Intern Program

INTERNSHIP REPORT ETHIOPIAN ROADS AUTHORITY (ERA)
UNIVERSITY OF HARAMAYA
HARAMAYA INSTITUTE OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
HOSTING COMPANY: ETHIOPIAN ROAD AUTHORITY
INTERNSHIP DURATION: THREE MONTHS
Haramaya, ETHIOPIA
November 2022

Declaration
I thus certify that the work described in the report on the internship at the Ethiopian Roads
Authority Jimma District (ERA) was completed as required by the internship program,
which ran from June 1 to July 30, 2021. I warrant that the information in the report is
accurate based on what I saw and did during my internship practice. This document's
writings are all original works that I made with my own hands.
This paper has properly acknowledged all informational sources that were relevant and used.
Name of student ID Signature Date
Dawit Mesfin 0546/10
This is to certify that, to the best of my knowledge and belief, the aforementioned claim made
by the candidate is true. I have given my consent for the presentation of this report.
Name of advisor Signature Date

Mr. Adis
i
Acknowledgment
First and foremost, I would want to express my gratitude to the Almighty GOD and to
Haramya University for giving me this chance despite the constraints of my home nation. A
special thank you and respect are also due to Mr. Adis, my academic adviser, for his
supervision, special guidance, collaboration, and encouragement during this endeavor.
Additionally, I would want to express my gratitude to Ethiopian Road Authority for accepting
my application for an internship and their genuine hospitality throughout my entire stay.
Additionally, I would like to express my gratitude to the staff of the Ethiopian Roads
Authority (ERA), particularly the members of the workshop and maintenance departments,
for their positive interpersonal relationships and willingness to share their practical
knowledge and expertise. Among the workers, I would like to express my heartfelt
appreciation to Mr. Tezera (a senior mechanic) for making things easy and smooth during my
job training how can I say my pleasure to spend my internship period with you? How
blessed I am! But what if all of us think like you?
ii
Executive Summery
This internship report is on a four Months regular program in Ethiopian road authority. It
was a good experience sharing and learning that I pass in the company. The purpose of the
internship is to introduce students to the actual working environment, and to reinforce and
enhance the theoretical knowledge gained in the class room with practical job experiences.
For the last four months working in ERA, I’ve gone through different activities in the
workshop. This report includes; Back ground of my hosting company and its history, Overall
internship experience, Tasks and the procedures that I’ve followed, the practical and
theoretical knowledge I personally gained including the challenges that I’ve faced while
performing those tasks, and the project I designed are described. The content of the report is
divided into number of distinct chapters. The topics that are included the rival’s overall
internship experience, the benefits I personally gained from the program, the design of my
project, about hydraulic break drum lifter which I try to change from a manual to a hydraulic
system also conclusions and recommendations for the company.
iii
List of Acronyms
ERA Ethiopian Road Authority
IHA Imperial Highway Authority
IDA International Development Association
IHA Imperial Highway Authority
ETCA Ethiopian Transport Construction Authority
RRP Road Rehabilitation Project
ERRP Emergency Recovery and Reconstruction Program
RSDP Road Sector Development Program
SRMC District Road Maintenance Contractors
ECWC Ethiopian Construction Work
Corporation SAE Society of Automotive
Engineers
ETCA Ethiopian Transport Construction Authority
iv
Nomenclature
L Length
B Bore diameter
E Modulus of elasticity,
n Number of threads in engagement,
W Width
D Outside or major diameter
d Mean diameter
F. s Factor of safety
k Radius of gyration
I moment of inertia
t thickness of throat
dl diameter of lever
dr the inner diameter of the ram cylinder
Dr the outer diameter of the ram cylinder
P the pressure acting on the cylinder
W load
t the thickness of the ram cylinder
σc compressive strength
τ shear strength
dp inside dia of plunger cylinder Dp
Dp outside dia of plunger cylinder
tp thickness of plunger cylinder
σt permissible tensile strength

distance between outer most layer to neutral layer
Y
Z section modulus
v
Table of Contents
Declaration.................................................................................................................................................i
Acknowledgement..................................................................................................................................ii
Executive Summery...............................................................................................................................iii
List of Acronyms.....................................................................................................................................iv
Nomenclature............................................................................................................................................v
List of figures.........................................................................................................................................ix
List of tables...........................................................................................................................................x
Chapter One.............................................................................................................................................1
1. Background of the company.............................................................................................................1
1.1 Brief History of Road Building in Ethiopia...................................................................................1

1.1.1. Organizational Background of ERA..........................................................................................2
1.2 The main product or services of the company...............................................................................5
1.3 Corporation Establishment.............................................................................................................6
1.4 Institutional Set-up.........................................................................................................................6
1.5 Vision of ECWC............................................................................................................................7
1.6 Mission of ECWC..........................................................................................................................7
1.7 Purpose...........................................................................................................................................7
1.8 Equipment and Technology Capacity.............................................................................................7
1.9 Main Objective of ECWC..............................................................................................................7
1.10 Main Customer of the Services....................................................................................................8
1.11 End Users of the Services............................................................................................................8
1.12 Organizational Structure and Arrangement of ERA................................................................9
1.13 Jimma Rood Construction Corporation Workshop....................................................................12
Chapter two............................................................................................................................................16
2.1 Overall internship experience........................................................................................................16
2.2 Section of the company I have been working on...................................................................17
2.3 Work flow in the section........................................................................................................17
2.4 Crucial parts on Work task that I have been Executed................................................................18
2.4.1 Gearbox Mechanical, Component Description.....................................................................18
2.4.2 Engine Service.......................................................................................................................22
2.4.3 Engine Components...............................................................................................................23
2.4.4 Engine Overall.......................................................................................................................25
2.4.5 Generally, Engine Maintenance Activity..............................................................................26
vi
2.4.6 Engine Assembling Order...............................................................................................27

2.3.3 Differential.............................................................................................................................28
2.4.2 Fuel System...............................................................................................................................36
2.4.3 Lubrication System....................................................................................................................36
2.4.4 Engine Cooling System.............................................................................................................36
2.5 Challenge I have been facing while during performing work task.............................................42
2.6 Measures has been taken in order to over comes these challenges..........................................42
Chapter three..........................................................................................................................................44
Design of hydraulic brake drum lifter................................................................................................44
3.1 Introduction..................................................................................................................................44
3.2 Background of the study..............................................................................................................44
3.3 Short Summery of the Project.......................................................................................................44
3.4 Problem Statement and Justification............................................................................................45
3.5 Literature review..........................................................................................................................47
3.6 Objective of The Project...............................................................................................................48
3.6.1 General objective...................................................................................................................48
3.6.2 Specific objective...................................................................................................................48
3.7 Scope of the Study.......................................................................................................................48
3.8 Significance of the study..............................................................................................................48
3.9 Methodology................................................................................................................................48
3.10 Part Design.................................................................................................................................49
3.10.1 Design of Ram Cylinder.....................................................................................................50
3.10.2 Design of Plunger Cylinder and Plunger.............................................................................52
3.10.3 Design of Plunger................................................................................................................53
3.10.4 Design of Lever...................................................................................................................54
3.10.5 Design of Reservoir.............................................................................................................55
3.10.6 Design of base.....................................................................................................................56
3.10.7 Design of Bolt......................................................................................................................57
3.10.8 Design of circular rod..........................................................................................................58
3.10.9 Design of Iron plate.............................................................................................................59
3.10.10 Design of iron ring............................................................................................................60
3.10.11 Selection of Bearing and Screw.........................................................................................60
3.10.12 Design of parallel fillet welded joints...............................................................................61
3.11 Cost Estimation..........................................................................................................................62
vii
3.12 Material selection.......................................................................................................................65

3.13 Working principal...................................................................................................................66
Chapter Four...........................................................................................................................................69
4. Overall Benefits Gained During the Internship Program...............................................................69
4.1. Practical and Interpersonal...........................................................................................................69
4.1.1 Theoretical Knowledge.......................................................................................................69
4.1.2 Practical Skill......................................................................................................................70
4.1.3 Leadership Skills..................................................................................................................70
4.1.4 Work Ethics Related Issues.................................................................................................71
4.1.5 Entrepreneurship Skills..........................................................................................................72
Chapter five............................................................................................................................................73
5 Conclusion and Recommendation....................................................................................................73
5.1 Conclusion..........................................................................................................................73
5.2 Recommendation..........................................................................................................................74
Reference.............................................................................................................................................75
viii
List of figures
figure1. 1Engine maintenance shop.......................................................................................................13
figure1. 2 Machine shop........................................................................................................................13
figure1. 3 Body repairing shop..............................................................................................................14
figure1. 4 Electricity shop......................................................................................................................14
figure1. 5 Electricity shop.....................................................................................................................15
figure1. 6 Lubrication and cleaning shop..............................................................................................15
figure1. 7 Tire repairing shop................................................................................................................15
figure2. 1 gear box.................................................................................................................................18

figure2. 2 gearboxes over view..............................................................................................................19
figure2. 3 housings.................................................................................................................................20
figure2. 4 internal parts..........................................................................................................................21
figure2. 5 Engine Part............................................................................................................................23
figure2. 6 differential.............................................................................................................................28
figure2. 7 The pins, the planet gears, the bearing rods and Hub- reduction housing............................30
figure2. 8disassembled wheel................................................................................................................30
figure2. 9 full assembly of the hub reduction........................................................................................31
figure2. 10 Injection Pump....................................................................................................................33
figure2. 11 turbo charger (heavy duty)..................................................................................................33
figure2. 12 fuel system...........................................................................................................................36
figure3. 1 removing brake drum by using curved metal........................................................................46

figure3. 2 removed brake drum............................................................................................................46
figure3. 3 ram cylinder..........................................................................................................................52
figure3. 4 plunger cylinder.....................................................................................................................53
figure3. 5 plunger...................................................................................................................................54
figure3. 6 lever.......................................................................................................................................55
figure3. 8 reservoir.................................................................................................................................56
figure3. 9 base........................................................................................................................................57
figure3. 10 nut........................................................................................................................................58
figure3. 11 circular rod..........................................................................................................................59
figure3. 12 iron plate.............................................................................................................................60
figure3. 13 iron ring...............................................................................................................................60
figure3. 14 bearing.................................................................................................................................61
figure3. 15 parallel fillet welded joints..................................................................................................61
figure3. 16 assemble drawing of brake drum lifter................................................................................68
figure4. 1 Team Work on the Motor......................................................................................................70
ix
List of tables
table3. 1weekly plan activity..................................................................................................................49
table3. 2material selection......................................................................................................................66
table3. 3Cost analysis summery..............................................................................................................63
table3. 4 Result and Decision.................................................................................................................64
x
Chapter One
1. Background of the company
1.1 Brief History of Road Building in Ethiopia
Historic chronicles of the 17th and 18th centuries show that there were a number of small roads
trails and foot paths, in addition to the traditional shoulder porter age, animals like mules,
donkeys and horses and camels were used as a means of transportation in Ethiopia.
In the 18th century, especially during the reign of Emperor Tewodros, although the technology
was primitive it was believed that planned road construction efforts were made. It is also
believed that Emperor Yohannnes IV, who succeeded Tewodros, was engaged in road building.
However due to the danger of invasion by Egyptians, Derbush and Turkish the Emperor was not
able to achieve his desires. It was prior to the second Italian occupation i.e. between the years
1896 and 1936 that a great success was made in road construction. Emperor Menilik was said to
be a successful road builder participating himself in the construction. In 1903 the road from
Eritrea to Addis Ababa and the road from Addis to Addis Alem were built. In addition, it was
during this time that the first Asphalt roads appeared in Addis.
During the Italian occupation roads were built by them and they were established to meet the
requirements of the Military control rather than to promote the overall development of the
country’s economy. In addition, the roads lacked most of the modern location, design and
construction features desirable for present-day high-speed traffic. The roads and trails built and
improved during the 5 Years Italian occupation were about 6000km.Approximately 2500 km of
them were given a single asphalt surface treatment, drainage structures were usually of stone
masonry and at least three tunnels were built. However, when Ethiopia regained its
independence, the Italians in their fleeing attempt almost undid what they created by blasting
bridges and dynamiting roads.
From the time the Italian packed off to home to the eventual creation of the Imperial Highway
Authority (1941 to 1951) road construction or maintenance activity was almost subsided for a
stagnation period of one decade because of lack of funds, equipment and experts
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HARAMAY UNIVERSITY DEPARTMENT OF MECHANICAL
ENGINEERING
1.1.1. Organizational Background of ERA

