Bibek Yadav

KATHMANDU UNIVERSITY SCHOOL OF ENGINEERING DEPARTMENT OF MECHANICAL ENGINEERING INDUSTRIAL TRAINING REPORT ON INTERNSHIP AT EASTERN MANAGEMENT PRIVATE LIMITED BATAS ORGANIZATION Bibek Yadav (42085) June 2019 INTERNSHIP EVALUATION INTERNSHIP AT EASTERN MANAGEMENT PRIVATE LIMITED By Bibek Yadav (42085) This is to certify that I have examined the internship report and have found that it is complete and satisfactory in all respects, and that any revision required have been made. _________________________________________ Mr. Prashanta Nakarmi Service Manager Internship Supervisor Eastern Management Pvt. Ltd. _________________________________________ Mr. Pratisthit Lal Shrestha Internship Coordinator Assistant Professor Kathmandu University _________________________________________ Eastern Management Private Limited Batas Organization Acknowledgement First of all, I would like to express my gratitude to EMPL family and my Internship Supervisor and Service Manager of EMPL, Satungal Mr. Prashanta Nakarmi. I would also like to express my heartfelt thanks to Service Advisor Mr. Ashmin Nepal, Service Engineer Mr. Anish Thapa, Mr. Samsul Ansari & Mr. Dipesh Adai for providing me assistance to successfully complete my Internship. I would also like to convey my sincere gratitude to my Industrial Training Co-ordinator Mr. Pratisthit Lal Shrestha, Asst. Prof. of Department of Mechanical Engineering and Mechanical Engineering Department, Kathmandu University for the Industrial Training opportunity for allowing us to be familiar with the professional environment. At last I would also like to thank all the service technicians for their assistance at the time of my internship to make it a fruitful one. i Abstract The Industrial Training was a 3 months period carried out at Eastern Management Private Limited, Nepal as a part of my BE in Mechanical Engineering Degree. The motive of the Industrial Training was to expose the students to the practical environment of their own field allowing them to enhance the knowledge gained through the academics and gain some practical experience. The training period was scheduled for different tasks from floor to office works dedicated mostly to learning by doing. Starting from the maintenance works to job cards and finally online NAV software. This period was an opportunity for me to enhance my skills in my upcoming career field. Experienced chain of commands & various service operations in a service oriented auto industry in a realistic scenario. ii Table of Contents Acknowledgement ................................................................................................................................... i Abstract ................................................................................................................................................... ii LIST OF FIGURES ..................................................................................................................................... vi LIST OF ABBREVIATIONS ...................................................................................................................... viii Chapter 1................................................................................................................................................. 1 Introduction ............................................................................................................................................ 1 1.1 History ........................................................................................................................................... 1 1.2 Mission .......................................................................................................................................... 2 1.3 Vision ............................................................................................................................................. 2 1.4 Goal ............................................................................................................................................... 2 1.5 Values ............................................................................................................................................ 2 1.6 Organizational Structure and hierarchy ........................................................................................ 3 1.7 Products of the company .............................................................................................................. 3 1.8 Human Resource Management .................................................................................................... 5 1.9 Unique Observation about the company...................................................................................... 5 1.10 Similar other industries ............................................................................................................... 5 Chapter 2................................................................................................................................................. 1 Technical Specification about the company ........................................................................................... 1 2.1 Equipment’s, and its applications ........................................................................................... 1 2.1.1 Air compressor ................................................................................................................ 1 2.1.2 Hydraulic press ................................................................................................................ 1 2.1.3 Greasing gun ................................................................................................................... 2 2.1.4 Hydraulic mini crane ....................................................................................................... 2 2.1.5 Hydraulic & transmission jack ......................................................................................... 2 2.1.6 Bench Vice ....................................................................................................................... 3 2.1.7 Grinder ............................................................................................................................ 3 iii 2.1.8 Pneumatic Gun ................................................................................................................ 4 2.1.9 Slider ............................................................................................................................... 4 2.1.10 Battery Charger ............................................................................................................... 5 2.1.11 Toolbox & Tools Room .................................................................................................... 5 2.2 Plant Layout ............................................................................................................................ 6 2.3 Service process ........................................................................................................................ 8 2.4 Service Flow Chart................................................................................................................... 