Wonji shoa sugar factory

On job training report of Automotive Engineer

On
Field Equipment Maintenance Department

By Getnet Amenu
Jan 12, 2023

wonji
 Acknowledgement

First of first is Alpha and Omega thanks to almighty GOD for this day and the past.
Next I would like to express my special thanks to the Managing and Planning
department for their guidance and support. I would like to extend my gratitude to the
sugar training center management and coordinators and its entire staff for their
wonderful acceptance and hospitality on the one month theoretical and the three
months. I am grateful to work with the all section department technician and I hope I
will do better with you it is an honor.

1
Contents

Acknowledgement ......................................................................................................... 1
Contents ......................................................................................................................... 2
List of figures ................................................................................................................. 4
Chapter One ................................................................................................................... 5
Introduction .................................................................................................................... 5
Background and objective.......................................................................................... 5
Background ............................................................................................................ 5
Objective ................................................................................................................ 6
Chapter Two................................................................................................................... 7
FIELD EQUIPMENT MAINTENANCE DEPARTMENT .......................................... 7
Workshop managing department ........................................................................... 7
General operation and maintenance activities in FEMD ....................................... 7
Major maintenance schedule.................................................................................. 8
Equipment maintenance workers ........................................................................... 8
General maintenance work order ........................................................................... 8
Fluids...................................................................................................................... 9
Workshop Management ......................................................................................... 9
Managing department ........................................................................................ 9
Planning and Ordering section ........................................................................... 9
1▪ Ordering of purchase request.................................................................. 10
Composition of PR ................................................................................. 10
Spare part order flow ............................................................................... 11
2▪ Planning ................................................................................................... 11
The Annual plan ....................................................................................... 11
- Action plan ......................................................................................... 11
- Reform plan ........................................................................................ 12
- Strategic plan ...................................................................................... 12
3▪ Preparation of Technical Specification and Evaluation .......................... 15
Technical Evaluation ............................................................................... 16
4▪ Understanding and Using of Vehicle and Machinery Manuals ............... 17
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 5• Preparation of Office Memorandum ....................................................... 18
6 • Re-ordering ............................................................................................ 18
7• G.RN. (Good Receiving Note)................................................................ 19
Reception ......................................................................................................... 19
Auto-Electric Maintenance Team ........................................................................ 19
Major electrical maintenance ........................................................................... 19
Corrective maintenance I have involve in are.................................................. 20
Wheel tractor maintenance team .......................................................................... 23
Machineries in these section and quantity ................................................... 23
Quantities of machineries in general............................................................ 24
System in the machineries ........................................................................... 24
Corrective maintenance I have involve in are.................................................. 24
Periodical service ......................................................................................... 26
Heavy equipment maintenance team ................................................................... 29
Machineries in these sections........................................................................... 29
Implements ....................................................................................................... 29
Tillage implement ........................................................................................ 29
Primary tillage .......................................................................................... 29
Secondary tillage ...................................................................................... 29
Radiator repair ............................................................................................. 29
Repair procedure ...................................................................................... 30
Corrective maintenance I have involve in are.................................................. 30
Transport vehicle maintenance team ................................................................... 32
List of vehicles under TVMT .......................................................................... 32
Corrective maintenance I have involve in are.................................................. 33
Body repair and painting section ..................................................................... 37
Chapter Three............................................................................................................... 39
Problems in General ..................................................................................................... 39
Conclusion and Recommendation ............................................................................... 40
Conclusion ........................................................................................................... 40
Recommendation ................................................................................................. 41
Reference ............................................................................................................. 42

3
List of figures

Figure 1 Maintenance work order .................................................................................. 8

Figure 2 Oil and Fuels.................................................................................................... 9
Figure 3 Spare art purchase flow ................................................................................. 11
Figure 4 transport vehicle maintenance team .............................................................. 12
Figure 5 Heavy equipment maintenance team ............................................................. 13
Figure 6 Auto electric maintenance team .................................................................... 13
Figure 7 Wheel tractor maintenance team .................................................................. 14
Figure 8 Battery section ............................................................................................... 20

4
Chapter One

Introduction

Background and objective

Background

[1] Wonji Shoa Sugar Factory is found at Oromiya Regional State and situated around
10 kilometers to the South of Nazreth town and 102 kilometers to the South East of
Addis Ababa on the right bank of the Awash River . It is the oldest and the pioneer in
the history of Ethiopia’s sugar industry. It embraces an extensive stretch of land
which is surrounded by mountains and hills virtually from all sides.

Among the first large scale agro-industrial schemes in the upper Awash Valley was
the Dutch firm established in the Wonji plain in 1951. Within the first decade of its
establishment the WonjiShewa sugar estate enjoyed considerable success which led to
the establishment of the second factory at Shewa.