Following the eviction of the Italian occupiers, the Imperial Ethiopian Government was
convinced that a Road Agency solely responsible for rehabilitating/restoring and expanding the
road network throughout the country had to be established. Accordingly, the Imperial Highway
Authority (IHA) was established under proclamation No. 115/1951 as a semi-autonomous
agency with specific duties to plan, design, construct, and maintain roads. Responsibilities for
construction and maintenance of roads remained under a single autonomous authority (IHA) for
26 years (1951-1977). The Ministry of Transport and Communication turned out to be the
supervising authority of ERA. The Ethiopian Roads Authority has been re-established under
proclamation 133/1978 incorporating, among others, the Rural Roads Department in addition to
the Highway Department.
In 1980, the Military Government that took power in 1974 reformed the agency into the Ethiopia
n Transport Construction Authority (ETCA) by proclamation No. 189/1980 and became
answerable to the newly formed Ministry of Construction. The proclamation enlarged
responsibility of the Authority by expanding its task to incorporate the construction of Airports,
Seaports, Railways, and Municipal Roads.
Following the shift from a command-based economy to a market oriented one in 1991, ERA was
re-established by proclamation No.63/1993 with a view to providing a strong administration
under the leadership of a Board. As part of its reform, the government assigned administration
of rural roads to the regional self-governments and main roads to ERA as part of the Federal
Government’s responsibility. ERA’s role regarding rural roads was then limited to rendering
support such as overall network planning, training and technical assistance as required by
Regional Governments.
To cope up with existing situations, ERA was again re-established by proclamation No.
80/1997 with the objective to develop and administer highways, and to ensure the standard of
road construction. With the establishment of the new cabinet of Ministers in October 2001, a
Ministry of Infrastructure and later on Ministry of Works and Urban Development has been
formed with the responsibility of developing the infrastructure of the nation. ERA, which is one
of the organizations under the Ministry of Works and Urban Development and accountable to
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the Board, is responsible for planning and formulating long and short-term plans and
programs for road
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construction, design, maintenance of trunk and major link roads, as well as for administration of
contracts. Currently, the main responsibilities of ERA are network planning; management of
contract projects and force account operations. The long-term objective is to focus on policy,
planning and contract administration and to pull out gradually from direct operational works.
From its year of establishment 1951, the Organization managed to undertake various physical
and policy issue assignments. During its establishment the total road network amounted to
6,400 km, which was mainly built during the Italian invasion. A program development of road
started in 1951 with establishment of IHA. The programs were: -
A) First highway program (1951-1957)

The program involved a total capital investment of birr 77 million and largely consisted of the
reconstruction and maintenance of 1525 km of badly damaged and 2686km of all-weather
roads. The road constructed during this time include: - Addis –Assab (860km), Addis-Jimma
(355km) and Addis-Nekempt (331km). Moreover, road maintenance was carried out on Addis-
Adigrat, Addis –Blue Nile and Addis-Shasemene trunk roads.
B) Second Highway Program (1957-1966)

The program provided for the continued maintenance and improvement of 4500km of main
highways, for the construction of 800km of new roads and improvement of 1000km of other
existing roads. The amount disbursed in this program is 110 million birr.
C) Third Highway Program (1965-1968)

The program involved a total outlay of Birr 60 million which went into the construction of
700km of primary and secondary roads, 1000km of feeder roads and 1040km of asphalt
surfacing works.
D) Fourth Highway Program (1968-1973)

During the Fourth Highway Program 820 km of new, primary and secondary roads were
constructed. It is during this program that four feasibility studies of future road works and
technical assistance and advisory service in the reorganization of the Authority started. The
program also included expert assistance in the area of engineering, operation and maintenance,
overseas training with practical orientation for equipment superintendents, foremen and
mechanics and others. Out of the total program of the planned 2246km roads 1600km were
completed.
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E) Fifth Highway Program (1974-1976)
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In this program great emphasis was given to the construction of feeder road network to support
the agricultural development, strengthening the institutional capability of the Road Agency and
providing assistance to the local contracting industry. The program covered the construction of
539km of feeder road and 322 km of asphalt surfacing projects. It also involved the purchase of
road maintenance projects worth Birr 14 million and further strengthening of the organization
and developing the domestic construction industry.
F) Sixth Highway Program (1976-1978)
During this time the rehabilitation 284 km of primary roads, 280 km of secondary roads,
construction of 809 km new gravel feeder road, 657km of service-to traffic and 1660km of rural
roads were executed. With regards to road construction and maintenance, the authority for the
first time in its history, turned into a sectorial approach in contrast to the former project by
project approach to read planning. To realize this two Road Sector Programs were carried out.
The first from 1979 to 1982 and the second from 1984 to1987.
Unlike the previous programs, the Fifth and the Sixth Highway Programs shifted emphasis to
the construction of relatively lower standard roads in conjunction with agricultural projects such
as the Minimum package program, the coffee processing projects and the Amibara Irrigation
projects. During the Fifth and the Sixth High way programs, the construction of the Butajira-Zwa
y, AselaDodola, Agaro-Gera, Gelemso-Mechara, Dejen-Mota, Sodo-Bulki, Nekempte-Bedele
and Bonga-Mizan Teferi roads was carried out. The most important features of the two programs
was that local contractors managed to successfully participate in road work contracts with the
assistance of government and the International Development Association (IDA)
In ERA history, major high way construction works were dominated by international contractors
between 1960 and 1970. The major roads from Awash to Mille, Agaro to Bedele, and Dilla to
Moyale and Nekemte-Ghimbi were built by foreign contractors with the assistance from donors,
specifically the World Bank and KFW. Between 1972 and 1976, the domestic construction
industry had started to develop and became active to same extent in the road construction sector.
Unfortunately, their development was impeded by the adverse policy environment created by the
Derg regime. In its history, ever since mid-1975 ERA’s Force Account Construction capacity
expanded and executed major projects such as: -
• The rehabilitation of the Addis-Awash-Mile Road with World Bank and Government funding
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• The Construction of feeder roads and service to traffic roads such as the Bonga-Mizan, Mizan-
Gore-Tepi and Gore-Gambella
The Construction and rehabilitation of run-ways like Bahir-Dar, Diredawa, Debrezeit, Assab and
Bole Airports. The Imperial Highway Authority has been renamed three times and substantially
reformed seven times by law in its history. Although responsibilities for construction and
maintenance of roads remained under a single autonomous Authority (IHA) for 26 years (1951-
1977), destabilization of such responsibilities began when, in addition to the IHA, the ministry of
Transport and communication was assigned through cabinet reform of the military government
in 1977 to construct, improve and maintain or cause the construction, improvement and
maintenance of roads. Then followed the reform of IHA in 1978 under which the board was
dissolved and the ministry of Transport and Communication became the supervising authority
of ERA.
According to proclamation No 133/1978, the reestablished Ethiopian Roads Authority included

Rural Roads Department in addition to the Highway Department and other Departments and
divisions. The purpose was to reconstruct, rehabilitate and maintain Rural Roads. In 1980, by
proclamation No 189 of 1980, ERA was reformed into the Ethiopian Transport Construction
Authority (ITCA) with increased responsibility that included Airport, Seaports, Railways and
Municipal Roads. With regard to road construction and maintenance, the Authority for the first
time in its history turned in 1977 to a sectorial approach in contrast to the former project by
project approach to read planning. It was in 1979 to 1982 and in the period of 1984 to 1987.
1.2 Services provision of the company

ERA provides many main provisions that give services for different parts.
These are: -
 Maintenance and rehabilitation work and give priority in order to preserve and improve
the existing road network so that existing assets are preserved and vehicle operating costs
are reduced.
 Upgrade the trunk and link roads to better standards so that the basis for modernization in
terms of road infrastructure is acquired.
 Expand the network through the construct of new regional and link roads, whenever
network stability and economic development assessments justify it at the regional and
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national level and the main target of my company is to increase the road density.
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 Developing the human resource in the road sector through strengthening the training
centers establishing appropriate staff incentives and sponsored to upgrade their
educational level.
 Improving the rural transport services of the country.
 Enhance the local private contractors in the road construction and maintenance capacity
through the promotion and use of private contractors. A policy of involving private
contractors in maintenance work is about to materialize now by awarding almost all of
future periodic maintenance works in addition to the construction works already
underway through their participation.
1.3 Corporation Establishment
Ethiopian Construction Work Corporation (ECWC) is a new government development agency;
which was under ERA. Council of Ministers Regulation No. 248/2011, to carry out mainly road
and bridge construction, maintenance, has established ECWC on July 08 /2011, and
enhancement works. ERCC is established for the following goals: -
 To work as a contractor and carry out road and bridge construction, maintenance
and enhancement works in Ethiopia as well as other countries.
 The corporation will also provide construction equipment and machinery maintenance
and rental services
 The corporation also plans to produce and sale construction materials to perform other
related activities to achieve its goal.
1.4 Institutional Set-up

ECWC is well known in conducting construction works according to standards, providing the
necessary components for road construction projects on a timely and balanced basis, following
and evaluating the completion of road construction projects.
Transportation of goods and passengers is the backbone of any economy. A widespread road
network encourages and improves economic transactions and communication. Ethiopia n
Construction Work Corporation is specialized in the construction of roads and bridges. The
company has built many roads and bridges across the country. The selected examples from the
early days of the company up to the present time demonstrate my expertise. While Ethiopia n
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Construction Work Corporation was part of the Ethiopian Road Authority operation department
perform different tasks: -
 Asphalt road construction

 Gravel road construction
 Bridge construction
1.5 Vision of ECWC

“To take the leading position in Africa and to be globally competitive construction company”
1.6 Mission of ECWC