9 2.5 Troubleshooting Services ...................................................................................................... 10 2.5.1 Regular servicing ........................................................................................................... 10 2.5.2 Hub greasing ................................................................................................................. 10 2.5.3 Troubleshooting of Heating Issue ................................................................................. 10 2.5.4 Clutch Issues .................................................................................................................. 13 2.5.5 Gearbox repair .............................................................................................................. 15 2.5.6 Troubleshooting of steering issues ............................................................................... 17 2.5.7 Differential repair.......................................................................................................... 18 2.5.8 Troubleshooting of brake problems ............................................................................. 19 2.5.9 Troubleshooting of fuel supply problems ..................................................................... 20 2.5.10 Engine overhaul ............................................................................................................ 21 2.6 Service Management .................................................................................................................. 23 2.7 Inventory Management .............................................................................................................. 23 2.8 Quality Management .................................................................................................................. 23 2.9 Kaizen Principle ..................................................................................................................... 23 Chapter 3............................................................................................................................................... 25 Training Details ..................................................................................................................................... 25 3.1 Training Methodology .......................................................................................................... 25 3.2 Work Assigned ...................................................................................................................... 25 3.3 Works Accomplished............................................................................................................. 25 3.4 Limitations............................................................................................................................. 25 iv 3.5 Problems encountered ......................................................................................................... 26 Chapter 4............................................................................................................................................... 27 Conclusion ............................................................................................................................................. 27 Chapter 5............................................................................................................................................... 28 Weekly Log Book ................................................................................................................................... 28 5.1 Gantt chart for Trainee ......................................................................................................... 28 5.1.1 Floor Job ........................................................................................................................ 28 5.1.2 Office Works.................................................................................................................. 29 Recommendation .................................................................................................................................. 31 Bibliography .......................................................................................................................................... 32 v LIST OF FIGURES Figure 1: EMPL Workshop, Satungal Figure 2: Organizational structure and hierarchy of EMPL Satungal Figure 3: Products of EMPL Figure 4: Air Compressor Figure 5: Hydraulic press Figure 6: Greasing gun Figure 7: Hydraulic mini crane Figure 8: Hydraulic jack Figure 9: Transmission jack Figure 10: Bench vice Figure 11: Grinder Figure 12: Air gun Figure 13: Slider Figure 14: Battery charger Figure 15: Toolbox Figure 16: Tools room Figure 17: EMPL Satungal layout Figure 18: Service Flow Chart Figure 19: Clogged radiator Figure 20: Worn pressure plate-1, flywheel-2 & clutch plate-3 Figure 21: Uneven clutch plate wear vi Figure 22: Broken countershaft & main shaft gear Figure 23: Broken & Worn components of differential case Figure 24: Broken teeth of pinion shaft Figure 25: Training Methodology Figure 26: Job Card vii LIST OF ABBREVIATIONS EMPL Eastern Management Private Limited ECU Electronic Control Unit EML Eicher Motors Limited FIP Fuel Injection Pump VECE Volvo Eicher Commercial Vehicles viii Chapter 1 Introduction 1.1 History Eastern Management Pvt. Ltd. (EMPL), an enterprise of Batas Organization was established in 2008 an exclusive sole distributor of Volvo-Eicher commercial vehicles in Nepal. The corporate office of EMPL is located at Gairidhara, Kathmandu and branches in Kathmandu, Birgunj, Hetauda, Itahari and Nepalgunj. It has joint operations with local entrepreneurs in Pokhara, Janakpur, Narayanghat, Butwal, Trishuli, Birtamod, Dang and Dhangadi that deals with both sales, after sales services as well as spares parts of the vehicles. Since its inception, EMPL has sold more than 4500 vehicles in Nepal till date. EMPL is one of the largest automobile company in the country with professionals and trained manpower in both sales as well as after sales service and is wide spread over the nation. The company employees about 179 professionals and makes sure that each of our employees provide you the best service. [1] Figure 1: EMPL Workshop, Satungal Eicher Motors Limited India (EML) was founded in 1948 AD. Eicher has a joint venture between Sweden’s AB Volvo- Volvo Eicher Commercial Vehicles Limited. EML and Volvo Group’s 50:50 joint venture Volvo Eicher Commercial Vehicles (VECV) designs, 1 manufactures and markets commercial vehicles, engineering components and provides engineering design. [2] EMPL imports all the vehicles for sales and spares parts for after sales services from EML India. With the proven performance of Eicher vehicles over the past few years in the demanding Nepalese terrain, EMPL is the market leader in the light commercial segment and growing fast in the heavy segment. [1] 1.2 Mission One Aim: To deliver quality product to our customers for profitable growth. One Plan: Provide best quality product, Profitability of our valued customers, No compromise in safety. One Team: People working together in a team towards a common goal. 1.3 Vision To be most successful and respected automobile company in Nepal. 