The Wonji-Shewa sugar estate emerged in 1951 when the Ethiopian government
concluded an agreement with a Dutch company, United N.V. Handles Vereeniging
Amsterdam (HVA) that enabled the latter to secure 5000 hectares of land both for
sugar cane plantation and to build a sugar cane factory. It was signed between the
Ethiopian government and HVA on 12 June 1951. The land was leased for a period of
sixty years with an option of renewal for further thirty years. The company agreed to
pay a nominal rent, Eth $1 per gasha (forty hectares).

After an enormous amount of pioneering work done, the Wonji plain was totally
changed into an industrial zone. Heavy engineering works were done. Irrigation and
drainage canals were dug; roads, bridges, culverts and aqueducts were also
constructed. Following the completion of the sugar factory at Wonji, Emperor Haile
Selassie I officially inaugurated the Wonji-Shewa sugar Estate on 20 March 1954.

The new company was named as HVA-Ethiopia and became a joint corporation since
1958. Eventually, the Shewa sugar factory was constructed and began its production
under 22, 400,000 capital in 1962.

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The addition of a confectionary works in June 1961, whose products were Desta
sweets. The training center provides technical an agricultural training to different
employees, while various upgrading courses are given to further improve the skill of
personnel. In addition to this the enterprise gives support to those who enroll it under
graduates, graduates and post graduates programs.

Objective

 The major objective of this report is to explain the practical on job training in
field equipment maintenance department for 3 months

Specific objective

 To show our finding about the problems

 To make us( trainee engineer) dig and know more about FEMD
 Understand the maintenance procedure of FEMD

There are five main departments, i.e. maintenance, factory (sugar production),
agriculture (cane production), harvesting and general service.

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Chapter Two

FIELD EQUIPMENT MAINTENANCE DEPARTMENT

FEMD is established initially with the wonji sugar factory and major objective of the
department is to avoid machines an equipment breakdown and enhancing
performance. The department has more than six decades of experience from the old
mechanical equipment to the modern electrically controlled machineries and transport
vehicles

Workshop managing department

The maintenance department is responsible for all maintenance work carried out on
the mobile fleet operating all over the company premises. All types of maintenance is
performed throughout the season starting from overhauling programme with
preventive maintenance, routine maintenance and ending with corrective
maintenance. The maintenance department controls and monitors sections included
Reception, wheel tractor, heavy equipment, transport vehicle and auto-electric
maintenance teams.

General operation and maintenance activities in FEMD

 Inspection
 Testing
 Measurement
 Cannibalization
 Adjustment
 Repair
 Fault detection
 Replacement of parts
 Service
 Lubrication
 Cleaning

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Major maintenance schedule

- Annual overhaul
- Periodic maintenance
- Hourly – heavy equipment machineries
- By km - for light and heavy duty vehicles
- Break own maintenance

Equipment maintenance workers

 General manager
- Is a top level management mainly responsible for the departments goal and
budget
 Team leaders
- Handles high level planning and oversees maintenance supervisors
 Supervisors
- Schedule day to day work, overseeing repairs regularly inspect the facility,
weekly\daily maintenance schedule, recruiting, supervising, and training
technicians
 Lead mechanic ( Forman’s)
- Distribute the day to day work across each mechanics and follow up the
operation
 Mechanic
- Handles upkeep and repair day to day work as directed by their foreman
an supervisors
 Junior mechanic
- Assists an executes a day to day work with the mechanic

General maintenance work order

Reception Maintenance Supervisor Forman

team

Mechanic and
junior mechanic

Figure 1 Maintenance work order

8
Fluids

Figure 2 Oil and Fuels

Workshop Management

The workshop management in the maintenance department consists of

 Managing Department and

 Planning and Ordering

Managing department
Major objectives

 Scheduling work
 Allocating time and labor resource
 Compliance and regulations
 Minimize down time at any circumstances
 Extend asset life
 Enhance equipment
 Training

Planning and Ordering section

The planning and ordering section is one of the sections that FEMD has in order to
perform and manage the planning process. It involves different duties and
responsibility addressing for the department. In my two week duration I do have
mostly seen and participate on particular discussions, preparations and operations.
These can include-

 Planning

 Reporting

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  Order of Purchase Request

 Preparation of Technical Specifications and Evaluations

 Understanding and using of Manuals

 Re-ordering

 G.R.N

1▪ Ordering of purchase request

Purchase Requisition (PR)

[2]A purchase requisition is a document that an employee within your organization

creates to request a purchase of goods or services. When you fill out a purchase
requisition, you are not yet purchasing anything. This is just beginning the process of
a purchase by asking for internal permission.

A purchase order is the confirmation of an order by the head of the department. The
purchase requisition form is sent internally from one employee to another. The
purchase order is sent externally from an employee to a vendor.

The purchase scope could be nationally or internationally

Both requisition and order for the purchase will be documented and stored in the
planning and ordering section.

