal process is shown 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 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.
32
2.8.1 Common symptoms of a failing or bad Starter, their causes and remedies
They include the following:
a. Grinding noise. When the starter drive gear is worn out or not engaging properly, they
will often produce a grinding noise that is similar to the one that is heard if engine is
started and then accidentally the starter is hit again. If the grinding symptom is
ignored, it may also result in damage to the engine flywheel. It should be diagnosed
immediately upon detection.
b. Freewheeling. Freewheeling occurs when the engine is cranked and simply a whining
noise is heard from the starter without the engine cranking. When this occurs, it
means the starter gear is not engaging with the flywheel. This is a bad situation that
could result in the need for a starter replacement. If this is occurring, the vehicle
should be serviced as soon as possible.
c. Smoke. Seeing smoke is cause for immediate concern, and can indicate a few
different problems with the starter or starting circuit. Smoke usually indicates that too
much power is being drawn through the electrical supply to a starter, either because
the starter is shorted, has been operated too long without a rest or there is a connection
problem. Smoke might also be accompanied by a burning smell. If smoke is seen, the
vehicle should be serviced by a professional as soon as possible.
d. Oil soak. The starter is often located around the bottom of the engine and is
vulnerable to soaking from leaks from the engine oil or other drive train fluids. An
oil-soaked starter likely has a short life remaining. Consider correcting the leak and
replacing the starter before a malfunction occurs.
e. Malfunctioning solenoid. The solenoid transmits electrical current from the battery to
the starter motor when the key is turned in the ignition of the vehicle and also pushes
the starter drive into the flywheel to allow cranking. Without the solenoid, the starter
does not work. If the key is turned to the crank position and nothing happens, try
jiggling the transmission gear shift lever first. If the engine still will not crank, there
might be something wrong with the solenoid.
f. When you turn the key to crank the engine, nothing happens. The engine does not turn
over.
g. When the key is turned to crank the engine and all that is heard is one loud click. The
engine does not turn over; or when the key is turned to crank the engine and the
engine turns over very but very slowly and then stops.
h. When the battery is good but the car fails to start.
2.8.2 Safety procedures while troubleshooting a starter motor

While troubleshooting a starter motor, certain safety measures need to be observed. They
include the following:
33
a. If you have to lift up the car or truck to access the starter motor: Use jack-stands to
support the car or truck off the ground, and use safety glasses while working
underneath the vehicle.
b. You will need a helper to crank the engine as you perform some of the tests, and to
help you perform the very important Voltage Drop Test.
c. When jumpering 12 Volts to the S-terminal wire (circuit) make sure you do not short-
to-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.

a. The state of charge of the battery was determined.
b. The ignition switch was checked if it was sending power to the solenoid.
c. The starter motor was checked if the problem lied in itself.
d. The solenoid was tested to see if it was working.
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.
34
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.
35
2.9.1 Common faults with the clutch system, their causes and remedies
They are summarized in table 4 below.
Table 4: Clutch diagnosis/troubleshooting chart
Faults Possible causes Remedy(ies)