To satisfy the customers and stakeholders of the Corporation by delivering Roads and bridges
construction, rehabilitation, upgrading and maintenance, Construction equipment and machineries
maintenance and lease, Construction materials production and sales, Services timely, with
competitive price and environmentally friendly manner.
1.7 Purpose
The purposes for which the Corporation is established are:
 To engage in domestic and overseas construction works as a contractor in constructing,

upgrading and maintaining roads, bridges and other civil works;
 To engage in the business of maintaining construction equipment and machinery;
 To engage in the rental business of construction equipment and machinery;
 To produce and sell construction materials;
 To undertake in any other related activities necessary for the attainment of its purposes.
1.8 Equipment and Technology Capacity

Ethiopian Construction Work Corporation is well equipped with different materials for its day-to
day job. ECWC has plenty number of construction materials and also ECWC has a large storage
of spare-parts. Now becoming the biggest road construction company with complete utilization
of technologies.
1.9 Main Objective of ECWC

 It approved the right of the customer for getting information.
 Briefly shows for the customers about the service of the corporation type, quality and
standards.
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 Making strong bond of corporation, customers, and end users
1.10 Main Customer of the Services

 Ethiopian Road Authority
 Parts of national administration
 Parts of urban administration
 Airport Company
 Rail Way Corporation
 Sugar Corporation
 The companies that get the maintenance of Automobile service
1.11 End Users of the Services

 Government board (minister of transport)
 Ethiopian Madden insurance company
 Material and Service Suppliers
 Basic Workers association
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1.12 Organizational Structure and Arrangement of ERA
Chart 1.1. Organizational Structure and Arrangement of ERA
The corporation has ten divisions to fulfill the goals
 Road Construction Division

 Road Maintenance Department
 Equipment Management & Maintenance Division
 Procurement & Supply Division
 Finance Management Division
 Human Resource Management Division
 ICT & Organizational Development Division
 Internal Auditing Services Division
 Legal Services Division
 Ethics Office
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Corporate Planning and Business Development Department Main functions:
o Annual operational management

o Road construction and maintenance single price division
o Preparing the budget for the corporation’s head office and its projects as I l as insure
implementing the working plan
o Preparing corporate evaluation reports for upper management
o Including new projects in the annual planning in advance
Road Construction Division Main functions:
o Enabling the Ethiopian Road Construction Corporation’s Road construction projects

to achieve their goals and allow the corporation to maintain its competitiveness in
the Construction Industry.
o Conducting construction works according to standards.
o Providing the necessary components for road construction projects on a timely
and balanced basis.
o Following and evaluating the completion of road construction projects.
Equipment Management and Maintenance Department Main function:
o Strengthen the central equipment work unit and provide the necessary maintenance
for the equipment
o Production of various spare parts to reduce shortages and cost
o Inspecting equipment regularly and providing maintenance for their proper functioning
Purchase and Supply Department Main function:
o Conducting single and collective purchases and distribution of purchased items
Finance Management Department Main functions:
o Until the middle of the fiscal year, the Cooperation should register any property it took
over from ERA and gives new ID number before the end of the fiscal year.
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o Recording the corporation’s income and costs on a regular basis in order to prepare
a monthly, quarterly, semi-annual, and annual profit/loss report as well as to report
on assets, liabilities, and liquidity
o Closing accounts at the end of the budget year
o Payment of government- i m p o s e d charges on a timely manner
Human Resource Management Department Main functions:
o Planning and implementing the corporation’s human resource requirements and

supply Regularly training provided by the department and implementing teaching
programs Providing general services for the corporation’s head office
ICT and Organizational Development Department Main functions:
o Implementing and regulating new changes to the corporation

o Guiding the corporation’s department heads and employees towards conducting proper
business environment practices
o Implementing a system that measure the success of department heads and rewards
them accordingly. Conducting studies on methods of improving the corporation’s
resource management and efficiency
o Providing a network to allow for efficient communication within the
corporation, allowing for information follow-up and better decision making
Internal Auditing Services Department Main functions:
o Prepare a sampling report that to analyze the risk and work processes, including
equipment maintenance, purchases, supply, and finances, of the road construction
& maintenance projects relying on the other departments in the head office. The
report includes data on finance, assets, management, and information technology.
o Prepare a sampling report on the working progress, operations, and targets of the
road construction & maintenance projects as well as the head office.
o Identifying current operation problems that interfere with the corporation’s goal in order
to improve the practices.
Legal Services Department Main functions:
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o Following up on open cases incoming and prepare appropriate respond and arguments
for ongoing court cases of the corporation and preparing adequate information in order
to protect the interest of the corporation.
o Provide legal advice and prepare to properly investigate and answer legal dilemmas
that are faced by employees across all departments
Discipline Regulating Department Main functions:
o Identifying and improving work practices that have potential to lead to unethical or
undisciplined practices. Responsible for taking actions against discipline violations and
follow up on disciplinary action.
Road Maintenance Department Main functions:
Enabling the Ethiopian Road Construction Corporation’s Road construction projects

to reach their goals and allow the corporation to maintain its competitiveness in the
Construction Industry. Conducting construction works according to standards. Providing
the necessary components for road construction projects on a timely and balanced
basis. Following and evaluating the completion of road construction projects.-
1.13 Jimma Rood Construction Corporation Workshop

The company is mainly opened for the purpose of keeping vehicles and machines long life and
also giving maintenance and repair vehicles on a working site to prevent unwanted work delay. It
has its own structures for performing the tasks. It has different sub division workshops to
accomplish different tasks such as: -
 Engine maintenance shop

 Machine shop
 Body repairing shop
 Electricity shop
 Welding shop
 Lubrication and cleaning shop
 Tire repairing shop
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ENGINEERING
Under the above workshops different tasks were performed these are: -
 Engine maintenance shop: -in this shop heavy duty and light duty vehicles
overhaul maintenance were performed.
figure1. 1Engine maintenance shop
 Machine shop: - in this shop there are different types of machines like lathe,
milling, shaper, hydraulic press and drilling machine are available to modify or to make the
different vehicle parts and construction equipment.
figure1. 2 Machine shop
Body repairing shop: -in this shop the bodies of vehicles which is damaged due to different
causes and for other reason will be repaired.
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figure1. 3 Body repairing shop
 Electricity shop: -in this shop the vehicle electric system will be checked such as
battery functionality, lighting systems, starter motor and alternator etc.
figure1. 4 Electricity shop
 Welding shop: -In this shop, there are two types of welding namely electric arc welding
and oxyacetylene gas welding. The main welding activities: such as, molding work in
different shapes, construction equipment servicing, fabrication of designed parts and
spare parts, fabrication of doors and windows, blades, modification and metal
fabrication, were out equipment welding, newly fabricated parts joining, tear out
equipment and maintaining of machineries are performed in the welding shop.
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ENGINEERING
figure1. 5 Electricity shop
 Lubrication and cleaning shop: -in this shop like other shops vehicles lubrication
systems were checked for it’s in a workable situation if any problem it will be adjusted to a
required level.in this shop engine lab. Oil were checked and adjusted. Cleaning was also
performed.
figure1. 6 Lubrication and cleaning shop
 Tire repairing shop: -in this shop tires were changed and repaired and also air was fill
to the tire. In this shop there is an air compressor driven by electric motor is available
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figure1. 7 Tire repairing shop
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Chapter two
2.1 Overall internship experience
First of all, Haramaya University institute of technology mechanical engineering and university
industrial linkage Office played the most important role in giving m y internship paper. I started
to make some contacts, phone calls to the companies which I think the most suitable ones. At the
end of First semester, I met some neighbors who can help me in this situation. Then I told them
what kind of company that I want to work in and after a while one of them came up with the idea
of this ERA company. By the other day I came to this company and took a visit. Since I can get
lots of experiences from the company, I agreed to work here and with the help of the senior
director of the company Mr. Senay I got accepted to this company namely “Ethiopian Roads
Authority Jimma District on May 15/2021 and I started the program on June 01/2021 and finally
finished my internship program with the company on July 30/2021. When I first joined the work
crew, I knew nothing about what is going on there. At first all I had to do was to see the parts
carefully and try to remember all the part names in their standard nomenclature. The company got
many experienced senior mechanics and also junior and starter ones. Among those experienced
mechanics, Mr. Tezera and MR. zuber was some of them. There are also mechanical engineers
who lead all activities at workshops. And also, there are employees who still in education
program. The ones with higher levels helped me with the standard names and also with detailed
explanations of everything I asked for like the braking system, the air systems, the oil systems,
the cooling and many others. Unlike to the local garage here the names were not a challenge, as
all named in Standard names, I wrote them on a note pad that I hang on to and try to remember
them. I also wrote the functions of the major parts of the trucks in case I forgot. In two or three
days I have come to know many names and started to understand what the mechanics were saying.
Fortunately, when I got there on the first month, there was a DAEWOO car which needs a full
service. There are two services those are annual and basic services and there was also a car which
needs a full engine service. All the parts were disassembled and I were able to see all the details
of an engine and it was a great demonstration for me. When I were in the campus, I had some
ideas of an Engine which I grasped in some courses. So, I knew some of the names like the
cylinder head, oil sump, piston, piston rod, crankshaft, cam shaft, combustion chamber and the
like. During the service I saw how an Engine is given a careful service. After the motor is fully
serviced, I have gained a great knowledge about how each part works, how
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ENGINEERING
they move, their shape too. Such a chance (full engine service) is a rare one. I knew lots of things
like there are lots of cylinder heads such as six-piece, three-piece, two piece and single piece
cylinder heads. The numbers one, two, three and six indicates in how many parts that the
cylinder head which locally ca1led “Testata”is divided to. Six-piece cylinder heads are found
mostly on DAEWOO, on this DAEWOO car I also knew other parts and their functions like the
push rod, the rocker arms, etc. the cars are six pistons so for a piston house there are two push
rods and two rocker arms. One of the push rod and the rocker arm are for the intake valve and
the others are for the exhaust valve. On the rocker arms a valve adjustment which I will explain
under firing order must be done. Since I knew these and other things in the first five days, I
forgot some of them until I serviced another motor. In these five days I were assigned on this
truck so I can get the best out of it. This happened because of the engineers and one of the Chief
mechanics of the company Mr. tezera to help us. He was so helpful and at the same time
confident in the works he does. After I finished that car, I were immediately assigned on other
trucks for annual servicing. Actually, in this company I do lots of things like gear box servicing,
motor servicing, full wheel servicing, differential servicing, hub reduction servicing, brake shoe
servicing and anything on the trucks including welding, cutting, etc.…but the body working
(welding cutting and painting) is for others division. Until I became independent in some tasks, I
used to do simple tasks like fetching fastening materials, help in supporting or carrying and
cleaning purpose by using air hose for clear observation of the damaged section.
2.2 Section of the company I have been working in
Engine maintenance shop, Machine shop Body repairing shop, Electricity shop, welding
shop and Lubrication and cleaning shop
2.3 Work flow in the section

Workflow patterns follow concepts of economized in terms of less time, utilizing small
man power in aggregate towards of becoming cost effective. The usage shall follow
strategies of simplifying maintenance as well as reducing working time and materials
used.
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2.4 Crucial parts on Work task that I have been Executed