1.4 Goal Happy and wealthy customers is our goal. 1.5 Values Honesty: We will strictly follow our code of ethics in all our dealings with our customers. We will be honest and truthful in all our dealings. Counselling: we will understand requirements and provide best products to the customer. Respect: we will treat our customers and employees with respect. Family: we view all our customers and employees as part of our extended family. 2 1.6 Organizational Structure and hierarchy Organizational structure and hierarchy of EMPL, Satungal is given below:- Service Manager Service Advisor Service Engineer Senior Mechanic Junior Mechanic Figure 2: Organizational structure and hierarchy of EMPL Satungal 1.7 Products of the company The products of EMPL are listed below:i. Truck PRO 1049 C FSD, PRO 1059 C HSD, PRO 1055 C DSD, PRO 1080 XP, PRO 1080, PRO 1095 XP, PRO 1112 XP, PRO 1114 XP, PRO 3015, 30.25 CBC, 35.31 CBC, PRO 6031, 20.16 & 20.16 M CONTAINER ii. School Bus iii. Tipper PRO 1055T, PRO 1080 XPT, PRO 1095T, PRO 1112 XPT, TERRA 25 6S, TERRA 25 9S, TERRA 16 XP & 6025T iv. Special purpose vehicles Transit Mixer v. Route permit vehicles 3 vi. Generators Genset generators Figure 3: Products of EMPL 4 1.8 Human Resource Management Human resources required for the EMPL are Chairman, General Manager, Sales & Service Managers, Accountants, Engineers, Mechanics, drivers, guards & other personnel. These right human resources required are selected based upon qualifications and experience and are governed by the human resource department. Human resource department is located at Gairidhara i.e. the main office of EMPL which regulates the human resources of EMPL branches located all over the country. HR manager is responsible for selecting the required personnel for moving the company towards a progressive path. Various allowances such as fuel allowance, EMI schemes for owning vehicles at attractive rates, etc. are available for officers & workers to attract and retain them. 1.9 Unique Observation about the company EMPL Workshop Satungal is among one of the few authorized places for maintenance of EICHER vehicles in Nepal. The workforce at the workshop are very efficient and effective performing maintenance works at a high rate. The quality of service offered at the workshop has been highly appreciated by the customers and there are a lot of happy customers which is the wish of any organization. The workshop has done the perfect utilization of its available resources from work space, tools to employees. While providing off-road services to customers they are able to handle the vehicles maintenance time quickly. One of the most appreciating thing about the workshop is that no employee hesitates to provide a hand in case needed while performing any maintenance works. 1.10 Similar other industries i. Sipradi Trading Private Limited Sipradi Trading Private Limited (STPL) is a sole distributor of Tata Motors Ltd. India established in 1982 AD and certified with ISO 9001:2008. Sipradi is a major player in automotive business, one of the most driving brand. The company offers sales, after sale services and spare parts of Tata Motors commercial as well as passenger cars. The company has its network widespread all over Nepal with 22 sales network and 25 service centres dedicated to commercial vehicles, 16 showrooms and 25 service centres dedicated to passenger vehicles and 300 spare parts outlet across the country. [3] 5 ii. IME Motors Private Limited IME Motors Private Limited is the sole authorized distributor of Ashok Leyland commercial vehicles in Nepal. The company offers sales, after sales services as well as spare parts of the vehicles. The company has occupied a good market share and is well on course to becoming one of the most prolific automobile agencies in foreseeable future. [4] 6 Chapter 2 Technical Specification about the company 2.1 Equipment’s, and its applications 2.1.1 Air compressor Air compressor is used to compress the atmospheric air and stores it in a tank and is made available in the working bay through pipes fitted with control valves. The compressed air is used by mechanics to operate air guns and greasing gun. Figure 4: Air Compressor 2.1.2 Hydraulic press Hydraulic press works using fluid and is used to increase the mechanical effort applied to perform works easily. It is used to press fit components together and also to dismantle press fitted components. Eg:- Press fitting and disassembly of gears of countershaft, dismantling of gears from main shaft, removal of bearings from differential drive pinion, etc. Figure 5: Hydraulic press 1 2.1.3 Greasing gun Greasing gun uses compressed air to lubricate vehicles components through grease fittings of nipple. The gun supplies lubricant at high pressure. Figure 6: Greasing gun 2.1.4 Hydraulic mini crane Hydraulic mini crane is used to lift heavy components during their removal from the vehicle or during their installation. Hydraulic mini crane is used to lift the engine and heavy gearbox so that they can be easily removed from the vehicle and again installed easily after repair. Figure 7: Hydraulic mini crane 2.1.5 Hydraulic & transmission jack Hydraulic jack is used to lift components while performing various maintenance operations. It is used to lift axles to remove wheels, lift the vehicle during hub greasing, lift the axles to change tyres and for other many operations that requires lifting of some components. 2 Figure 8: Hydraulic jack Figure 9: Transmission jack Transmission jack is fully mechanical and is used to lift and lower the gearbox during installation and removal respectively. It is also used for the installation of heavy differentials on some vehicles. 2.1.6 Bench Vice Bench vice is used to clamp the job piece to that certain operations can be performed on the job piece. Figure 10: Bench vice 2.1.7 Grinder Grinder uses abrasive wheel which is used to sharpen tools. 3 Figure 11: Grinder 2.1.8 Pneumatic Gun Pneumatic gun uses compressed air to loosen and tighten bolts. It helps to perform the work easily and quickly. These guns are used to loosen and tighten bolts of various components of a vehicle while they are not used while for the maintenance of engine components. Figure 12: Air gun 2.1.9 Slider Slider is used by mechanics to lie on the slider and reach the under lying parts of a vehicle for performing maintenance works. Figure 13: Slider 4 2.1.10 Battery Charger Battery charger is used to charge vehicle batteries. It is used to charge those batteries that are discharged during testing or maintenance of vehicles and also discharged batteries of vehicles. Figure 14: Battery charger 2.1.11 Toolbox & Tools Room Tools are of various types and are used for different purposes. Toolbox consists of general tools used to perform maintenance works. These are separate for each mechanics and they are responsible for it. These tools include wrenches (open, combination & box), screwdrivers, pliers. feeler gauge, hammer, ratchet, sockets, extension rod, T-handle, compression tester, etc. Figure 15: Toolbox 5 Figure 16: Tools room Tools room is a separate room where special tool are stored. Tools such as bearing puller, oil seals installer, compression tester, hydraulic jack, transmission jack, pitman arm puller, valve lock lifter, ring compressor, ring expander, clutch alignment arbor, diaphragm spring adjusting wrench, etc. are stored here. 2.2 Plant Layout EICHER workshop at Satungal is a service centre dedicated to maintenance of EICHER vehicles. Fixed position layout is employed in this workshop. Vehicles are kept at one location and different tools and equipment are brought there to carry maintenance works. Its physical arrangement for the maintenance services has the following plant layout. 