a. Adjust linkage.
a. Improper linkage b. Trim bumper stop and adjust
adjustment. linkage.
b. Improper pedal travel. c. Replace as necessary.
Fails to Release (Pedal c. Loose linkage. d. Replace bearing.
pressed to floor). Shift d. Faulty pilot bearing. e. Replace disc.
lever does not move e. Faulty driven disc. f. Install fork onto stud. Lightly
freely in and out of f. Fork off ball stud. lubricate fingers at release
reverse gear. g. Clutch disc hub binding on bearing.
clutch gear spline. g. Repair or replace clutch gear
h. Clutch disc warped or bent. and/or disc.
i. Loose pivot rings in cover h. Replace disc (run out should
assembly. not exceed 0.020″).
i. Replace plate and cover
assembly.
a. Adjust linkage to
a. Improve adjustment (no specifications.
lash). b. Install new disc and correct
b. Oil soaked driven disc. leak at its source.
c. Worn facing or facing torn c. Replace disc.
Slipping. from disc. d. Replace pressure plate or
d. Warped pressure plate or flywheel.
flywheel. e. Replace pressure plate. (Be
e. Weak diaphragm spring. sure lash is checked before
f. Driven plate not seated in. replacing plate.)
g. Driven plate overheated. f. Make 30 to 40 normal starts.
Caution: Do not overheat.
g. Allow to cool–check lash.
a. Oil on facing. Burned or a. Install new disc and correct
glazed facings. leak.
Grabbing or b. Worn splines on clutch b. Replace transmission clutch
Chattering. gear. gear.
c. Loose engine mountings. c. Tighten or replace mountings.
d. Warped pressure plate or d. Replace pressure plate or
flywheel. flywheel.
e. Burned or smeared resin on e. Sand off if superficial, replace
fly wheel or pressure plate. burned or heat checked parts.
36
a. Weak retracting springs. a. Replace pressure plate.
Rattling-Transmission b. Release fork loose on ball b. Check ball stud and retainer.
Click stud or in bearing groove. c. Replace driven disc.
c. Oil in driven plate damper. d. Replace driven disc.
d. Driven plate damper spring
failure.
a. Improper adjustment. No
lash. a. Adjust linkage.
Throw-out bearing b. Release bearing binding on b. Clean, re-lubricate, check for
noise with clutch fully transmission bearing retainer. burrs, and nicks among others.
engaged c. Insufficient tension between c. Replace fork.
clutch fork spring and ball d. Install properly.
stud. e. Replace spring.
d. Fork improperly installed.
e. Weak linkage return spring.
a. Worn release bearing.
b. Fork off ball stud (heavy a. Replace bearing.
Noisy clicking). b. Install properly and lubricate
c. Pilot bearing loose in fork fingers at bearing.
crankshaft.
a. Bind in linkage or release a. Lubricate and free up linkage
Pedal stays on floor bearing. and release bearing.
when released b. Springs weak in pressure b. Replace pressure plate.
plate. c. Adjust linkage to get proper
c. Springs being over traveled. lash, make sure proper pedal
stop (bumper) is installed.
Hard pedal effort a. Bind in linkage. a. Lubricate and free linkage.
b. Driven plate worn. 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, fan and an
extension cord

a. The parking brake was engaged, the gear shifter put in neutral, and the clutch pedal
pressed to the floor.
37
b. The access opening for the clutch assembly was located under the truck just behind
the oil pan. A torch light was used to see where the adjustment plate was.
c. With the clutch pedal depressed, a large flathead screwdriver was used as a lever to
rotate the flywheel assembly till the adjustment plate was at the bottom and fully
accessible.
d. Using a socket, only the left hand bolt which secures the retaining strap was removed.
e. The retaining strap was removed and set aside.
f. Using a wrench, the adjusting bolt on the splined shaft was rotated clockwise (handle
towards the side of the driver) until the proper amount of clutch adjustment was
achieved.
g. Reassembling was done and the car was road-tested and found to be functioning
properly.
The opened clutch system is shown in Fig.12 below.
Figure 12: The opened clutch system.

The removed pressure and clutch plates are shown in Fig. 13 below.
Figure 13: The removed pressure and clutch plates.
38
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 method that evaluates those four elements
of an organization and may 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-to-
day 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.
40
CHAPTER FOUR: SKILLS ACQUIRED, CHALLENGES FACED,
RECOMMENDATIONS AND CONCLUSION
4.1 Introduction
This chapter covers the skills acquired from the field attachment training, challenges faced at
work, recommendations and conclusion.
4.2 Experience gained/achievements from the training

From the industrial training, I acquired a number of skills and knowledge through the application
of the theoretical knowledge learnt in class into the practical operations which led to an
improvement and widening of my engineering knowledge. All activities were carried out while
taking note of all the safety precautions necessary to prevent accidents and produce the desired
results accurately and in time while using the right tools and following the correct procedures.
The following were the achievements from the training.
a. Maintenance of vehicles and equipment.
b. Exposure to the demands and challenges of the workplace.
c. Appreciation of the professional and therefore better work ethics.
d. Improved confidence in problem-solving.
e. How to relate to different categories of people likely to be met in real-life situation.
f. Opportunity to meet and work with potential employers.
g. Gained first-hand experience working as an engineering professional.
h. I learnt how to work with other engineering professionals and the value of team work in
engineering.
i. I was able to increase my technical, interpersonal and communication skills, both oral
and written.
4.3 Challenges faced during the training

