ACKNOWLEDGEMENT
First and foremost , i would like to thank God the almighty for his guidance and love , for this
endeavour would not have been possible without his authority. Additionally , thanks should
also go to the garage team for their invaluable patience to generously gave me knowledge
and expertise about vehicle maintenance.
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INTRODUCTION
At ZIMASCO it is mandatory for every student trainee to compile a monthly report as part of
his/her training . The reports enables trainees to share what they learned , improve their
knowledge about their arears of study thereby preparing them for their careers and future
endeavors. The following work seeks to report everything that I have learnt in the month of
July under the maintenance department.
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WEEK ONE
In the first week of July I learned how to remove engine and transmission from the vehicle as
well as fitting engine and transmission back to the vehicle. I will explain below in detail how
to do these tasks after carrying out risk assessment:
REMOVAL OF ENGINE
PREPARATION ,TOOLS , MATERIALS AND EQUIPMENT
Carryout pre-task risk assessment and wear proper protective clothing
Select suitable tools which include but not limited to the following : spanners ,
sockets , socket wrench , pliers , screwdrivers , pry bar , drip trays , rags , crane/block
and tackle , lifting chains
STEPS
Disconnect the battery
Loosen the bonnet mountings and and everything attached to it and then remove the
bonnet using a crane
Loosen the cab station mounting bolts and everything attached to it like hydraulic
hoses and electrical wiring
Disconnect the coolant lines at the same time allowing coolant to drain
Disconnect electrical wiring and other cables
Support the engine with your crane before removing the engine mountings
Remove bell housing to engine bolts and also remove flexplate to torque converter
bolts
Double check everything and lift the engine from the vehicle and put it on stands
REMOVAL OF TRANSMISSION
PREPARATION ,TOOLS , MATERIALS AND EQUIPMENT
Carryout pre-task risk assessment and wear proper protective clothing
Select suitable tools which include but not limited to the following : spanners ,
sockets , socket wrench , pliers , screwdrivers , pry bar , drip trays , rags , crane/block
and tackle , lifting chains
Disconnect hydraulic lines from the steering pump and the hydraulic system pump
Disconnect oil cooler lines
Disconnect electrical connections to solenoids and sensors
Disconnect gear selector cable and transmission neutralizer air hose from the
transmission
Partially support the transmission with a crane
Remove the transmission mounts
Lift up the transmission and put it on a firm level ground supported on stands
WEEK TWO , WEEK THREE AND WEEK FOUR
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I spent the above weeks of July at the garage service bay , where I was carrying out daily
service on mobile equipment. I learned that when it comes to keeping vehicles running safely
and efficiently , getting them serviced regularly is one of the best things you can do. A
vehicle service is a healthy check with routine maintenance for a vehicle which assesses
everything from your engine’s fluid levels to the general wear and tear of the vehicle
components . Regular servicing vehicles has the following advantages:
Prevents vehicle breakdowns there by saving costs
Avoid expensive repairs
Guarantees vehicle safety
Enhances the life of the vehicle
Improves vehicle performance
At ZIMASCO , all vehicles are serviced everyday at the garage service bay , and there is a
daily vehicle maintenance time table put in place , to control when and which maintenance
action should be taken thereby ensuring orderly work and right allocation of time for
servicing vehicles. The following is the current daily vehicle maintenance time table :
TIME DAILY DAILY
0800-0900 BH 04 FEL 29
0915-1000 XGMA,BREAKER,FEL31 SCANIA BUS, FEL 38
1000-1100 FEL 37 , BH 05 YOUTONG BUS
1100-1200 FEL 30,FEL 39 LOCO 11, F/LIFT 36
1200-1300 T13 , LOCO 9 FEL 34 , T17
1330-1430 MC4 , BH 06 LOCO 10 , T11, T16
1430-1530 H01 , FEL 33 T12
1530-1615 FEL 28 , FEL 32 M/BREAKER SHANTUI
The following is a list of the actual checks that are carried out to each and every vehicle
which came for service , and I will give a brief description of how the checks are carried out
as well as the importance of the checks in vehicle maintenance :
VEHICLE FLUIDS
Engine oil
Brake fluid
Automatic Transmission Fluid
Clutch fluid
Hydraulic oil
Coolant
Gear oil [in final drives, differentials and manual gearboxes]
Windshield washer fluid
POWER TRAIN
Coolant and engine oil leaks
Inspect the condition of engine compartment guards especially , radiator and radiator
fan guards
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Auxiliary belts and timing belts condition
Air , oil and fuel filters condition
Inspect the engine loose bolts , nuts and look for damaged components
Inspect the transmission for any leaks , loose or damaged components
Inspect the driveline for any missing or loose bolts and nuts
Inspect the condition of the prop shaft universal joints and center bearings and
properly lubricate them using a grease gun
Inspect the differentials and final drives for leaks and abnormal noises
BRAKING SYSTEM
Inspect the braking system for air leaks
Drain condensate from air resevoirs
Inspect the condition of brake components especially : brake pads , brake shoes ,
brake callipers , slack adjusters brake camshafts and brake shoes. Also lubricate
slack adjuster and brake camshafts
SUSPENSION
Inspect the treads and sidewalls for any cuts , scrapes , punctures , bulges , bumps or
cracks . Inform the tyre service professional to take a closer look or fix the problem
Lubricate all moving suspension components such as ball joints , leaf springs
swinging shackles , cradle pins on wheel loaders
Inspect axle bolts , U-bolts for cracks or damage and tighten the if they are loose
Lubricate king pins
Check shock absorbers/struts , arms , bars linkages , bushings and joints for any signs
of damage
ELECTRICAL SYSTEM
Check the condition of the battery terminals and always clean them to remove
terminal corrosion , also check electrolyte level
Check electrical wiring for loose connections and poorly insulated wiring
Check the operation of all vehicle lights especially turn signals , brake lights ,
hazard warning lights
Check the operation of reverse and tipping buzers
Check the condition of alternator belts , that is belt tension and signs of cracking
FINDINGS
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All plastic brake master cylinder resevoirs and caps have worn out threading which
is causing brake fluid to gradually seep out
There is no mechanic creepers at the garage
RECOMMENDATIONS
If possible all plastic brake master cylinders have to be replaced with metal master
cylinders which are more robust and generally they don’t warp or deform easily
which makes them better and long lasting
At least five mechanic creepers have to be purchased to promote easier maintenance
under vehicles
CONCLUSION
All in all , sticking to a vehicle maintenance schedule , doing daily vehicle maintenance in the
proper way and keeping records of what you have done , can help extend the life of your
vehicle and protect you and the company against breakdowns , expensive repairs and other
unwelcomed surprises.
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