2.4.1 Gearbox Mechanical, Component Description
figure2. 1 gear box
The gearbox is a splitter and range gearbox with 12 gears, split and range gears are synchronized,
the others gears are unsynchronized.
The main parts of this gearbox are:
 A clutch housing
 A basic housing
 A range housing
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2.4.1.1 GEARBOX, OVERVIEW
figure2. 2 gearbox over view
1 Clutch housing 9 Control housing
2 Main housing 10 Shift rod
3 Range housing 11 Input shaft
4 Main shaft 12 Clutch cylinder
5 Counter shaft 13 Output shaft
6 Reverse axle 14 Cross-tooth flange
7 Oil pump 15 Brake axle
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8 Planetary gearing
2.4.1.2 Housings
figure2. 3 housings
1 Clutch housing
2 Main housing
3 Range housing
4 Control housing
The main sections of the gearbox are the clutch housing (1), main housing (2), range housing (3)
and control housing (4). The main housing, clutch housing, range housing and control housing
are cast from aluminum.
The clutch housing (1) contains the input shaft as well as the clutch servo.
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ENGINEERING
The main housing (2) contains the main shaft, intermediate shaft, reverse axle and shift
mechanism. The splitter gear is located in the forward section of the basic housing.
The range housing (3) contains the planetary gearing and shift mechanism, actuator and output
shaft. Furthermore, there is a connection flange for power take-off, emergency steering servo
pump at the rear of the housing.
2.4.1.3 Internal Parts
figure2. 4 internal parts
1 Input shaft 7 Sun gear
2 Splitter gear (Low split) 8 Intermediate shaft
3 Splitter gear (High split) 9 Reverse gear
4 2nd gear 10 Planetary gearing
5 1st gear 11 Output shaft
6 Reverse gear 12 Cross-tooth flange
13 Range gear shifting fork
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Input shaft: The input shaft, which transfers the engine power to the gearbox via the clutch disc,
is mounted in the clutch housing in conical roller bearings. The gear is fitted on the shaft with
needle bearing.
Note: the input shaft always rotates in a clockwise direction (viewed from the front)
Intermediate shaft: The intermediate shaft is attached by conical roller bearings to the clutch
housing and the rear end cover of the basic housing. The splitter gears (first three gears at the
front of the shaft) are pressed onto the intermediate shaft and others are machined directly into
the shaft.
Main Shaft: Both ends of the main shaft are fitted with conical roller bearings. The front end is
attached to the input shaft, while the rear end fits into the rear end cover of the basic housing.
All gears on the input shaft are fitted with needle bearings.
Output shaft: The output shaft is fitted in the range housing with roller bearing and is linked to
the range gear.
Note: the cross-tooth flange is standard on all gears of all mode variation.
Reverse shaft: The reverse shaft is suspended (between a spacing sleeve) in the main housing.
The reverse gear runs on a needle bearing and changes the direction of rotation of the main shaft,
which allows the vehicle to reverse. The reverse gear run the oil pump.
2.4.2 Engine Service

Engine is the main part of the truck it can able to produce the power it required to produce the
dynamic force for accelerator. Engine is fitted at the front portion of the truck over the engine
support that mounted to chassis (frame). Engine includes different types of equipment with
different size and shape. These have higher accuracy of manufacturing process for perfect
application. Engine parts most of time made from aluminum and cast iron, but all parts of engine
it made from one type to have the same heat capacity and resistance of corrosion.
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ENGINEERING
figure2. 5 Engine Part
2.4.3 Engine Components

The engine is mainly categorized in to two main part this are engine head (the upper part)
and engine block (the lower part).
1. Engine head (cylinder head) the upper part of the engine that covers and encloses
the Cylinder and many of the first engine system are work under this engine Head. The
main component parts found in the engine block are discos on the following procedure.
 Over cam shaft: The shaft that has intake and exhaust cams for Operating the valve
 Cam lobe: Changes rotary motion into reciprocating motion.
 Valve: this is work by opening and closing depends on the requirement. Since the size
of intake valve greater than exhaust valve because the inlet Air or air fuel mixture has less
pressure as compare to exhaust gases.
 Intake valve: used to permit the air to enter in to combustion chamber.
 Exhaust valve: used to remove the exhaust gases from the combustion Chamber.
 Valve spring: used to Keeps the valves Closed
 Valve lifter: Rides the cam lobe and helps in opening the Valves.
 Cooling fins: it is used to cool the engine thorough the water jacket
2. Engine block It is the Foundation of the engine that contain the necessary parts which
contains pistons, rings, crank shaft, connecting rod, cylinders, timing sprockets and
sometimes the in block cam shaft. Found between cylinder head and oil sump.
 Gasket: found between cylinder head and engine block and used to reduce friction,
produce proper connection between them, to prevent mixing of water jacket, oil
gallery and compassion.
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 Cylinder: it is holes that provide smooth movement by attaching with liners

 Cylinder liner (cylinder sleeves): which is fitted into the cylinder bore, it provides
wear resisting surface for the cylinder bores
 Wet liner: it is surrounded or wetted by cooling water and also it acts as a seal
for the water jacket
 (Dry liner: which have metal-to-metal contact with the cylinder block. They are
not directly in touch with the cooling water
 Piston: that used to change four stork cycles in the cylinder to some sort of power by
up and down movement.
 Compression rings: consists of two rings that are used to seal against compression
lost during compression stork.
 Oil ring: used to wipe and return excessive oil from the cylinder walls to the oil sap.
 Connecting rod: used to connect the piston and crank shaft, in order to
produce reciprocating motion on crankshaft by the help of piston movement.
 Crankshaft: it combines with connecting rod in order to converts reciprocating motion
of the piston in to rotary motion in order to produce the engine output.
 Flywheel: it is attached at the end of crankshaft that provides
o Reduces vibration
o Cools the engine (air cooled)
o Used during initial start-up
o Transfers power from engine to drive train
The other engine component part comparatively works to gather with engine head and engine
block.
 Oil sump or oil pan: Oil sump is the bottom part of the engine, it contains oil. A drain
plug is provided the oil sump to drain out the oil. First it works by removing large particle
from oil thorough strainer in order to pump, oil must be cooled then move in to oil filter
before going to lubrication system pass thorough oil glary to the hole engine. The oil
spray by the help of oil injector that is control through regulator valve. Oil not only
available for lubrication system, but also coolant, increase life, used as cleaner, reduce
friction and to remove noise.
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 Radiator: it is used to transfer the excess heat to the atmosphere It mainly consists of
an upper tank and lower tank and between them is a core. The upper tank is connected to
the water outlets from the engines jackets by a hose pipe and the lover tank is
connecting to the jacket inlet through water pump by means of hose pipes.
 Thermostat valve: It is a valve, which prevents flow of water from the engine to
radiator. After the water attaining maximum temperature operating, automatically
begins functioning. Generally, it prevents the water below70°C.
 Water Pump: It is the heat of the cooling system that pumps the coolant
 Water Jackets: it provided around the cylinder, cylinder head, and valve seats Water
Jackets
2.4.4 Engine Overall

Engine is the power plant of an automobile. The heat energy produced by burning of the fuel is
converted by the engine into mechanical power or rotary motion through its various parts. The
motion is started in the flywheel connected to the crankshaft. After completing various cycles of
operation in the engine, the flywheel transmits this motion to the wheels through the
transmission system.
The automobile engine has a piston that moves up and down, or reciprocates in a cylinder. The
piston is attached to a crankshaft with a connecting rod. The pressure developed in the
combustion chamber pushes the piston away and thereby, forces the crankshaft to rotate. When
the crankshaft rotates the mechanical arrangement allows the piston to reciprocate in the
cylinder. The engine cylinder is a cylindrically shaped container supported in position in the
cylinder block, attached to or an integral part of the crankcase. The volume enclosed by the
upper part of the cylinder and the top of the piston at its lowest position is called the combustion
chamber. The engine also powers the drive belts, which help operate other vehicle accessories
(e.g., Air conditioner, power steering, electrical system). Because an engine has many moving
parts, its components have to maintain regularly in order to maximize longevity and efficiency.
Standard maintenance items include replacing the engine oil and filter, air filter, engine coolant,
spark plugs and injector nozzles and timing belts.
The overall engine servicing includes
 Proper removal and disassembly of the engine.
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ENGINEERING
 Removing every replicable part like rings, gaskets, journal bearings, cylinder liners and
any others.
 Cleaning and lubricating all parts.
 Transport to machine shop if any operation is needed
 Return.
 Reinstallation and assembly using manual.
 Engine rebuilding.
 Testing and commissioning.
2.4.5 Generally, Engine Maintenance Activity

Identification of the Problem; this includes good inspection and observation on the engine. Its
noise, sniff, exhaust concentration and other abnormal things will be detected while operation.
Customers input / problems experience, Mechanics previous experience and knowledge, Service
year and maintenance time and Power output also will be considered. Mechanics check whether
the engine required maintenance or not, if it requires, where and how. Since engine is the power
house of the vehicle and has many parts mentioned above can go wrong. For that matter
intensive investigation has to be carried out. Sometimes the problems may not be identified
easily by inspection. At that time the technician may has to disassemble the engine and check
for assumed parts.
Recommended Solutions; After the problem has been identified, a possible solutions and
method has been stated, this activity does up to the final step of engine maintenance. This will
vary according to the identified problems of the engine. This includes orders for newly installed
parts. Disassembling, Repair, Modify and Replacing of Parts; The next step is to decide if total
disassemble of the engine is necessary or not. After that detachment from main body part will
be followed. Steps followed when disassembling the equipment’s such as different sizes of
open ranch, torque ranch, ratchets and other special purpose tools etc. For the part need to be
replaced a form contain the spare parts is forwards to store man. If the part exists in the store, it
will be delivered to the mechanic, and replaced in place of the defected parts. Most parts of a
vehicle
are repairable during service, with the exception of parts that have been blown up or otherwise
completely destroyed. Parts that require modification by machining send to the machine shop.
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Engine Test Stand and Test Drive of the Vehicle; after finishing all the proposed maintenance
activities the engine has to be tasted before installation or full operation. Testing an engine is
just as important as the regular maintenance. An engine test stand is a facility used to develop,
characterize and test engine that allows engine operation in different operating regimes and
offers measurement of several physical variables associated with engine operation. A test drive
is the driving of a vehicle to assess its drivability, or road worthiness, and general operating
state.
A person who drives a vehicle for the test in the garage is a mechanic itself who has an
appropriate driving license. Test drive is done to ensure that repair was completed, successfully
and ensure the safety of the car after the repair that will decides whether the vehicle is
maintained well or not.
2.4.6 Engine Assembling Order