Composition of PR
 Tittle (Purchase Requisition)

 Date

 Requested for ( FEMD)

 Account Number ( Stock and cost №)

 Vehicle description

- Plate №

- Account №

- Engine №

- Chassis №

- Model

 Part description

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 - Name of the part

- Store code

- Part №

- Quantity

Spare part order flow

Writes store
Supervisor request Store Planning and
ordering section
If available If not

Order by
GRN PR
evaluation
Purchase
Store Purchaser department
control
If it Technical
Pass evaluation

Figure 3 Spare art purchase flow

2▪ Planning

[3]Planning is the process of deciding in advance what is to be done, who is to do it

and how it is to be done and when it is to be done. The determination of a course of
action to achieve the desired result and bridges the gap from where we are to, Where
we want to go. The planning and ordering section formulate different types of plan
regarding to the whole department includes

The Annual plan contains milestones that carry the plan forward through a series of
smaller goals that lead to a broader vision of where the maintenance section aims to
be by the end of the year. The FEMD 2015 annual plan is to upkeep the machineries
and improving the technical service for the whole sections.

And their is also a Monthly plan that the section set goals to be accomplished at the end
of the month. There is also a daily, quarterly and fortnight plan depend upon the scope

Rather than annually and monthly plan these section also formulate

- Action plan – is a detailed plan outlining actions needed to reach one or more goals.

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 - Reform plan – is plan formulated where the industry makes change in its system. It has
goals and main activities and represent numerically.
- Strategic plan – is a definition of an industries future and identifies its goal and
objective.

The section give numerical plans on a tabular documentation depend on the types of
machinery or vehicle in each team and types of maintenance that the teams going to
do. The below graphical representation describes the type of machine each section has
and type of maintenance that the sections could perform.

Heavy duty
vehicles Inspection

Service
Light
vehicles
Partial
maintenance

Motor cycles Full maintenance

Break down  Low

maintenance  Medium
 High
Vehicle component
maintenance  Light
 Medium
 High

Figure 4 transport vehicle maintenance team

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 Wheel tractor Inspection

Service
Crawler tractor
Partial
maintenance
Trailer
Full maintenance

Break down  Low

maintenance  Medium
 High

Figure 5 Heavy equipment maintenance team

Motor cycle Inspection

Service

Light duty
vehicle Partial
maintenance

Full maintenance
Wheel tractor

Break down  Low

maintenance  Medium
Crawler tractor  High

Figure 6 Auto electric maintenance team

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Wheel tractor

Inspection
Stalk trailer

Stalk trailer (high

Service
bed)

Other trailers

Partial
Trailer maintenance
equipments

Irrigation
pump Full maintenance
Diesel generators

Compressors
Break down
 Low
maintenance
 Medium
Mobile  High
welding

Tire maintenance
 Dodota
 Wonji
 Field

Figure 7 Wheel tractor maintenance team

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3▪ Preparation of Technical Specification and Evaluation

FEMD’s planning and ordering section prepares a technical specification which is a

document that outlines the requirements and features that a product has to have in
order to work as intended.

As I have seen the format[3] the Planning and ordering section creates an effective
technical specification while purchasing certain goods like heavy and light duty
vehicle. The specification includes:-

1. Date and Tittle of purchase

2. General

- Service requirement

- Technical data

- Technical warranty

- Spare part

- After sales support

3. Technical specification

- Engine

- Electrical system

- Transmission

- Steering

- Brake types

- Body type

- Payload capacity

- Ground clearance and etc.

4. Point of fundamental compliance

5. Merit points allocations

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Technical Evaluation

FEMD’s planning and ordering section also formulate technical evaluation. Technical
evaluation is the prosses of assessing the offers received to meet the determined
requirement in the technical evaluation. Technical and quality evaluation is one of the
most important stages of the Procurement Journey This stage of the Journey ensures
that[4]:

 The department decision is objective and uses the disclosed criteria

 The decision making process is fair, transparent and auditable

The department can demonstrate best value in the tender process.

The panel members should read and score the quality/technical aspects of the tenders
independently. They should use the pre-defined evaluation criteria and scoring system
already communicated as part of the tender process.

The Planning and ordering section formulate technical evaluation significantly for two
processes. These are:-

 Vehicles and Machinery and

 Spare parts purchases

Technical Evaluation for Vehicle and Machinery

FEMD and Industry’s Procurement department has better experience especially on

heavy equipment and formulate an effective technical evaluation The evaluation of
equipment, regardless of what amount of prior information we can secure on its
performance, should be made by the department by a method that provides
information that applies to its particular situation and needs.

[5]To use, or more importantly, to extend the use of equipment without making a
proper evaluation of its suitability, can lead to a mistaken understanding of its value.
Best results are obtained in the evaluation when a defined procedure of evaluation is
followed and when personnel who understand such a procedure follow it.

The major evaluation procedure usually involves two steps :

(1) An appraisal based on available information and intended to guide the selection of
equipment before physical installation and testing, and

(2) Evaluation of a test installation under plant conditions.