6 Figure 17: EMPL Satungal layout 2.2.1 Office Reception, billing account, service manager & service engineer’s office are located on the ground floor. On the 1st floor there is customer waiting lounge, meeting rooms and training rooms. 2.2.2 Working Bay There are 6 working bay and one express bay in which maintenance works are carried. 2.2.3 Parking Vehicles in queue for maintenance or after maintenance if stays in the workshop then they are parked here. 7 2.2.4 Washing & Greasing Bay After maintenance works are carried out on vehicles they are brought here if cleaning is to be performed on the vehicle. Nipple greasing is performed after cleaning operation if required. 2.2.5 Spare Parts Store Spare parts are stored over here for the smooth flow of maintenance works of vehicles. The store of EMPL, Satungal is the biggest for EICHER vehicle spare parts in Nepal. 2.2.6 Changing Room Technicians change their casual dress and wear on there working dress and get ready for maintenance works. They wear protective clothing and safety shoes. 2.2.7 Security Guard Security guard stays here and keeps track of every person and vehicles entering the workshop. 2.3 Service process Vehicles have to go through a number of stages for performing the maintenance works. The maintenance work follows the following process: i. Entry The details of vehicle entering the workshop is recorded by the security guard at the main gate. Vehicle number, date & in time of entry are recorded. ii. Job Card Opening The first stage of maintenance work is the opening of a job card. A service advisor interacts with the driver/owner about the vehicle’s problem and decides about the probable solution to the problems. The details of maintenance works to be performed are listed. Mechanics are assigned. Then a service engineer takes charge of the maintenance works on the floor. The job cards are recorded in the system for use in future maintenance activities. These details can be accessed from all the EICHER service centres in Nepal no matter where the maintenance works were performed previously. 8 iii. Maintenance works The maintenance works listed in the job card are carried out by mechanics. Damaged parts are replaced with new ones solving the problem of the vehicle. Any update in the maintenance works are updated in the job card. iv. Job Card Closing Once the maintenance operations are finished then the job card is closed. Any change in the maintenance works than listed in the beginning of inspection are updated. v. Billing Account Once the maintenance work is completed, the driver/owner has to pay the charges for the maintenance works and spare parts at the billing account. vi. Exit Once the vehicle has been maintained then the service advisor provides a ‘GATE PASS’ to the driver/owner and the vehicle can exit the workshop. The details of the vehicle exiting the workshop is recorded at the gate by the security guard. Vehicle number, date & out time of entry are recorded. 2.4 Service Flow Chart Maintenance work follows the following sequence: ENTRY JOB CARD OPENING MAINTENANCE JOB CARD CLOSING BILLING EXIT Figure 18: Service Flow Chart 9 2.5 Troubleshooting Services 2.5.1 Regular servicing Odd servicing: During regular odd servicing fuel strainer, fuel water separator, fuel filter, engine oil filter element, by pass filter, engine oil & air filter are replaced with new one. Even servicing: During regular even servicing all works as performed in odd servicing are performed plus gearbox oil as well as differential oil are changed and hub greasing is also performed. 2.5.2 Hub greasing Hub greasing is performed on regular basis during even servicing and in case of oil leaks repair. Procedure for hub greasing: First the wheel and then the axle shaft is removed.  Hub components are dismantled and cleaned in diesel.  Damaged components are replaced with new one, while the one in good condition are retained.  Bearings are greased, grease is also applied inside the hub where the cone fits.  New oil seals are used whenever the hub is dismantled.  Then the hub is assembled. Inner oil seal - Inner tapered bearing - hub filled on axle - cone - shim – outer tapered bearing - lock nut - lock plate – axle shaft – wheel. Note: As some components vary with models the above sequence may change slightly from models to models. 2.5.3 Troubleshooting of Heating Issue Heating system is responsible for maintaining optimum operating temperature of an engine. Coolant is circulated through water jackets around the combustion chambers, cylinders, valve seats, and valve stems by a centrifugal pump driven by the engine to achieve optimum operating temperature on modern IC engines with engine cylinder temperature varying from 35 or less to as high as 2750 C. About 22-26% of the energy produced by fuel combustion is rejected by the cooling system ensuring the engine operates in the most efficient range. [5] 10 Overheating as well as overcooling both decreases the efficiency of an engine. A thermostatic valve is used to regulate the flow of water to achieve proper operating conditions. Various heating issues can arise in IC engine. Some of the causes and remedy are briefed below: Defective thermostat Thermostat is a temperature sensitive valve that blocks the flow of water through the radiator at low engine temperature so that the engine heats easily and reaches efficient operating range quickly. The fluid recirculates in the jacket through a bypass passage. Once the temperature of the engine start to rise the thermostatic valve starts opens and becomes fully open at a certain stated temperature allowing water to circulate the water through the radiator providing cooling effect to the engine. The coolant temperature controlled fairly accurately by the opening and closing of the thermostat. Failing of thermostat to perform effectively results in an engine to overheat or perform badly in cold conditions. Temperature changes erratically, gauge reading can be very high. Defective thermostat is replaced with a new one to achieve proper performance.  Defective radiator pressure cap Radiator cap is used to raise the temperature of water by about 45 F inside the radiator increasing the boiling point of water and also allows coolant to flow to expansion tank once rated pressure is reached. Increased boiling point allows more heat to be absorbed by the coolant before boiling. Damaged pressure cap can cause a decrease in pressure of coolant lowering its boiling point that results in water boiling inside the radiator. It can also cause problem in drawing coolant back into the radiator from the expansion once the coolant is cooled. Damaged pressure cap are replaced.  