After all the parts I expressed on the above by disassembling, maintenance and repair or replace
if it is not able to operate by maintain the regular operation after testing by their own machine
rejected and I use new spare part and wash all of the parts with gasoline or benzene and replace
the water and the oil on the oil sump then after checking all the parts I start to assembling to
make full engine. First engine block with bolts that used to join with cylinder head set on the rot
able stand of engine. Then insert the line with 3 seal and then shaft tappets crank shaft that has
lobe. By the lobe and tappet on the cylinder block then the crankshaft on the main journal with
bearing both seat and hamper by cap with torque450Nm tie the gear of put clearance adjustment.
Then the cylinder head with spring loaded valves (exhaust and intake) mounted on the cylinder
block. Then the push rod insert through head cylinder to cylinder block they contact to tappets
and at the cylinder head seat locker arm over the push rod and the spring loaded valves and tie
with bolts in addition to fuel nozzle insert through the cylinder head over the piston on the
cylinder on the cylinder on the regular portion. Then the injection pump with all parts fitted,
compressor with parts fuel filter fitted and contact with injection pump by tube and also the
injection pump contact to fuel nozzle by pressure tube, fitting both Intake and exhaust manifold.
The injection pump gear cam shaft gear adjusts zero level, fly wheel housing, fly wheel contact
with crank shaft by bolt, beside of fly wheel fit starter, cap with breather, all fuel filters and
contact to the oil pump by tube through the block, mount the belt drive on both pulley, fan on
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the front of engine crank shaft by bolts, AC generator contact with all parts of current line,
steering
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pump. The piston and connected rod by pin frame and on the piston put the compression ring,
oil ring. The connected rod connected to crank shaft pin bolt and cap with 200Nm torque. After
all the parts full assembled Then check all the operation of the engine then after testing with the
help of the overhead crane or other crane fitted to their own truck.
2.3.3 Differential
We all know that for a vehicle to move there must first be power generation and the generated
power intern makes the crankshaft to rotate. This rotation will be changed to the motion of the
vehicle. After the vehicle is put into motion, there must be a mechanism to turn the vehicle to
the left and right. The part which creates this mechanism is called the differential. When there
is a problem with the effective turning, I do maintain this important element of the trucks.
Usually, the problems of a differential of a heavy truck are its gears and they need their oil to be
changed regularly. Every element which needs oil for lubrication will have its own oil type
according to the standards made by SAE (Society of Automotive Engineers). For example, the
string box needs oil type of SAE no 10, the engine needs SAE no 40, the gear box needs SAE
no 90 and the differential needs SAE no 140. The no shows the thickness of the oil.
figure2.6 differential
A vehicle’s wheels rotate with different speeds, mainly when turning corners. The differential
is designed to derive a pair of wheels with equal torque while allowing them to rotate at different
speeds. In vehicles without a differential, such as karts both deriving wheels are forced to
rotate at the same speed, usually on a common axle driven by a simple chain drive mechanism.
When cornering, the inner wheel needs to travel a shorter distance than the outer wheel, so
with no differential, the result is the inner wheel spinning and the outer wheel dragging, and
this results in difficult and unpredictable handling, damage to tires and roads, and strain on the
entire drive train.
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The following description of a differential applies to a traditional rear wheel drive car or truck
with an open or limited differential. Torque is supplied from the engine, via the transmission to
a drive shaft which runs to the final drive unit that contains the differential. A spiral bevel
pinion gear takes its drive from the end of the drive shaft, and is encased within the housing of
the final drive unit. This meshes with the large spiral bevel ring gear known as the crown
wheel. The crown wheel gear is attached to the differential carrier or cage, which contains the
sun and the planet gears, which are a cluster of four opposed bevel gears in perpendicular plane,
so each bevel gear meshes with two neighbors and rotates counter to that it faces and does not
mesh with. The two sun wheel gears are aligned with the same axis as the crown wheel gear,
and drive the axle half shaft which is connected to the vehicle’s driven wheels. The other two
planet gears are aligned on a perpendicular axis which changes orientation with ring gear’s
rotation. Most automotive applications contain two opposing planet gears; other differential
designs employ different numbers of planet gears depending on the durability requirements. As
the differential carrier rotates, the changing axis orientation of the planet gears imparts the
motion of the ring gear to the motion of the sun gears by pushing on them rather than turning
against them (i.e. the same teeth stays in the same mesh or contact position), because the planet
gears are not restricted from turning against each other within that motion, the sun gears can
counter rotate relative to the ring gear and to each other under the same force (in which case the
same teeth do not stay in contact).
2.3.4 Hub-reduction
This part in the power transmission system is the most important one in mechanizing the
rotation of the driven wheels after receiving the rotation and the power from the differential
by the axle's half shaft. When I say the differential helps in delivering the power and the
rotation to the driven wheels, it doesn't mean that I don't need any other mechanism after all.
The necessary mechanism for the effective rotation of the driven wheels is provided by this hub
reduction. Mainly the hub reduction is consisting of housing, three identical small sized spur
gears, three same size and shape pins, one big internally threaded spur gear and lots of small
sized circular rods which act as bearings. The housing looks like the following figure
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ENGINEERING
Pins
Planet gears
Bearing rods
figure2. 7 The pins, the planet gears, the bearing rods and Hub- reduction housing
Assembly of the above parts will be as follows. First the pins are covered by the small circular
bars which acts as a bearing four rounds up which of course the pins are first covered with
grease. Then insert the pins after placing the identical gears in place. Remembering that, it is
done one gear at a time. After all the three gears are installed, I put the ring gear on them and
finally I find the hub reduction to be fully assembled.
figure2. 8disassembled wheel
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ENGINEERING
figure2. 9 full assembly of the hub reduction
Now let’s see how the power which is generated in the combustion chamber due to the burning
of the fuel with the compressed air and transmitted to the crankshaft then to the transmission then
to the gears in the differential and then to the half shafts, can be transferred to the driven wheels
by the hub reduction. Let’s take one of the half shafts. This shaft is splined at both ends. One
end is meshed in the differential and the other one in the hub reduction. The end which is found
in
the hub reduction meshes with second largest gear which is internally splined. This gear again
meshes exactly with the three small and identical gears. These gears as explained above are
pined by the three pins. Then these three identical gears mesh with the largest and internally
threaded gear. For this gear train the identical gears are the planet gears, the internally
threaded one will be the ring gear and the last but not the least one will be the sun gear since
all the other gears revolve around it. As shown in the figure above the ring gear has two types
of threads.
Both types are the same in profile except their height. The planet gears mesh at the larger height
gear profile. The smaller height gear profile is the last mesh in the hub reduction. This mesh
takes place between the ring gear (smaller height profile) and the gear which made on the wheel's
component which is locally called the 'mosso'. The bolts which tie the tires firmly are found on
this part. For the rotation of the mosso I have two big sized bearings. The drum is installed on
these bolts. When the mosso rotates, the drum also rotates with it. Of course, the tires are also
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ENGINEERING
installed on these bolts. To illustrate the process; when the half shaft rotates, it makes the
second largest gear to rotate which in turn rotates the three identical spur gears. These gears
again rotate
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ENGINEERING
the ring gear by meshing at the larger height gear profile. The mesh between the small gear
height profile and the mosso produces the significant rotation of the wheel.
2.3.5 Switch/Cortelo
It is a manual battery switch. An automatic cortelo/switch is introduced in the new model
euro trackers. Its main purpose is to turn the power off or to disconnect the battery from the rest
of the circuit. Disconnecting the battery from the rest of the circuit is necessary because of the
need to avoid shorting or Massa (locally). Shorting may be created when small scale accidents
happen or sometimes animals like rats may cut the insulating materials of two or more lines.
When two or more bare lines meet at any time, shorting will be created. The cortelo/switch is
located just beside the battery in manually operated trucks. But in the new models where the
cortelo is automatic, I don’t find it there instead the circuit is connected to be on/off when the
motor starts/ stops respectively.
2.3.6 Thermostat
It is the equipment that is found in the water-cooling system. Its main function is to maintain
the temperature of the water in the engine to be at about 90˚c and when the water in the engine
reaches the desired temperature, it lets the cooled water come into the engine and passes out the
hot water through another line to the radiator to be cooled. The reason why I use a thermostat is
that the engine itself needs some temperature for at least the expansion of the combustion
chamber or locally called liner (camcha). If this temperature can’t be obtained, then the
combustion chamber contracts and the movement of the piston will be compromised since the
piston rings will have the chance to escape and finally the air will pass the combustion chamber
easily and the motors/engine's performance will decrease.
2.3.7 Fuel pump/Pampeta
It is the part of the fuel pumping system which pumps fuel from the fuel tank to the injector
pump (Pompa) during maintenance. That means when the truck is required to change fuel
filters air is introduced in the fuel line between the fuel pump and the injector pump which is
completely unwanted. After the truck is changed with what is required which is the fuel filter and
others, it must be checked whether the filter works properly or not or whether there is a fuel
leakage or not. In doing so, the air which is introduced during maintenance should be displaced
by fuel. So by pushing the fuel pump again and again I fill the line with fuel but in times of
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ENGINEERING
duty, the fuel pump’s role will be over and becomes just like other fuel lines with a filter
just beneath it.
figure2. 10 Injection Pump
2.3.8 Turbocharger
When people talk about race cars or high-performance sports cars, the topic of turbochargers
usually comes up. Turbochargers also appear on large diesel engines. A turbo can significantly
boost an engine's horsepower without significantly increasing its weight, which is the huge
benefit that makes turbo so popular! Turbochargers are a type of forced induction system. They
compress the air flowing into the engine. One of the surest ways to get more power out of an
engine is to increase the amount of air and fuel that it can burn. One of the surest ways to do
this is to add cylinders or make the current cylinders bigger. Sometimes these changes may
not be feasible, a turbo can be a simpler, more compact way to add power, especially for an
aftermarket accessory.
figure2. 11 turbocharger (heavy duty)
2.3.9 Clutch servo
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ENGINEERING
When the clutch is held it means that the oil from the master cylinder is ordered to push the
valve which is located in the clutch servo so that air can pass easily and pushes the pressure
plate fork which in turn pushes the pressure plate and disconnects the clutch and the input shaft.
2.3.10 Foot brake valve
It is the part of the braking system which it has five lines in euro trackers through which air
passes. On these five valves, some codes say 11, 12, 21, 22, and 4. Codes 11 and 12 are printed
on the lines which are air-sucking lines to the brake from the air tanks. Codes 21 and 22 are
lines that pump or send air to the front and rare wheels. There are also valves on the front and
rare which expects the order for braking. This order comes from code 4. From lines 21 and 22
after the valve at rare and front wheels there comes two lines to each wheel.
2.3.11 Master cylinder
It is a small tank of oil that is located at the front part of the truck (the cabin). Its purpose is to
push the oil in it to the clutch servo which in turn pushes the pressure plate fork which is
according to the mechanism. The main purpose of the oil is to produce a safer way for the air
by opening the valve which is located in the clutch servo.
2.4 Systems
2.4.1 Air Flow System
The airflow system starts from a part that is located just outside of the cab locally called
dabrator. The function of dabrator is to collect air from the atmosphere. The air collected passes
through a filter which is found inside the dabrator to filter the air. After the air is filtered it
directly goes to the most important component of the airflow system called the turbocharger.
The function of the turbocharger is to supply filtered air to the motor with much more speed
than normal. The component which is located in the turbocharger and increases the speed of air
is the fan. After the air passed the turbocharger, it will be divided into two lines, one going
directly to the compressor and the other going to the cooler to be cooled. Then the cooled air
enters the motor through six lines (for heavy trucks) in the intake manifold. Since I am dealing
with diesel engines, the air passed from the intake manifold a n d then passes the valve
according to the timing of the valve. The timing is determined by the cam shaft. After the air is
burned and power is generated, smoke as a bi-product is produced. This smoke is removed
through the six lines in the exhaust manifold and they get collected in one wide tube. Since the
air is given a greater speed when it enters, the smoke should also be expelled at that speed by
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the turbocharger. Of
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course a fan is used just beside the fan for filtered air and both of them are separated from each
other because of the need to avoid the mixing of filtered air and smoke.
Finally, the smoke is released into the atmosphere leaving carbon on the walls of the tubes that
it comes in contact with. The other major airflow system is the air production in the compressor.
Its work starts when the filtered air from the turbocharger enters it. The compressor can be
considered a small motor/engine consisting o f pistons and crankshafts. When the air enters, it
will be compressed by the pistons to the desired pressure usually 12 bar, and takes its way out to
the four tankers. Now, this is the place where all the air/ gas operating systems get their air
supply. Among the four tankers two of them are for the foot brake valve and also for the hand
brake, one is for the braking system on the trailer and the remaining one is for the different
functions of the truck like for the whistle, for the clutch servo, for the auxiliary gearbox, for the
differential in case the truck gets stuck in mud during rainy seasons and for other purposes.
When I apply the foot brake, the foot brake valve starts its work which means that the two air
sucking lines sucks the air from the tankers and passes it to the air-delivering or air-sending
lines to the brakes. But only the two different lines are not enough for the braking, there is also
another line which is the command line which orders the brake to start its function i.e. braking.
When I say brake is applied, I mean to say that the lines are filled with air. After I used the
brake for the time I needed, I must continue driving. For this to happen, I have to remove the
air from the line. This is done by valves that are installed at different locations. For example,
the air which is filled between the foot brake valve and the rare wheels is removed through a
breather installed at the front of the cab. The air which is sent from the foot brake valve is given
the order to brake at the rear wheels by the ordering lines which are all installed on a valve. As
I know a heavy truck is consisting of four wheels on the rare side, so the braking must be
applied to all four wheels. Therefore, the four lines are drawn from this valve to the braking
element chamber locally called sofeto. Finally, when I release the brake, the air between this
valve and the air chamber (sofeto) will breathe on this same valve that is installed for such
purposes. The same is true for the hand brake. Since I am looking a t the air operating systems,
I find a very important valve which is called Reducer Valve. The main function of this valve is
to reduce the 12-bar pressured air to small amounts so that the reduced air pressure can be used
for small-scale purposes like the whistle, the clutch servo, etc.
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If we're using all the 12-bar pressure for the whistle, it would be very disturbing because of the
very loud sound that it produces.
2.4.2 Fuel System
The fuel system consists of the fuel tank, water separator, fuel filter, injection pump, and
injection nozzle
Fuel Water Fuel Injection Injection