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The need to evaluate machines and equipment arises when this equipment or
machines become the subject of any operations and transactions. Evaluation is
performed for different purposes. It may be needed when:

 Determination of collateral value;

 Statement on the balance sheet of the enterprise, revaluation for reflection in
accounting and financial reporting (for accounting purposes);
 Making management decisions;
 Concluding purchase, sale or lease agreements;
 Determination of property shares;
 Making a contribution to the authorized capital;
 Imposition of penalties on the property of the debtor company;
 Liquidation and utilization of property;
 Insurance, etc.

Technical Evaluation for Spare Parts

It is necessary to master the spare parts’ management and the maintenance

management at the same time since these two elements are interrelated and essential
for the industry in order to ensure continuity of service. FEMD’s has limitation on
spare part management but its evaluation document is good while purchasing spares.

4▪ Understanding and Using of Vehicle and Machinery Manuals

The FEMD's planning and ordering allows us to discover different types of manuals
concerning different vehicles and machinery. A technical manual is a well-defined
document that explains the means for operating, maintaining, supporting or installing
a machine, process, system, or piece of equipment.

A technical manual is a “how-to guide or manual” created for a single objective of

making it simple for the end-user to understand the technicality of using a product or
service. The planning and ordering section supplies for all section but not centralized.

There are different types of manual depend on for whom it written.[6] These include:-

Service/Repair manual - helps technicians and other trained people service, maintain,
and repair equipment. It usually contains information on the problems and breakages
that may occur and guidelines on how to fix them.

User manual - assists people to use a particular system or device. It provides

instructions for both skilled and unskilled users for setup, operation, and maintenance
of a product. It may have precautions and problem guidelines.

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Operation manual - provides guidance for the staff to perform their functions
correctly and efficiently. It describes what and how should be done, which is
especially important for the quality of goods and services. Moreover, it contributes to
the safety of products and services.

5• Preparation of Office Memorandum

The FEMD department Uses office memorandum in a day to day operation. It is a

document used for internal communication with in the whole Wonji shoa sugar
factory. It is a way of communication between employees in all departments and
sections with in the factory. It entails disseminating information on the
implementation of new rules or policies, important meetings to attend, or any new
decisions or reforms that have been made or will be made on a particular day.

A standard office memorandum issued by a member of a governing body or an

organisation, is simply a means of communication that allows two members (or
department heads in some situations) of the same organisation/governing body to
communicate certain data.

FEMD's office memo composes:-

 The issue’s date,

 Essential details,
 And the number of personnel involved in the task are all included
 To be copied ( for concerned personnel or department)
 Stamp and signature

6 • Re-ordering

Reordering document is written to ask someone to make, supply, or deliver the same
goods again used to ensure a sufficient quantity of product availability in an
inventory. This helps to avoid running out of stock of the product. It also supports the
user to avoid excessive purchase or storage of a product. The reordering request is
prepared by the planning and ordering section and sent to the purchasing department.

As i requested on the qualified personnel’s reordering could be formulated by such

reasons. These includes:-

 Mistake happen on the quantity of the primary PR

 Need for additional parts because of stock out
 Need for additional repair

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[7]There is a phrase called A reorder point (ROP) which means a specific level at
which your stock needs to be replenished. In other words, it tells you when to place an
order so you won't run out of stock.

7• G.RN. (Good Receiving Note)

The planning and ordering section works in hand to hand and have a direct connection
with the purchasing department and store control unit. I do have a chance to observe
the work procedure and responsibilities of the store control unit.

G.R.N preparation is one of job responsibility on store control init. It is a record of

goods received from suppliers, and the record is shown as a proof that ordered
products had been received. Moreover, the record is used by the buyers for comparing
the number of goods ordered to the one delivered. GRN plays an important role
among various departments for several companies. Primarily FEMD’s store, Store
control unit, procurement and financial/accounting departments use the record for
stock updates and the payment of goods procured.

Reception

When a driver or operator comes to FEMD the first bureau they have to visit is
reception. It is the beginning of the work flow to all sections.

Responsibilities involves in this section are:-

 Filling the job card

 Make sure all the boxes are filled
 Lead the driver or operator to given section
 Record the vehicle and machine history

Auto-Electric Maintenance Team

Major electrical maintenance

 Battery
 Starting system
 Charging system
 Lighting system

19
 Figure 8 Battery section
The team is responsible in most of the department where auto electric maintenance
operation is done. The section has also managing department which controls,
coordinates and record its maintenance activities. I have been involved in most of the
maintenance operation. The following specific maintenance operations are some of
the work I have been intended in my two week duration on AEMT.

Corrective maintenance I have involve in are

Model:-Versatile Tractor (365 hp)

P. №:- WT- 0139

Problem faced

 Charging system problem.

 Purchased wire for the positive post have low quality.