Improper water coolant level Proper amount of water is needed inside the radiator to achieve required cooling. Coolant is a mixture of water and antifreeze. Proper amount of antifreeze as stated by manufacturer should be used in the vehicle as it lowers the freezing point and higher the boiling point of coolant. Improper coolant level results in engine overheating. Use of less amount of antifreeze than stated may cause the water to boil early. Proper level of water 11 and correct water-antifreeze should be maintained for proper performance of cooling system.  Defective water pump Water pump circulates water from the radiator through the water jackets in to the engine by centrifugal action of the pump’s blades. Wearing or damage of impeller blades of pump causes the reduction in capacity of water circulated through the engine decreasing the cooling effect resulting in increased engine temperature. In such cases water pumps are replaced with new one. Sometimes the leakage at the pump casing face and the cylinder block can be also the cause of reduced cooling, surfaces are cleaned and are joined properly using sealant.  Clogged radiator Radiator is fitted at the front of a vehicle used to lower the water-coolant temperature by transferring the heat content of the mixture to the air passing through the radiator. Water flows through the tubes of the radiator, air flows over the tubes and heat is exchanged between them transferring the heat of the water-coolant to the air. In a dusty environment, the dust of the air get stuck to the radiator surfaces blocking the passage of air through the radiator. Also, due to use of dirty water the radiator tubes can get clogged from inside. Any damage or leaks to radiator too can causes a decrease in cooling capacity. If clogged from outside then it is cleaned by spraying pressurized water from the engine side of the radiator. If it seems to be internal clogging then it is put into a tank of caustic soda and then pressurized water is sprayed from both inside and outside. Figure 19: Clogged radiator 12  Defective clutch fan Clutch fan controls the amount of air flow through the radiator at different engine speed by reacting to the air rushing over it from the radiator. At low engine temperature the fan blade speed is lower than its pulley speed. As radiator heats up, air passing over it get more heated up in turn heating up a small bimetallic coil in the front of the clutch fan, releasing an internal valve. The valve release heavy silicone fluid locking up the fan blade with the fan pulley and the speed of the pulley and fan blade becomes same sucking more air through the radiator. Defect in clutch fan can cause the fan speed to be same as its pulley all the time or it may rotate loosely. Any defect causes in adequate amount of air to be sucked through the radiator which degrades the cooling effect. Damaged clutch fan are replaced with new one for stated performance.  Coolant leakage Leakage of coolant anywhere in the cooling system can cause a reduced amount of cooling of the engine resulting in overheat. One of the prime location of leak is the cylinder head gasket surface so to prevent this genuine gaskets should be used and in case the head or block surface are damage should be machine to provide proper sealing to the water passage from the block to the head. 2.5.4 Clutch Issues Clutch is the gateway of power transfer from the engine to the gearbox. It is used to engage and disengage the power transfer allowing for smooth gear change. The friction plate/clutch plate is responsible for the power transfer from the engine to gearbox.  Clutch slippage Friction lining on both side of the clutch plate is responsible for power transfer. With continuous engagement and disengagement the friction material wears down and the power transfer ability of the clutch degrades. As the wear starts to occur with use, slippage occurs at high load but as wearing continues, lack of power can be felt even at low loads. Even with the engine operating smoothly the output power decreases and low pickup occurs. In such cases new clutch plates are used to solve the slippage problems. 13 Slippage of clutch can be easily acknowledged by loss of power, sometimes burning smell can also be felt if fibre woven clutch are used. Slippage of clutch wears down flywheel on one side and on the other side it wears down the pressure plate. Figure 20: Worn pressure plate-1, flywheel-2 & clutch plate-3  Defective clutch release bearing The friction plate/clutch plate must be free i.e. disengaged at the time of gear change. The clutch release bearing is used to disengage the clutch to discontinue the power from the engine to the gearbox so that the gear shift can be performed smoothly. The axial force exerted by release bearing to the coil/diaphragm spring must be even so that the clutch disengages properly otherwise the clutch plate may drag at some places causing gear change to be harder. Damaged release bearing can provide uneven axial force or trouble in disengaging the clutch. Worn out release fork or release arm can also be the reason for this. Proper inspection should be done and troublesome components should be replaced. Figure 21: Uneven clutch plate wear 14  Clutch chatter Clutch chatter is a shaking that is felt when the clutch is engaged. It is normally caused by broken engine mounts and glazed clutch or pressure plate facings which can be due to liquid leaks contaminating the friction surfaces from the engine’s rear main seal, transmission input shaft seal and clutch salve cylinder. Other possible causes are bent clutch disc, damaged facing, damaged pressure plate, excessive runout on pressure plate, worn or damaged pilot bearing, etc. Proper inspection should be done, damaged components should be replaced and leaks should be sealed.  Hard clutch pedal Clutch pedal is pressed by the driver to disengage the power from the engine to the wheels when required, normally for gear changes. Clutch linkage may be mechanical or may be assisted hydraulically or by air to allow the driver to comfortably depress the clutch pedal. Damage to clutch linkage may prevent the pedal from depressing. In case of hydraulic assisted clutch lack of clutch fluid or leak or jamming of clutch cylinders can cause clutch pedal to be hard. Fluid level should be at proper level and there should be no damaged hoses and the clutch cylinders should work smoothly for proper functioning of clutch pedal. In case of hard clutch pedal these components are inspected and the damaged ones are replaced with new ones. 2.5.5 Gearbox repair Gearbox is used to vary the torque in an automobile. It is used to achieve large amount of torque at the start and achieve high speed in top gear. It also provides the way to drive the vehicles in reverse direction. Power is transmitted from the engine through clutch to the top shaft. Torque variation is achieved by the combination