tank separator filter pump nozzle
figure2. 12 fuel system
 The fuel from the fuel tank passes through the water separate and the fuel filter
where water particles and other foreign materials are removed from the fuel
 Fuel fed by the injection pump plunger is delivered to the injection nozzle in
the measured volume at optimum for efficient engine operation.
2.4.3 Lubrication System
 Lubricating oil is plumed from the oil pump to the cylinder body oil gallery through
the oil cooler and the oil filter. It is then delivered to the vital parts of the engine from
the cylinder body oil gallery.
 Oiling jets installed on the cylinder body sport engine oil to the piston back side faces
achieving maximum piston cooling effect.
2.4.4 Engine Cooling System
The engine cooling system consists of the radiator, the water pump, the cooling fan, and
the thermostat to quickly increase cold engine coolant temperature for smooth engine operation,
the coolant is circulated by the water pump and thermostat through the bypass hose and back to
the cylinder body. When the coolant temperature reaches the specified valve, the thermostat will
being to open and a gradually increasing amount of coolant will coolant through the radiator.
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ENGINEERING
the thermostat will be fully open when the coolant temperature reaches the specified valve.
All of the coolants are now circulating through the radiator for effective engine cooling.
2.4.5 Firing Order
This is the most important and effective factor for the effective operation of the motor. If the
motor is required to function fully and properly, I need to set the firing order properly. When I
say firing order, I mean to say the order/timing in which the fuel burned and the smoke is
expelled. During the burning of the fuel, the exhaust valves are closed. After the burning is
completed, the bi-product which is the smoke is removed through the exhaust manifold during
which the exhaust valve is opened. This opening and closing of the intake/air and the
exhaust/smoke valves are mechanized by the work of the motor parts which are namely the rocker
arms/blanchery, spring, push rod/asta, and the camshaft/albero cam. To have the perfect
combination of the firing of the six chambers, I need to know and use the prescribed valve
combinations which are 15 24 36. Each chamber has its number. The number starts from the
chamber which is at the radiator side. The above number is used to adjust the twelve valves of
which six valves are for the intake and the remaining six ones are for the exhaust. The levels of
the six pistons are divided into three that is pistons 1 and 6 are at the same level, pistons 2 and 5
are also at the same level and last but not least pistons levels 3 and 4. Because of the three levels,
these piston combinations are given the codes 16 25 34. To do this valve adjustment I need to
rotate the crankshaft. When I rotate the crankshaft, I observe the valves’ up and down movement.
For the process of the adjustment, I carefully look until I find one of the intake valves to open
and the exhaust one to close. When I have such a combination, then I use the piston combinations
16 25 34 and 15 36 24. Let’s for example say I have the combination at piston 1. To proceed with
the adjustment, I use the piston combinations 16 25 34 i.e., if I have on valve 1, then I adjust on
valve 6. According to the combination 15 36 24, next to valve 1 there will be coming valve 5.
When this particular valve sets to its piston, I adjust valve 2(according to 16 25 34). Next to
valve 2, there will be coming valve 3 and I adjust valve 4. Following this procedure, I can adjust
all twelve valves perfectly. I may not expect valve one to be the first. It could be any valve; all I
need to do is just follow the two combinations. For deciding the opening of the exhaust and the
intake valves, I use an instrument called a space meter. This instrument looks like the shape of
the handle of a spoon but is flat and with different thicknesses. For such purposes use 35 and 40
space meters. I use 35 for the intake and 40 for the exauste
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These space meters are made to pass through the push rod and the rocker's arm. The reason why
I use the 40 for the exhaust is because of the need to remove more smoke than the incoming air.
2.6 Other Services
-perform annual service according to the manufacturer's checklist
-perform basic service according to the manufacturer's checklist
-replace the wiper washer reservoir
-removed gearbox from the truck
-install the gearbox on the truck
-removed the clutch servo
-installed the clutch servo
2.6.1 Annual Service Includes

Lubrication, oil, and fluid level
checks
1. Chassis lubrication
2. Cab lubrication
3. Check the oil level in the gearbox
4. Check the oil level in the retarder
5. Check the oil level in the transfer gearbox
6. Check the oil level in the driven front axle
7. Check the oil level in the rear axle
8. Check the oil level in the cab tilt pump
9. Check the fluid level in the clutch fluid reservoir
10. Check the coolant frost protection and fluid level
11. Check air
drier Checks in the
cab
12. Check compressor function and condition
13. Check of pressure drop on main brake circuits
14. Check pressure drop in the compressed air system
15. Check gear shift linkage and clutch pedal
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16. Check the brake pedal and foot brake valve
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External checks
17. Valve adjustment
18. Function check of wipers and washers
19. Replace the A/C air filter and check roof mounted A/C
20. Check the refrigerant tank, condenser, pipes, and hoses
21. Check air intake and air deflector
22. Check of cab anchoring, hydraulic system, locking devices, grille, and cab tilting
23. Check batteries – dirt, leakage, attachment, fluid level, connections, and battery box
24. Check the fuel tank, hoses, air vent pipe, and mountings
25. Check the fuel tank ventilation filter
26. Draining of fuel tank
27. Check of Ad Blue system
28. Check tire wear
Engine Bay
29. Check alternator mounting
30. Check drive belts and belt tensioners
31. Check the A/C – compressor for A/C unit
32. Check engine mountings
33. Check radiator fan, bearing tolerance, screw unions, fan shroud and fan ring with
rubber seal
34. Check radiator, hoses, pipes and air through- flow
35. Check intercooler, hoses, pipes and air through-flow
36. Check the engine, engine powered power take-off and compressor for leakage
37. Check the fuel piping and lines
38. Check the exhaust leakage
39. Check the air pipe between the air intake and the turbo
40. Check the turbocharger and EP regulator
41. Check engine sound
baffles Front suspension, steering
gear
42. Check the sealing on the servo pump, oil connections, oil hoses, and steering gear
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43. Check the steering link system
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ENGINEERING
44. Check front shock absorbers

45. Check the king pin bearings
46. Check the front wheel bearings
47. Check the front wheels
Check underneath the vehicle
48. Checking to seal, bearing play, and ventilation on driving the front axle
49. Check slack in mechanical linkage for clutch
50. Check clutch hydraulic and pneumatic control system
51. Check clutch wear
52. Check to seal on the gearbox, transfer gearbox, and power take-off, and check cables
53. Check to seal off the oil cooler for automatic transmission
54. Check ventilation for the gearbox, transfer gearbox, and PTO
55. Check for tightness on the retarder and check for lines
56. Check sound baffle for gearbox
57. Check transfer gearbox mounting
58. Check propeller shafts – universal joints, sliding joints, and support bearings
59. Check to seal of rear axle and hub reduction gear
60. Check bearing clearance in the pinion and rear axle input shaft
61. Check rear axle ventilation
62. Check springs and U-bolts
63. Check rear shock absorbers
64. Check front and rear axle suspension
65. Check chassis frame and cross members
66. Check the lubrication system (central lubrication)
67. Check compressed air lines and hoses
68. Check rear wheel bearings
69. Check rear wheels
70. Check brake linings
71. Check brake cylinders, levers, and forks
72. Check brake calipers and brake
discs Road test
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ENGINEERING
73. Check after start

74. Check during t h e road test
75. Check after the road test
76. greasing
77. Finish
2.6.2 BASIC SERVICE

Lubrication, oil, and fluid level checks
1. Chassis lubrication. Basic service
2. Cab lubrication. Basic service
3. The power steering system, oil level check
4. Check the oil level in hubs with oil-lubricated wheel bearings
5. Check the fluid level in the clutch fluid reservoir
6. Check coolant frost protection and fluid level
7. Check fluid levels in the windscreen and headlamp washer reservoirs
8. Check air
drier Checks in the
cab
9. Check of leakage in the service
brake External checks
10. Function check of wipers and washers
11. Check air intake and air deflector. Basic service
12. Check battery security, connections, and fluid levels
13. Check the fuel tank with hoses, pipes, and suspension straps
14. Check the fuel tank ventilation filter
15. Check tire wear
Engine Bay
16. Check drive belts and belt tensioners
17. Check engine, engine- powered power take-off, and compressor for leakage
18. Check fuel piping and lines
19. Check for exhaust leakage
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20. Check hoses and pipes for the intercooler
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Front suspension, steering gear

21. Check steering shaft joint, hoses, and pipes for power steering
22. Check gaiters and ball joint play
Check underneath the vehicle
23. Check slack in mechanical linkage for clutch
24. Check to seal the gearbox, transfer t h e gearbox, and power take-off
25. Checking propeller shafts and universal joints, sliding joints, and support bearings
26. Check to seal of rear axle and hub reduction gear
27. Check the exhaust pipe and silencer or particulate filter
28. Check springs and U-bolts
29. Check the air suspension bellows
30. Check brake linings
31. Check brake cylinders, levers, and forks
32. Check brake lever
travel Road test
33. Check after start
34. Check during t h e road test
35. Check after the road test
36. greasing
37. Finish
2.5 The challenges I have been facing while performing work tasks
 knowing part names because the names of the parts are in the italic language
 shortage of knowledge on how to use materials
 lack of knowledge about Maintaining parts
 Knowing the behavior of the workers Since there are different people
 There was no safety equipment and working uniform in the company
2.6 Measures have been taken to overcome these challenges

 I asked for the part name
 I asked how to use the instruments
 I have searched google and I asked the mechanic s
 I try to understand the behavior of the workers
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 I used books that I have taken on campus.