Measurement taken

 Replacing new wire with better quality

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  Reconnect the wiring harness with respect to their coinciding length and their
color coding also considered

Daewoo Dump Truck( K4DVF) (390 hp)

P. №:-③ 38071

Problem faced

 Horn problem

 Sign of short circuit and smoke

Measurement taken

 Identifying the short circuit harness( 3 days)

 Replacement of shorted wire with a new one

Toyota Hilux 4WD(148bhp 2.8-litre turbo diesel engine)

P. №:- ③42074

Problem faced

 The alternator is neither charging the battery nor supplying electrical current
to the system

Measurement taken

 Tracing of short circuit

 A 30A fuse repeatedly shorted after the vehicle is started

 This symptom tell us the alternator is working fine

 The shorted circuit is founded below the distribution box

 Replacing the wire with a new one

XCMG Cane Stalker ( 310 Hp)

P. №:- WT-0242

Problem faced

 The engine is not starting

21
  Starter motor is not rotating

Solution

 Check cable connections

 Check starter switch

 Check starter relay and magnetic switch

 Removal of starter motor

 Disassembly of starter motor

 Perform terminal inspection, cleaning and testing

 Assembly of the starter motor

 Checking the starter motor using battery before put back in to the machine

 Inserting the repaired starter motor to the engine

 Check the functionality by cranking the engine

Daewoo Dump truck(KD4 6F 6×4 , 390 hp)

P. №:-③37064

Problem

 Turn signal won't light on

 The wiper is not working

Solution

For turn signal

 Open distribution box

 Check wire for short circuit

 Replace the flasher

For wiper motor

 Open the cover of starter motor

 Perform a terminal and post connection check up

 Removing the wiper arm from the motor

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  Removal of starter motor

 Disassembly of starter motor

 Perform visual inspection

 The high/Low terminal are damaged

 Replace the starter motor by removing from another truck with the same
model

*John deere 9410R(410 Hp)

P. №:- WT-0175

Problem

 Head light turned off after few minute of engine operation

Solution

 Take direct power from the relay to the lamp

Wheel tractor maintenance team

WTMT is one of the sections in FEMD responsible for four wheel tractor
maintenance. Tractors are extremely useful pieces of equipment, and with the right
maintenance, they can run for years with very little trouble. Because there are so
many different kinds of tractors with specific applications, maintenance may vary
greatly from tractor to tractor.

Machineries in these section and quantity

- SAME tractor - 6
- Bell - 19
- Massey Ferguson MF - 2
- YTO - 4
- KAT - 14
- John Deere( four wheel) - 5
- Ursus – 4
- Dynapack tractor – 1

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Quantities of machineries in general
 Wheel tractors - 77
 Cane cart - 60
 Cane cart (high bed) - 18
 Other trailers - 29
 Irrigation pump - 3
 Diesel generator - 7
 Compressor - 2
 Mobile welding - 1

System in the machineries

 Cooling system
- all machineries uses water cooling system except bell tractor
 Fuel system
- Unit pump injection – SAME tractor
- Distributor type injection – New Holland tractor
- Inline injection – Bell, YTO, KAT, John Deere, Ursus tractor
- Common rail injection – Massey Ferguson tractor
 Brake system
- all machineries uses hydraulic brake except KAT tractor

In addition to the three common maintenance (overhauling, periodic and corrective

maintenance) the WTMT section controls a Tire maintenance team

However practical trainee schedule was too late for the overhaul program that is done
on summer time, i personally participated on maintenance practice with the section
technicians mainly the corrective maintenance job. Most tractors were maintained on
the overhaul program so there were some maintenance operation than the other
section on FEMD. These service operation mainly concerned on corrective
maintenance includes:-

Corrective maintenance I have involve in are

Model :- New Holland TD80(76Hp)

P. № :- WT-0143

Problem Faced

 Injection pump leakage

Rotary injection pump with centrifugal speed governor and automatic advance bosch
VE-Type

Cause of leakage :- Wear of the seal ( Governor seal)

24
Measurement taken

 Remove the modified and defective seal

 Change and insert the new and compatible seal

Model:-YTO 1804 .

P. № :- WT-0195

Problem faced

 Turbocharger bearing oil leakage

 Fuel injector washer wear

Measurement taken

- change the oil return gasket

- replace the injector washer

SAME Laser 180 (180Hp)

P. № :- WT-0072

Problem faced

 Exhaust smoke on air filter

 Diesel fuel leak out on injector

Measurement taken

- Perform valve clearance

- Clean the injector bore

- Flushing or cleaning the cooling system

The WTMT section present on its paper[8] about the its periodic maintenance. Mainly
focused area was discussed above and the periodic maintenance schedule and
presented as following.

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Periodical service

Service schedules generally maintain designed service life conditions. Since, it is not
necessary and possible also to carry out maintenance activities every hour. Activities
required to be carried out at regular intervals to maintain these conditions are
mentioned in service scheduled. Generally these are classified as 10, 50, 125, 250,
500, 1000 hour service schedule. The activities carried out in these schedules may
vary from one manufacturer to another.

10 hours service schedule.