of gears of different diameters in the gearbox. Power is generally transmitted from the primary to the counter shaft and then from the counter to the main shaft. An ideal gear is used to achieve the reverse motion of an automobile. The gears inside a gearbox transmits large amount of power and are continuously in motion when the vehicle is running. Due to continuous operation under large amount of forces the gears inside the gearbox gets damaged. The various issues that arises in a gearbox are:15  Broken gear teeth The gear teeth are the ones responsible for the positive drive transmitting the power without slippage. The teeth of one gear contact with the teeth of another gear transmitting power from one shaft to another. Metal to metal contact between the teeth results in high friction between the contacting surfaces causing the teeth to wear down with use. To decrease the friction lubricating oil is filled in the gearbox but with use the gears will eventually wear down. Some drivers who have a habit to race quickly and again slow down quickly exerts jerks to the gears inside the gearbox. With use these jerks can eventually lead to breakage of the gear teeth’s. Quick engaging of clutch can also result in gear tooth breakage. Figure 22: Broken countershaft & main shaft gear Counter shaft have some gears integral to it which few gears are press fitted on it. If the integral gears are broken then the shaft is replaced. If the press fitted gears are broken then they are replaced with new gears. Main shaft gears with broken teeth are replaced with new ones of the same size. Straight helical gears are also used instead of spur gears reducing the noise and increasing in the operating life.  Gear oil leakage Gearbox houses numerous gears that are used to achieve various torque and speed. Gear oil is used to decrease the friction between the contacting surfaces of gears. Oil recommended by the manufacturer should be used as other oil with different viscosity reduces the performance as the friction between the contacting surfaces as well as temperature will be different from what is expected. Gear oil is confined in the gearbox by using oil seals on the top shaft and liquid sealants in the main shaft casing. If any leak is detected from below of the gearbox or in the clutch assembly housing then it is inspected properly if it is 16 gearbox oil. To solve the leak the gearbox has to be taken out and new seals have to be used.  Hard gear shift Gear shift is achieved by means of cables and lever linkages to move the gear shift shaft. Loose linkage can create trouble in changing gears. Worn or bent shift linkage or selector fork assembly or damaged gear teeth can be the cause the hard gear. The way to solve is to replace the worm or damaged components. 2.5.6 Troubleshooting of steering issues Steering system allows the driver to steer the vehicle in proper direction as his/her will. Steering a heavy vehicle in the direction requires a large amount of force to be exerted by the driver at the steering wheel which creates trouble for the driver. To assist the driver in steering the vehicle comfortably power steering is integrated in the steering system so that it assist the driver to steer and in case of failure it can be used as complete mechanical steering system. A pump driven by belt or gears from the crankshaft is used to supply pressurized steering fluid to the steering gearbox to assist in steering. Damage to any components in the steering system can result in steering trouble for the driver. Some of the steering problems and their remedy are briefed below: Hard Steering Steering is assisted by the power steering pump to make the steering comfortable. Lack of steering fluid due to leaks will create drought for the pump and there would not be enough fluid for the pump to pressurize and the steering would become hard. Damage to internal components of a steering pump reduces the ability of pump to pressurize the steering fluid resulting in hard steering. Any damage to the components inside the steering gearbox can also be a cause. Steering oil level should be maintained at proper level with proper type of oil. Damaged hoses should be replaced. If the pump or gearbox is found to damaged, they should be replaced with good one for proper functioning of steering.  Steering wobbling Wear of tie rod ball joints & kingpin, tie rod misalignment, etc. can cause the steering to wobble. Generally worn components such as tie rod kit and kingpin is replaced while the misalignment of tie rod is made to correct alignment to solve the bubbling problem. 17 2.5.7 Differential repair Differential is used in vehicles to achieve different speed at the inner and outer wheels while taking a turn for safe cornering at turns. The outer wheels need to cover more distance than the inner wheels i.e. outer wheels needs to run at higher speed than the inner wheel which is achieved by gears in differential assembly. The differential assembly does no work in straight line motion but as the vehicle takes a turn it comes into action. Power input is given by a bevel drive pinion to the crown wheel attached to the main differential assembly case inside which are the pinion and side gears. Axle shafts are connected to the side gears. The difference in speed of the driving wheels is achieved by the use of pinion and side gears. All the components of a differential works in coordination with each other to achieve the difference in speed of wheels. Damage to any components of the differential assembly can cause a decrease in performance of the vehicle. Some of the issues commonly seen in differential assembly are briefed below: Broken gears Differential action is achieved by use of bevel drive pinion, crown, pinion, side gears and spider. The pinion gears rotate about the 4 fingers of the spider rotating the side gears, one at a decreased speed and the other at an increased speed while taking a turn. Wear of gear teeth as well as their breakage is a common problem. Spider generally wears down while it also breaks down sometime. One reason for the damage to differential components is its decrease in capability with use and another reason is bad driving habits of driver. Sometime overload also leads to damage to gears. Any components that are found damaged during a differential repair are replaced with new one. Good driving habit and time to time check-up for the condition of components can lead to long life of differential. 18 Figure 23: Broken & Worn components Figure 24: Broken teeth of pinion shaft of differential case  Crown oil leakage Transmission oil is filled in differential carrier housing to lubricate the gears inside the assembly reducing friction enhancing performance. Leakage of oil can occur from the oil seal installed in drive pinion shaft or from the joint between the differential housing and the axle which is sealed by using sealant. Leakage cause lack of lubricating oil for gears in differential assembly increasing wear and early failure. Crown oil should be inspected timely and changed at intervals as stated by manufacturers. 