 To overcome those safety problems, I have brought my safety instrument
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Chapter three
Design of hydraulic brake drum lifter
3.1 Introduction
Drum brakes (as opposed to disc brakes) are a braking system that slows a vehicle by pressing
brake shoes in to the inside surface of a metal drum attached to the wheel to create friction. Like
any braking system, drum brakes undergo wear and tear with use. Brake drum maintenance and
replacement requires that you first remove the brake drums from the wheels. This procedure is
usually fairly simple, requiring more than a half hour or so and common vehicle maintenance
Tools. Therefore, to perform this action it needs mechanism that extract drum from wheel hub
brake drum extractor or puller is a machine or mechanism that used to pull out or extract a drum
from the axial of the car furthermore this machine is used to decrease man power or loss of
energy.
3.2 Background of the study
Automotive vehicles include components that will need to be replaced or serviced after a
period of time. Such components include brake drum extractor. Often the components can be
difficult to remove because they rust or become corroded. The mechanic either break the drum
off with a hammer or uses a universal puller that cannot adapt well to the component being
serviced. Thus, current servicing techniques can lead to vehicle damage, significant time loss,
or other undesirable condition accordingly it is desirable to provide a tool that can easily
remove the component being serviced by the user.
3.3 Short Summery of the Project

Hydraulic brake drum lifter is designed to modify the way a brake drum is removed and
installed. The mechanism of the hydraulic brake drum lifter is to change the mechanical energy
applied by the person to a hydraulic energy to lift the brake drum. First pump the hydraulic by
lever for lifting the hub to meet the height requirements of the brake drum then fit the drum into
the iron ring after that tighten the bolts to hold the drum firmly and move the machine away by
using its wheels or bearings then lower the drum to its normal position. In this way the hydraulic
brake drum lifter could support the drum until the required job is performed and the drum could
be returned to its position easily without the use of high labor.
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ENGINEERING
3.4 Problem Statement and Justification

During the course of internship, I have seen cars waiting for bearing test or maintenance also
for braking system test or maintenance so many times. I immediately ask one of the workers He
told us that there is no mechanism machine they used for brake drum extract or to pull drum
then I try to develop this idea. Finally, I motivated to do this project in order to adequately
reduce this problem. ERA found in Jimma rehabilitation center was mainly maintenance.
Therefore, that from all cars and other trucks be maintained and repaired in this center. Mostly in
ERA site, the trucks come for maintenance and to be check, so that checking up the braking
system was must. During this time, the brake would need change when it damaged or smooth.
Therefore, to attach brake shoe first I need to remove the drum. In addition, the drum itself can
wear, crack or can have damage. And I try to see the mechanism and I found they accomplished
by hammer ing with standing three persons. These three persons are;
One person to hammer Second person to hold the drum and the other one to remove the drum by
his hands. And sometimes they will extract the brake drum in this company was manual by using
curved metal and two persons are required which makes the process hard and time taking. Since
they do not have any type of drum extractor, I found this as a problem of the company and I
summarized them below;
 Time killing: to remove or to pull the drum brake it takes long time to accomplished
 Safety problem: when those three persons stand to remove the drum brake they use
hammer and the probability to be out of target is so high, so the persons and the
equipment’s were in danger.
 Accuracy: the accuracy is low.
 And also, they use hummer to remove the drum, so it needs high man power and the
drum can be damaged because of the applying force through the hammer
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figure3. 1 removing brake drum by using curved metal
figure3. 2 removed brake drum
Decrease time consumption of workers so benefit to the company. Almost every day there is
the problem of maintenance wheel and brake lining which is caused by smoothness of drum in
order to change the drum or brake lining you must dismount the drum or brake lining. So the
project discusses on the hydraulic brake drum lifter which operates mechanically and
hydraulically.
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ENGINEERING
Why we remove or replace Drums?
Here we have several good conditions:

 Thin drums are dangerous drums, if not replaced; the drum can wear to the point
where it may literally disintegrate. In addition, if the drum fails, so do the brakes.
 Reduced braking efficiency: The increased inside diameter of a badly worn drum
won’t match up with a new set of lining unless the linings are arced (and nobody
does that anymore). Consequently, the lining only makes contact in the middle, which
reduces its effective braking ability.
 Increased pedal travel: Wear increases the distance between the shoes and the drum. If
the drum is worn excessively, the self-adjuster mechanisms may not be able to take
up all the slack resulting in a low pedal. There is also the chance that the wheel
cylinder may overextend to the point where it leaks or comes apart, causing brake
failure.
 Brake fade: Thin drums cannot absorb and dissipate as much heat as thick ones.
There is less mass in a worn drum so the brakes may overheat and fade much sooner.
 Noise: Thin drums can contribute to noise by failing the dampen vibrations.
 Drums should also be inspected for the following conditions;
 Cracked drums should not be reused, because they weaken the metal and increase the
risk of breakage.
 Broken or damaged wheel studs replace as needed.
 Hard spots or glazed spots in the drum are caused by excessive heat that brings about
metallurgical changes in the metal
3.5 Literature review
 OTC 6980 heavy-duty brake drum and rotor puller amazon.com is the essential
solution for removing frozen, rusted, or seized drums and rotors found on 1-ton
pickups, school buses, and larger vehicles .it has a usable spread of 17.5 inches. it
comes with two forcing screws for standard and brake drums. both screws are specially
treated for smooth operation. the integrated striking cap on each screw can help pop the
rotor or drum loose. an improved design simplifies the puller leg positioning on the
crossbar and the legs have a mild radius to the attach point on the drum or
rotor.Include8-foot ratchet strap to secure puller legs to the drum or rotor covered by
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OTC’s lifetime warranty [1]
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ENGINEERING
 OEMTOOLS BRAKE DRUM AND ROTOR PULLER-AUTOZONE

The OEMTOOLS BRAKE DRUM AND ROTOR PULLER are designed to remove
hubs, drums, and brake rotors. This puller is designed for one-man use, one person can
easily set the tool in place and use it for tough pulls where there is limited space to insert
the jaws.
Weighing less than 10 tons, this tool is outfitted with a forged steel frame rated to 7 tons
of pulling force for the toughest jobs. Jaws spread is up to 12-3/4’
3.6 The objective of The Project

3.6.1 General objective:
Design of brake drum lifter
3.6.2 Specific objective:

 To design different parts of the machine
 To estimate the cost of the machine
 To model detailed part drawing in Solid Works
3.7 Scope of the Study
The scope of the project is mainly concerned with doing the design analysis of the different parts
of the brake drum extractor. In addition, I prepared the part drawing of each component, and
the assembly drawing of the machine; I was also ready to prepare all analyses of the project by
referring to my design textbooks. I did not prepare the manufacturing process because the
company does not provide us with the material needed and shortage of time.
3.8 Significance of the study
This project has great significance in different areas for different people directly and indirectly.
Some of them are listed below:
 Time: This project will reduce the time lost due to the car being late for maintaining the
brake system of cars or time for extracting t h e drum
 Secondly, the company will be profitable due to the cars using their time properly.
 Reducing the loss of energy saves lost power for pulling the drum. it reduces injury when
they extract the drum
3.9 Methodology
When we design a brake drum lifter the following methods should be followed:
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ENGINEERING
 The first task is that observe the different problems in the company
 Then select a problem, which is fundamental to the company
 After that make a literature review of the problem
 Then collect data for the project from a different source
 Besides, identify the possible mechanisms
 Then select the proper material for each part
 Done each part design calculation
 After that design each part of the machine and make sure that the design is safe
 Next to this, draw a detailed drawing for each part and the assembly drawing
Table 3. 1weekly plan activity

Activity WEEK
1st 2nd 3rd 4th 5th 6th 7th 8th

Observation   
Identify the   
Problem
Data collection   
Identify possible  
mechanism
Mathematical   
modeling
Detail drawing with   
assembly drawing
3.10 Part Design

CONSIDERATIONS
• Load ( 𝑊) =0.06 ton(0.60kN)
• break drum dia = 353mm
• Lift range (𝑙) = 30cm
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• Man effort put on the handle (𝑒) = 1Kg

• The permissible tensile stress of steel alloy (𝜎𝑡 ) = 120 N/𝑚𝑚2
• No. of strokes for lifting load (𝑁) = 20
• The factor of safety (𝑛) = 2
• Permissible shear stress of steel alloy (𝜏) =20 N/𝑚𝑚2
• The permissible compressive stress of steel alloy (𝜎𝑐 )=120 N/𝑚𝑚2
• The permissible compressive stress of cast iron (𝜎𝑐𝑖)= 120 N/𝑚𝑚2
• Permissible shear stress of cast iron (𝜏𝑐𝑖) = 35 N/𝑚𝑚2
To find out the operating pressure we will calculate from the measured value of the brake drum
diameter and the load or Wight of the brake drum
𝐹
𝑃=
𝐴
F = W=Mg = 0.6Kn×9.81𝑚⁄𝑠 2=5.886kg

353𝑚𝑚 2=
𝐴 = 𝜋𝑟2 = 3.14×( ) 554.21mm2
2
Therefore, the operating pressure will be P=

5.886 𝑘𝑔 =60kpa
554.21𝑚𝑚2
3.10.1 Design of Ram Cylinder

It is a cylinder that produces a slideway to the ram. The ram cylinder is made up of cast iron
with a density of 7300 kg/𝑚3 . It is mounted on the base plate. The function of a cylinder is
to retain the working fluid and to guide the piston. The cylinders are usually made of cast iron
or cast steel.
Let, 𝑑𝑟 = inner diameter of ram cylinder =90mm
𝐷𝑟 = outer diameter of ram cylinder
𝑃 = pressure acting on cylinder =60 𝑘𝑃𝑎
𝑊 = load =0.60kN
𝑡 = thickness of ram cylinder
Length of the cylinder, L = 1.15 × Length of stroke
= 1.15×20cm= 23cm
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The thickness of the cylinder wall (t) may also be obtained from the
following empirical relation, i.e.
𝑡= 0.045𝑑𝑟+1.6mm
= 0.045×90mm+1.6mm
=5.65mm~6mm
By using thickness and inside diameter, I can calculate the outer diameter of the ram cylinder
𝐷𝑟 =𝑑𝑟 + 2𝑡
= 90+2(6)
= 102 mm
Checking for compressive strength
𝜎𝑐 = 𝑝/𝐴
𝜎𝑐 = 600/6361.72
𝜎𝑐 = 0.0943N/𝑚𝑚2
Checking for shear strength
𝜏 = 4𝑝/𝜋𝑑2
𝜏 = 4 ∗ 600/𝜋 ∗ 902
𝜏 =0.0943 N/𝑚𝑚2
The induced shear and compressive stresses are less than the permissible value. Hence the
design is safe.
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ENGINEERING
figure3. 3 ram cylinder
3.10.2 Design of Plunger Cylinder and Plunger