List of activities to be carried out in 10 hours service schedule:

1. Clean the tractor, if the tractor worked under dusty conditions & wash it with a
swift jet of water to remove the dirt and wipe off with a dry cloth.

2. Inspect the tractor critically to ensure that no leakage is taking place at any
point,

3. Check all the nuts and bolts for tightening properly on different parts of the
tractor and replace the broken ones, if any.

4. Check all the nuts and bolts for tightening properly on different parts of the
tractor and replace the broken ones, if any.

5. Top up the fuel level in the fuel tank at the end of each days operation. This
will keep your tractor ready for "next day and avoid condensation of water at
the bottom of tank or in the fuel line.

6. Check and top up, if necessary crank case with mobile oil. Dip stick with low
and full level mark is provided for the purpose. The oil level should be in the
middle of these two marks.

7. Check up the water/coolant level in the radiator/ dispenser bowl and top if
necessary. Do not allow water level to go below from the top of the radiator.

8. Check the belt pulley gear-box oil level when the pulley is in use and refill it
to the plug level with transmission oil.

9. Check the front and rear type-pressure. In general, the pressure in the front
tyres should be nearly 2 kg/cm2 and that in the rear tyres about 1 kg/cm2

Maintenance after 50 hours of tractor operation

1. Repeat the 10 hour service schedule

26
 2. Maintenance of Tractor Battery: -Inspect the battery for loose terminals and
electrolyte level.Wash the battery top with washing soda using warm water
and grease the terminals 32 with petroleum jelly to prevent corrosion.

3. Check the fan-belt tension and adjust it if required

4. Cleaning and servicing air cleaner

5. Servicing of fuel supply system

6. Check and adjust the brakes for proper operation

7. Check and adjust the engine clutch

8. Lubricate:

Lubricate the following:

a) Fan-hub bearing

b) Throttle-control lever

c) Engine-clutch-release bearing, and

d) Alternator bearing

9. Check the water-pump (water body) for leakage and tighten or replace the
packing

10. Loosen the vent plug and the drain-tap of the primary fuel filter and run off a
small quantity of fuel in order to remove any water which might have
accumulated.

11. Repeating the activities carried out in 50h maintenance schedule

12. Changing Crankcase Oil

13. Replacing the oil filter

14. Servicing the Crank Case Breather

15. Checking and servicing other parts of the tractor

Check the following and if needed put some lubricating oil.

a) Generator/ Alternator bearing

b) Distributor shaft

Maintenance after 250 hours of operation

1. Repeating the activities carried out in 125hours maintenance schedule

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 2. Valve clearance adjustment

3. Checking the battery

4. Cleaning the water separator, sediment bowl and fuel filters

5. Adjust engine clutch: Adjustment of foot operated clutches: To adjust the foot
operated clutch proceed as follows:

a) Determine from your operator's manual how much free travel in clutch
pedal is needed. Recommendations vary from 15mm to more than 60mm.

b) Check clutch pedal for free travel.

c) Locate means provided for clutch adjustments.

d) Adjust linkage until clutch pedal has sufficient free travel.

e) Tighten lock nut so that it holds adjustment securely.

Maintenance after 500 hours of operation

1. Front-Axle adjustment

Toe-in adjustment

The front wheels are slightly drawn in at the front side in such a way that the
distance between the front sides of wheels is slightly less than their back side.

2. Servicing Front-wheel Bearings

• Disassembling the Front-wheel bearings

• Clean the Front-wheel Bearings

• Greasing & refitting of front wheel bearings

3. Maintaining the Cooling system:

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Heavy equipment maintenance team

Machineries in these sections

 Articulate Tractors ( John Deere, Case Steiger, Versatile tractor)
 Grab loaders (CAMECO John Deere)
 Cane stalker (XCMG)
 Motor grader (CAT, MISTA)
 Front loader (CAT, Komatsu)
 Back hoe loader
 Truck crane
 Forklift
 Pusher
 Crawlers

- Dozer ( Komatsu, CAT, Dreesta)

- Excavator (New Holland long reach, CASE, power plus)

Implements

Tillage implement
Tillage is the mechanical manipulation of soil for any purpose, but usually for
nurturing crops. The implement inclues

Primary tillage
 Mouldboard plows
 Disk plows

Secondary tillage
 Disk harrow

Radiator repair
The section repairs when

- Coolant leakage
- Overheating
- Radiator discoloration
- Temperature gauge too high

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Repair procedure
- Identify the source of leak
- Inspect image fins an try to adjust them
- Stop the leak (by welding or using radiator leak stop RLS)
- Mount an insect while the engine is running
-

HEMT section is the widest section in FEMD consist not only agriculture machineries
but construction machineries also. Implement repair and maintenance is operated in
this section. On my two week duration experience on this section like other sections I
also involve on the service/ preventive maintenance and mainly on breakdown
maintenance.