2.5.8 Troubleshooting of brake problems Brakes are used to decelerate the vehicles. Generally, air brakes system are common in trucks and buses. Air brake system consists of compressor, compressed air tanks, drying and distribution unit, relief valves, brake chamber, brake valve, etc. Some of the brakes related issues are: No air in the system Compressor is used to supply compressed air to the air tank maintaining required pressure in the brake system. Any damage to the compressor components decrease its ability to compress the air and the required air pressure cannot be achieved. To rectify no air problem in brake lines the compressor is disassembled and the worn out components are replaced.  Low air pressure Compressed air runs through hoses and different control valves for brake operation. Any leakage in the compressor or in the brake lines or any 19 components cause loss of air decreasing the air pressure in the system resulting in insufficient braking. Troubleshooting of air leakage in the brake system is one of the troublesome task as hoses runs all along the vehicle and each and every length of hoses along with all the components needs to be inspected very carefully to detect the leak. Damaged hose are changed. Leakage in components are rectified by welding and eliminating the leak.  Less effective brakes Due to wear of brakes with use the brakes lining thickness decreases and it becomes difficult to press it firmly against the brakes drum causing less braking effect to be produced. In such cases old brakes linings are replaced with new one which are riveted on the brake shoes. 2.5.9 Troubleshooting of fuel supply problems Fuel is the basic ingredient needed by the engine for combustion to produce power. Fuel supply system consists of fuel tank, fuel strainer, fuel water separator, feed pump, hand primer, fuel filter, fuel injection pump, fuel line hoses & fuel injectors. Improper functioning of any of the components results in less supply of fuel resulting in reduced power. Some of the common issues of fuel system are briefed below: Low pickup Required amount of fuel need to be supplied by the fuel system to produce adequate power. Improper functioning of any components will result in less fuel delivered and the vehicle will experience low pickup. Fuel injection pump (FIP) is responsible for delivering metered quantity of fuel at high pressure and proper timing to respective cylinder for smooth operation producing sufficient power. FIP has internal components such as shaft, cam, plungers, springs, sleeves, etc. which wears with use and the amount of fuel to be supplied decreases. When low power is experienced and during inspection it is expected to be from FIP then it is repaired to meet the proper fuel requirements to meet the power requirements. Installation of fuel strainer in improper direction restricts fuel supply so it needs to be properly installed. Clogged fuel filters can restrict fuel supply. 20  Engine stops after minutes of start Fuel supply line must be free of air for the engine to operate properly. Mixing of air cause less amount of fuel to be delivered and the engine suffers and eventually stops. Bleeding of air is done by hand priming to manually supply fuel to the FIP pump. Sometimes few (1-2) of the fuel injectors are taken out of the head and hand priming is continued and the engine is cranked to bleed out the air from the air from the system.  Leakage of fuel Damaged hoses can leak fuel decreasing fuel economy. It also allows air to enter the fuel line. These causes less fuel delivery ultimately resulting in low power. Damaged fuel hoses are replaced with new and care is given during fitting as the hoses should be bent too much as sharp bends again restricts fuel supply. 2.5.10 Engine overhaul Engine is the power unit of an automobile. Fuel is combusted inside an engine to produce power to operate a vehicle. Various systems such as intake & exhaust, fuel supply, cooling, lubrication, etc. are operated in collaboration with each other for the proper functioning of an engine. The proper functioning of the engine is of prime importance for the performance of the vehicle. Engine overhaul is performed when engine seizure, low compression pressure, low power, etc. is experienced. Procedure for engine assembly and disassembly varies slightly from one manufacturers to another as the configuration of components slightly varies from one another. So the procedure should be followed as specified by manufacturer. The procedure for VEVolvo Eicher engines are given below:Procedure for engine disassembly  High pressure fuel lines and injectors are removed.  Intake & exhaust manifolds are removed.  Air compressor, FIP pump, feed pump, hand primer, power steering pump, alternator & viscous fan are removed. In some cases air compressor needs to be removed before removal of FIP pump.  Rocker cover is removed and then rocker shaft is removed.  Pushrods and valve cap are removed.  Cylinder head is removed. 21  Valve lifters are removed.  Timing plate cover and timing plate is removed.  Sump and then oil strainer is removed.  Pistons are removed.  Crankshaft is then removed.  Lubricating nozzles are removed. Procedure for engine assembly  First crankshaft is assembled in the crankcase.  Piston assembly is fitted into the cylinders using ring compressor.  Lubricating nozzles are installed.  Camshaft is inserted.  Then oil strainer and sump was fitted.  Then after the timing gears were fitted.  Valve lifters are inserted.  Then cylinder head with valves assembled are placed over the cylinder block with head gasket in between and bolted.  Pushrods are inserted and then rocker shaft is assembled and valve clearance is set to compensate or expansion due to heat.  Then valve cover is fitted.  Then the intake, exhaust, FIP pump, water pump, feed pump, oil cooler, hand primer, intake & exhaust manifolds, turbocharger, and other connections to the engine are made. Note: Gaskets are placed between two components of the engine to prevent leakage. During engine overhaul all the components are disassembled and inspected. Engine block, head and crankshaft are machined. New piston rings are used and depending upon the condition of piston they may be replaced. New journal bearings in connecting rod ends and crankshaft are used. New gasket set is used. New valve seats are pressed and if required valves are also replaced with new one. New valve stem oil seal are used. Other components that are found to be damaged are also replaced. 22 2.6 Service Management The service centre is managed by the Service Manager who is responsible for the maintenance activities of the whole workshop. Under the supervision of service manager there are Service Advisors and Service Engineers. Service advisor records the issues of the vehicle and does the paper works. Service engineer makes sure that the maintenance activities are being carried out properly on the floor. They order technicians to perform repair works on vehicles. They handle the paper works of the maintenance works. Senior technicians are junior technicians follow the orders of service engineer and advisors. Senior technicians performs complex maintenance activities and are juniors are ordered to perform general operations and are assisted by the seniors whenever needed. 