During the training, a number of challenges were faced as given below.
a. Most technical words used in motor vehicle work were not familiar to me but more
research and inquiries were made from the senior mechanics and through reading of
vehicle manuals.
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 at the workshop.
e. Delay of some spare parts of the vehicles which made some work not to be completed in
time.
f. Most of the work needed use of heavy tools and machine components which made the
work difficult, tiresome and time consuming. In such cases, help was sought from other
people in the workshop to help especially with lifting the heavy machine components and
tools.
g. Inadequate tools and equipment like spanners, cylinder head resurfacing machine,
crankshaft regrinding machine, and water jet cleaner which is used to clean the radiator;
caused delay of the work hence creating work backlogs.
h. Unfavorable weather conditions like heavy rainfall often disrupted activities at the
workshop. In such cases, operations were carried out under an erected temporary
structure, which could only accommodate small vehicles.
i. Relating theoretical knowledge to practical situations was a great setback.
j. Limited time to share knowledge with all engineers due to a tight schedule at the
workshop.
k. Inadequate financial support to cater for my daily expenses like transport, meals and
others.
l. Limited working space due to congestion at the Mechanical Yard.
m. Inadequate safety guards during operation of some machines like air compressor which
blows dust from air cleaner.
n. Lack of well scheduled training program and an immediate person who is responsible for
the affairs of the trainees. This made trainees not to fully exploit some of the most
important engineering aspects of the institution as there was no serious monitoring and
also access to some of the sections was either not easy or prohibited without the
permission of a supervisor.
o. There was poor sanitation at the Mechanical yard. For toilets were shared equally by both
male and female workers. This could put the health of workers at risk.
4.4 Recommendations
Following what transpired during the industrial training especially the challenges I encountered,
I recommend the following to KCCA Mechanical yard.
a. Proper waste management should be frequently carried out at the Yard. Rubbish
should be collected together and either burnt or disposed off to keep the yard clean
every time.
42
b. There should be a well-designed training program for trainees and an immediate
person responsible for their affairs.
c. All the necessary tools should be availed and close supervision carried out by
registering all the tools and the corresponding workers using them so that in case of
any tool loss, the worker is responsible and replaces them.
d. More safety gadgets should be acquired especially for air compressing.
e. More air compressors should be acquired so that more air filters can be cleaned
within a short time.
f. Cleaning air filters should be carried out from an open space where there is free
circulation of air to protect the person carrying out the operation from dust and other
harmful fumes.
g. Scraps should be removed from working areas to give more working space as well as
for safety purposes.
h. There should be a scrap yard where scraps are collected and stored.
i. Management should consider expanding the workshop so as to accommodate the ever
increasing number of vehicles and equipment at KCCA.
j. 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.
k. Materials should be acquired timely and availed immediately upon requisition, to
avoid delay in carrying out work in the workshop.
l. In a bid to improve sanitation of the workers at the Mechanical yard, I recommend
that male and female workers should use separate 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.
43
REFERENCES
Anon., 2001. A New Methodology for Engine Diagnostics and Control Utilizing ‘Synthetic’
Engine Variables: Theoretical and Experimental Results, Transactions of the ASME. Journal of
Dynamic Systems, Measurement, and Control, Volume 123.
Gao, Y. & Randall, R. B., n.d. Reconstruction of diesel engine cylinder pressure using a time
domain smoothing technique, Mechanical Systems and Signal Processing. 5 ed. s.l.:s.n.
Senyange, T., 2016. Eng. [Interview] (July-August 2016).
Srinivasan, S., n.d. Automotive mechanics. 2nd ed. s.l.:s.n.
44

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Makerere University Mechanical Engineering Student's Industrial Training Report at Kampala Capital City Authority

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MAKERERE UNIVERSITY

COLLEGE OF ENGINEERING, DESIGN, ART AND

DEPARTMENT OF MECHANICAL ENGINEERING

INDUSTRIAL TRAINING REPORT AT

KAMPALA CAPITAL CITY AUTHORITY

NAME: OKELLO JOB LAZARUS

REG. NO. 14/U/1050

STUDENT NO. 214000258

AREPORT SUBMITTED TO MAKERERE UNIVERSITY, DEPARTMENT OF

DEDICATION ............................................................................................................................... iii

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

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

2.2.1.1 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

2.2.1.9 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

2.3.2 Tools and equipment used ................................................................................................... 16

2.3.4 Technical procedures followed ............................................................................................ 17

2.4 Replacement of water pump of a Cesspool truck ................................................................... 17

2.4.2 Fault found with the water pump ......................................................................................... 20

2.4.3 Tools and equipment 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 of leaf springs .................................................................................................. 27

2.6.3 Maintenance of leaf springs ................................................................................................. 27