Regular heavy equipment maintenance involves scheduling routine tasks to ensure

machinery operates at peak performance. Preventive maintenance also involves visual
inspections, technical monitoring and oil analysis to anticipate problems and fix them
before they become serious.

Construction equipment maintainers look at repair work as proactive and reactive.

They also call it scheduled and unscheduled repairs. Proactive maintenance is far
more cost-effective than reactive, post-breakdown repair. Routine and preventive
maintenance saves construction companies enormous sums compared to suffering
expensive parts replacement and costly downtime when unexpected failure suddenly
happens. Some

Corrective maintenance I have involve in are

Model:- Case Steiger(385K)

P. №:- WT-0114

Problem faced

 Stuck engine

Measurement taken

 Engine rebuilding
 Crankshaft main journal lumbering (outsource)

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Model :- Komatsu Dozer (D6K)

P.№:- CT-0011

Operation done

 Exchanging of engine from CT 0011 to CT 0012 with the same model.

 Disassembly of CT 0011 engine from the dozer to cane stalker
- Remove the engine cover

- Remove air cleaner bracket bolt

- Remove exhaust muffler

- Remove radiator guard and radiator

- Disconnect fuel supply and return hoses

- Remove the dozer canopi

- loosen the engine support bolts

Model :- Cane Stalker

P №:- WT 0220

Operation done

 Remove air cleaner

 Unplug hoses ( radiator, fuel)
 Unplug electrical harness
 Remove the support bolts

Model: - New Holland long reach Excavator (E 265B)

P. №:- CT-0017

Operation done

 Disassembly of hydraulic pump

 Perform valve clearance (using Z- Method )

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Transport vehicle maintenance team

List of vehicles under TVMT

 Auto bus
 Daewoo dumb truck and cargo
 Daewoo low bed
 Toyota land cruiser
 High bed
 Nissan d ⁄c and UD Mws
 Sino Mws
 Motor cycles

TVMT’s section is also one of the sections in FEMD responsible for the management,
maintenance and repair of all City vehicles, and equipment, especially major repairs
to the vehicles and equipment of the higher staff vehicles, heavy duty vehicles and
motor bikes. Rebuilding and replacing vehicle components are done as required, as
are official vehicle inspections.

The department managers and technicians mostly have done then preventive
maintenance unlike other sections. All vehicles are subject to wear and tear and unless
maintained at regular intervals, this wear and tear will eventually result in unsafe
vehicles and vehicle breakdowns. Regular planned maintenance is a critical step in
preventing this. Effective vehicle maintenance practices result in a vehicle that is safe
and fit for purpose and not likely to cause injury to people using it or affected by its
use.

Like my duration on other sections I have a fruitful duration and experience with
transport vehicle maintenance team. The following maintenance and service action
have been done on my two week duration on TVMT. These includes:-

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Corrective maintenance I have involve in are

Model:- Daewoo dump truck(6×4 series)

P, № :- 37067

Problem faced

 Whirling noise while decelerating and accelerating above certain Km/Hr

 Vibration while driving
 Clicking sound while turning and curving

Measurement taken

 Front axle service

- Wheel, Drum,and Hub removal

- Hub bearing cup and Seal disassembly

- Cam brake and Spindle disassembly

- Steering knuckle removal

- king pin removal

The assembly procedure will be the reverse of disassembly and cleaning and
replacement of parts takes place while assembling.

 Replacement [2(replacing the gaskets, oil seals, grease s)]

- Damaged washer

- Replacing the fasteners if the corner of the head are worn.

Model:- Toyota land cruiser

P,№:-③ 56116

Problem faced

 Wheel service time reached

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Measurement taken

 Wheel service
- cleaning

- brake service

- greasing

Model:- Daewoo dump truck (10*4 series)

P, №:- ③ 36858

Problem faced

 Vibration on Rear suspension

Measurement taken

 Trunnion assembly service

 Side plate cannibalized from the same model p.№
 Sending Copper bush preparation on workshop

Model:- Daewoo dump truck (10*4 series)

P,№:- ③ 36857

Problem faced

 Noise and Vibration on left side of the front axle

Measurement taken

 Front axle service

- Wheel, Drum,and Hub removal

- Hub bearing cup and Seal disassembly

- Cam brake and Spindle disassembly

- Steering knuckle removal

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 - king pin removal

 Replacement of king pin

Model:- Daewoo dump truck (10*4 series)

P,№:- ③ 37062

Problem faced

 Less power reached on the wheel

 Power transmission problem
 Friction disk wear
 Pressure plate face is cracked

Measurement taken

 Dismounting of propeller shaft

 Dismounting of gear box
 Replacement of friction disk
 Replacement of pressure plate

Model:- Toyota land cruiser

P,№:- ③ 56116

Problem faced

 Belt replacement Km reached

Measurement taken

 Belt replacement \

Model:- Nissan

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P,№:-③ 37291

Problem faced

 Gear box bolts are loosen and some are lost

 Gear box bolts that are tightened are different from each other
 The right tire is weared on its left side
 The right front wheel is in Toe-in position
 Bearing is torn out
 Wheel hub plate have only one screw