2.7 Inventory Management EMPL, Satungal has the biggest inventory for EICHER spare parts in Nepal. All the parts for various models of EICHER vehicles are made available in adequate quantity for smooth operation of maintenance activities. EICHER spare parts are distributed to authorized service centres and dealers all over Nepal from here. Spare parts are imported from EICHER India. All the details about the spare parts are stored in a software which provides information such as quantity, location, price, etc. 2.8 Quality Management Quality in both product and service is of prime importance for the success of a company. EMPL insures that quality service is provided to customers by providing trainings to its employees and providing them with standard tools and equipment’s to perform operations in standard way. Quality in product is insured by importing genuine EICHER vehicles and after sales spares from EICHER India. Some of the components such as braking system components, lubricants, etc. that are used by EICHER from other manufacturers are brought from the respective manufacturers authorized sellers in Nepal. Only genuine products are allowed to be used during maintenance in workshop. 2.9 Kaizen Principle The principle of Kaizen i.e. continuous improvement is implemented in the workshop to analyse the current processes and find out the loop holes and then rectifying it. Small changes 23 are easy to make in any process then to change the process. The small changes can lead to a drastic change in a long run. The five steps of Kaizen principle are: Sort Keeping only what is necessary and discard everything else.  Set In Order Arranging and labelling only necessary items for easy use. Identify clear locations for items for easy access & return once the task is completed.  Shine Cleaning workspace and tools to maintain the standard of operations.  Standardise The state that exists when the first three pillars are properly maintained.  Sustain Making a habit of properly maintain correct procedures always. 24 Chapter 3 Training Details 3.1 Training Methodology NAV Software Manual Job Card Floor Job Work Schedule Planning Figure 25: Training Methodology 3.2 Work Assigned i. Floor Job ii. Office  Filling Manual Job Card  Learning NAV Software 3.3 Works Accomplished S.N. Work Completion Status i. Floor Job 100% ii. Office 100%  Filling Manual Job Card  Learning NAV Software 3.4 Limitations Some of the limitations are:- 25  Lack of ECU based systems in EICHER vehicles imported in Nepal since ECU based vehicles are just starting to be imported. 3.5 Problems encountered Some of the problems encountered during my Industrial training period are:i. Difficulty in communication with technicians while working on floor as they mostly use local name for spare parts, not their standard name. 26 Chapter 4 Conclusion The Industrial Training period at Eastern Management Pvt. Ltd. was a very wonderful learning experience. I got chance to habituate myself in the field of a service oriented auto industry. During the Internship, I got insights of most all the aspect of the workshop. I learned to perform service operations cooperating with technicians, to fill manual job card, perform some office works and learned the company’s system software NAV. Freedom in an environment with lots of things to learn broadened my knowledge. The friendly behaviour of the employees sharing their knowledge and experience made my Internship period comfortable. 27 Chapter 5 Weekly Log Book 5.1 Gantt chart for Trainee S.N. Activity 1 Floor Job 2 Office Work Week: 1-11 Week 12 INDEX Work Completed 5.1.1 Floor Job Floor job was dedicated to learning the way maintenance works are carried out on a vehicle in troubleshooting various problems and being able to cooperate with new people. During the 11 week period I worked with mechanics as helper on the floor observing, participating and performing different maintenance works that were performed on various vehicles with different problems as well as solutions. During the first few weeks I was mostly allowed to observe and perform very minor operations such as tightening nut and bolts, cleaning components being repaired, etc. During those weeks I learned about the processes that were actually used by the technicians to perform different maintenance operations such as installation, removal, assembly and disassembly of engine, gearbox, differentia, etc. After few weeks, I was allowed to perform maintenance operations alongside with some technicians. During this period I learned got practical experience of various maintenance operations such as assembly and disassembly of engine, gearbox, differential, hub greasing, servicing, brake adjustments, radiator installation & repair, replacement of flat tyres, etc. I got chance to get my hands dirty performing maintenance works as well as observations of maintenance works gaining practical knowledge of what I have learnt from various undergraduate courses. The floor job enhanced my knowledge. 28 5.1.2 Office Works  Manual Job Card Job card was used to note down the customer complaints and advice possible repair for the complaints. I interacted with the customer (operator/owner) whoever came with the vehicle and noted down the problems faced by them and filled the job card. Figure 26: Manual Job Card 29 The complaints of customer were first noted in job cards and details about the vehicle were noted. Details to be noted are shown in figure above. Then they were updated in the company’s online software NAV. The details recorded helped in future maintenance forecasting.  System (NAV Software) Microsoft Dynamics NAV software is used by EMPL to keep record of all the documents. All the details of job cards, warranty records, inventory details, employee’s details, and vehicle records, etc. all the documents of the company are recorded in this software. I learned to update the details such as Job cards, spare parts required and note details related to the maintenance works performed on vehicles. 30 Recommendation EMPL Workshop at Satungal being an authorized service centre of EICHER in Nepal should use the Interns or Trainee in a better way for the benefit of both the Organization and the Interns or Trainee. The company should have a predefined rule for Interns covering the overall aspects of the workshop. There should be provision for proper monitoring of the Interns by few people reliving the pressure on any one person. They should be assigned various service operations alongside the technicians while working on floor so they can gain practical knowledge of most of the service operations. 31 Bibliography [1] About Us: Company’s Overview. Retrieved 2019, Eastern Motors Pvt. Ltd. https://www.easternmotors.com.np/companys-overview/ [2] “Eicher Motors.” Wikipedia, 15 May 2019, https://en.wikipedia.org/wiki/Eicher_Motors [3] About Us: Company’s Overview. Retrieved 2019, SIPRADI. http://www.sipradi.com.np/company_overview [4] About Us: Company’s Overview. Retrieved 2019, IME Motors Pvt. Ltd. http://www.imemotors.com.np/about-us/ [5] Rajput, R.K. (2009). Internal Combustion Engines. New Delhi: Laxmi. 32