Measurement taken

 The technician finds its bolts and replace them

 Toe-in adjustment

Model:- Toyota land cruiser

P,№:- ③ 56120

Problem faced

 Unstable steering, shaking, swaying during lane change

 Thumping sound when deceleration and driving around curves

Measurement taken

 Torque rod bushing replacement

Model:- Yamaha motor cycle( DT-125D, 0.9L engine)

P,№:- MB-0094

Problem faced

 The bike won’t start

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Measurement taken

 Carburetor service
- Calibration

 Fuel cock replacement

Body repair and painting section

Body repair and painting section is the part of transport vehicle maintenance team
responsible for vehicles that encounters accident and return them damaged body to its
original position. After the body repaired and returned to its previous position the
painting team make the body to have a paint cover which will be visually attractive.

But this section is not working actively because of absence of tools and equipment
and also replaceable spare parts. When the body repair and painting work is needed
the section department outsources the job to other private maintenance organization.
So there were none access of the section in my two week duration but I have refer and
read many articles[9] found in the section and understand the operation of body repair
and painting theoretically.

While painting the Painting teams Clean and smooth, smooth and clean first. Keeping
a surface clean during the collision repair process is a must.The section uses the
proper wax and grease removers, solvents and cleansers to keep the portions of the
vehicle to be painted clean throughout the entire process. Even during the many
phases of sanding, a surface is cleaned before and after. For the “smooth” mentioned
above, this requires sanding – and several iterations of sanding. The technicians may
sand with a machine, with a block or by hand. Each type of sanding is followed by a
finer grade of sandpaper to get the surface to the desired, jewelers smoothness.

Over-spray, or paint that has made its way to other parts of the car, is unacceptable.
To make sure this doesn’t happen, paper is taped and applied to the vehicle to prevent
the tiny air-borne particles of paint from going anywhere other than on the surface it
is intended for.

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Once the prep work is complete, the vehicle or parts to be sprayed are brought into
one of our two paint booths for the next phase of repair: the application of colour and
clear coat.

These steps are done while maintaining the vehicle body that encounters accident or
body damage includes pre painting and painting activities:-

Step 1: The vehicle is thoroughly inspected and all relevant data is recorded. This data
is compiled into an estimate that determines the cost of repair;

Step 2: Once the estimate is completed, the insurance company will review the
estimate.

Step 3: In disassembly hidden damage is often found, and inner structure repairs are
determined. Many times this will require scheduling insurance re-inspection and
ordering additional parts.

Step 4: The required parts for your vehicle are ordered, and availability is checked. If
a part needs to be special ordered, the order will be placed as soon as possible.

Step 5: In the structure repair area, the unitized body is returned back to the factory
specification.

Step 6: The Body Repair Department replaces the exterior panels, and all metal
finishing that may be required. The vehicle begins to come back to life as sheet metal
is installed and aligned.

Step 7: Paint Preparation is a critical step in the refinishing process of every vehicle.
All panels are properly prepared for paint, then primed and sealed to assure good
adhesion when the final top color and clear coats of paint are applied.

Step 8: Final moldings and detail pieces are put back on the vehicle in the reassembly
area. All the vehicle’s systems are checked during this process. The vehicle is almost
complete and ready for delivery!

Step 9: During the repair process the vehicle has likely accumulated dust from the
repairs, so it’s important that the vehicle be completely cleaned.

Step 10: Delivery is the last step in the repair process.

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 Chapter Three

Problems in General

 Unavailability of
 spare parts
 power tools
 safety tools
 measuring, testing and diagnosing tools
 Unknown resources because of not recording
 Improper upkeep the machineries
 Improper placement of disassembled and dismounted parts
 Traditional maintenance practices
 Complete maintenance system
 Recording of maintenance history
 Cleanliness
 workshop hygiene
 disposal of arts
 disposal of oil
 Illogical modification

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 Conclusion and Recommendation

Conclusion

The whole experience relate to the field equipment maintenance department was very
exciting and fruitful. Training and working in FEMD has really given an insight what
is like to work in such large and wide industry. Working with the management
department has been a good experience and acquire major management trends
working with technical teams in each section have given additional knowledge and
improvement of skill for our carrier experience. The practical training program
illustrates more the theoretical courses and helped to identify the focus point of the
significance of our involvement in the maintenance department

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 Recommendation

 Consider supplying spare part for the department

 Improve the modification practice
 Improve the maintenance system
 Improving the store
 Proper recording of vehicle an machinery history
 Executing the reform effectively will make a big an radical change for
maintenance department also
 Consider improving the cleanliness of the work shop

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Reference

1. African labor and foreign capital the case of wonji shoa sugar estate; on
journal of political sciences and public affairs
2. Heavy equipment section database
3. Planning and ordering section database
4. Wheel tractor section data base

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