The plunger cylinder is made up of cast iron and it is mounted on the base plate. It provides a
slide way to the plunger to build up the pressure.
Let
𝑑𝑝= inside dia of plunger cylinder= 20 mm
𝐷𝑝= outside dia of plunger cylinder
𝑡𝑝 = thickness of plunger cylinder
Assume the thickness of plunger cylinder (𝑡𝑝)= 5 mm
the length of plunger cylinder (l) =100mm
Load acting on plunger (p) = 2kg
Tensile strength of cast iron (𝜎𝑡 ) = 120 N/𝑚𝑚2
𝜎𝑡 = 𝑝/𝐴
𝜎𝑡 = 19.62/706.85
𝜎𝑡 = 0.0277N/𝑚𝑚2
Hence the induced tensile strength of cast iron is less than the permissible value. So, the
design is safe.
By using thickness and inside diameter, I can calculate the outer diameter of the plunger cylinder
𝐷𝑝 =𝑑𝑝 + 2𝑡
= 20+2(5)
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ENGINEERING
= 30 mm
Outer diameter of plunger cylinder (𝐷𝑝) = 30 mm
figure3. 4 plunger cylinder
3.10.3 Design of Plunger

Let the plunger is made up of cast iron which reciprocates in the plunger cylinder to increase
the pressure of the oil.
Let, 𝑊 = load acting on the plunger
𝑑𝑝= diameter of the plunger
𝑃 = pressure developed in plunger cylinder
from above inside diameter of the plunger cylinder is fixed i.e. 20 mm which is equal to 𝑑𝑝
Load acting on plunger = pressure × area
= 60kpa×0.000314𝑚2
= 18.84 Ν
= 1.92 kg
I take Load acting on the plunger =2kg
Assume plunger displacement = 11.5 cm
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ENGINEERING
figure3. 5 plunger
3.10.4 Design of Lever

A lever is made up of steel alloy and is used to apply load on the plunger. It is attached to the
plunger with the help of a pivot.
Assumptions,
1. The effort put on the lever by man = 1 kg
2. Load acting on plunger = 2
kg Velocity ratio of lever = 3
required distance from fulcrum to load = 11.5
cm Total length of lever = 3× 11.5
= 34.5 cm.
I take the length of the lever = 35 cm
Permissible tensile strength of steel alloy (𝜎𝑡 ) = 120 N/𝑚𝑚2
Where
𝑀 = maximum bending moment
𝐼 = moment of inertia
𝜎𝑡 = permissible tensile strength
𝑌 = distance between outermost layer to neutral layer
𝑍 = section modulus
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Calculation of bending moment:-

𝑅𝑎+ 𝑅𝑏 = 2 kg
𝑅𝑎 + 1kg = 2kg
𝑅𝑎 =2kg-1kg
𝑅𝑎 = 1kg
Bending moment at C = 0
Bending moment at B = 1× 9.81× 0.235 = 2.305 N-m
Bending moment at A = (1× 9.81× 0.35) – (2× 9.81× 0.115) = 1.17 N-m
From the above calculation
Maximum bending moment = 2.3N-m
Where 𝑑𝑙 = diameter of lever
= 0.0219 m
= 21.9 mm
I adopt the diameter of the lever = 25 mm
figure3. 6 lever
3.10.5 Design of Reservoir

The volume of oil circulating in the system is 835c.c
But, I take the volume of oil is 33% greater than the volume circulated in the system. Volume
of oil in the reservoir = 835+33% × 835
= 1110c.c
Where
𝐷𝑟 = outer dia of ram cylinder

𝐿 = height = 120 mm
66
ENGINEERING
Width = 20mm
I adopt inner dia of reservoir (𝑑𝑟) = 122mm Assuming
thickness of reservoir (𝑡𝑟) = 4mm
Therefore outer dia of the reservoir (𝐷𝑟) =𝑑𝑟+2×𝑡𝑟
= 122+(2×4)
= 130mm
figure3. 7 reservoir
3.10.6 Design of base

Fix the dimensions of the base plate as
𝑙 × 𝑏 × 𝑡 = 200×150×25
Where 𝑙 = length of the base
𝑏 =width of the base
𝑡 =thickness of the base
The base is made up of cast iron.
Permissible compressive stress of steel alloy (𝜎𝑐 ) = 20 N/𝑚𝑚2
Compressive area of base =200×150
= 30000𝑚𝑚2
Permissible shear stress of cast iron (𝜏) = 35 N/𝑚𝑚2
Shearing area = π × 𝑑 × 𝑡
= π × 90× 25
=7068.58𝑚𝑚2
Where 𝑑 = inner dia of ram cylinder

𝑡 =thickness of the base plate
67
ENGINEERING
Load acting on base = load off all parts that are on base
=13.72+0.52+0.26+0.1348+2.1+0.23+0.04+1.15+35.77+7.89+60=121.81 Kg=1195N
Checking for compressive strength
𝜎𝑐 = 𝑝/𝐴
𝜎𝑐 = 1195N/30000
𝜎𝑐 = 0.039N/𝑚𝑚2
Checking for shear
strength
𝜏 = 4𝑝/𝜋𝑑2
𝜏 = 4 ∗ 1195N/𝜋 ∗ 902
𝜏 =0.039 N/𝑚𝑚2
The induced shear and compressive stresses are less than the permissible value. Hence the
design is safe.
figure3. 8 base
3.10.7 Design of Bolt

Bolts are screwed joints that are used to connect two parts. In my case, this bolt is used to
connect the drum and iron ring. Screw fasteners induced two types of stress, these are;
1. Internal stress due screwing up force.
2. Stress due to force.
3. Stress due to the combination of stress (1) and (2)
68
ENGINEERING
Therefore, for the design of screw joint, both stress is considered.
69
ENGINEERING
Given parameter, w=bending force =0.6KN
There are three bolts, n=3
I know that, the upward force acting on iron ring P=0.60KN
Assumption; 𝜎𝑡 = 𝜎𝑐 = 150 𝑀𝑝𝑎
𝜎𝑠ℎ𝑒𝑎𝑟 = 120 𝑀𝑝𝑎, factor of safety fs =2 𝜎𝑛𝑢𝑡 = 160 𝑀𝑝𝑎
ℎ=height of bolt = 200 mm
The core and outer diameter of the threads.
𝑑𝑖 = 38mm, 𝑑𝑜 = 40 𝑚𝑚
Therefore, similarly the allowable stresses
150
𝜎𝑎𝑙𝑙 = = 37.5𝑀𝑝𝑎
4
160
𝜎𝑚𝑎𝑥 = = 40 𝑀𝑝𝑎
4
120
𝜎𝑚𝑖𝑛 = = 30 𝑀𝑝𝑎
4
figure3. 9 nut
3.10.8 Design of circular rod

The circular rod is part of a design to solve the problem of drums being taken from the car
wheel safely and with less labor force. There is no own formula but specifying its height and
diameter.
70
ENGINEERING
Height of circular rod 200mm
Diameter of circular rod 50mm
Area of the circular rod 𝐴 = 𝜋𝑟2
= 3.14*0.32
= 0.283𝑚2
figure3. 10 circular rod
3.10.9 Design of Iron plate

The iron plate is the base of the design which carries a hydraulic jack, circular rod, and
drum holding ring attached by a welding machine. The iron plate is rectangular in shape
materials which made from cast iron because of all the load drops on the surface of the iron plate
so, it will be strong and resist impact load.
Iron plate width (𝑤) = 500mm
Iron plate length (𝑙) = 700mm
Iron plate thickness (𝑡) = 20mm
Area of the iron plate 𝐴 = 𝑤 ∗ 𝑙 ∗ 𝑡
= 0.5m*0.7m*0.02m
= 0.007𝑚2
71
ENGINEERING
figure3. 11 iron plate
3.10.10 Design of the iron ring

The iron ring is used to hold the drum taken from the wheel of the car which achieves by
using three bolts on the surface of the ring.
Iron ring diameter 400mm
Iron ring thickness 100mm
Iron ring surface length 800mm
figure3. 12 iron ring
3.10.11 Selection of Bearing and Screw

Bearing is a machine element that supports another moving machine element. It provides
relative motion between the contacting surfaces of the member. I select the roller contact
bearing because it has low starting friction than the sliding bearing. Sliding bearing starts
from rest with practically metal-to-metal contact and has a high coefficient of friction.
72
ENGINEERING
figure3. 13 bearing
Select the screw that has a 30mm diameter, now
The bore diameter must be 30mm.
I select bearing number (206), having
Bore diameter=30mm
Outside diameter=62mm
Width=16mm
3.10.12 Design of parallel fillet welded joints

The parallel fillet welded joints are designed for shear strength. Consider a double parallel fillet
welded joint as shown in the Figure below:
figure3. 14 parallel fillet welded joints
73
ENGINEERING
If (τ) is the allowable shear stress for the weld metal,
Let s=10mm
Throat thickness t =s*sin45
=0.707*10mm
=7.07mm
The shear strength of the joint for a single parallel fillet weld,
P = throat area × allowable shear stress = 0.707 s × l × τ
Shear strength of the joint for double parallel fillet weld,
P = 2 × 0.707 × s × l × τ = 1.414 s × l × τ
I find the length of weld from double parallel fillet weld P
= 1.414 s × l × τ
60*103𝑁 = 1.414*10mm*𝒍*35 N/𝑚𝑚2
𝒍= 121.2𝒎𝒎
The minimum area of weld or the throat area,
A = 0.707 s × l= 0.707*10*121.2 = 856.88𝑚𝑚2
3.11 Cost Estimation

Cost analysis is a rough estimation of the cost of the machine. It includes the Cost of labor
participation in the design, Material cost, Machine cost, Power cost, and manufacturing cost. To
know the total cost of the machine, I should sum up all costs which are listed above.
Labor cost encompassed the cost of the person who has to participate in sheet metal
bending manufacturing starting from the design up to the end of the manufacturing
process.
A Engineer: Designer and quality control. pay 200 birrs per day.
B, Laborer: Each pays 65 birr per day. The manufacturing process takes 3 days, so the labor
cost can be obtained by =3 laborer * 65 birr per laborer * 3 days =585 birr
74
ENGINEERING
Total labor cost = 600 birr + 585 birr =1185 birr

The machine cost It is a cost pay for the machine if they are rented per hour. Machining
process including -thread making -drilling -cutting All these processes are made in the
company since the company has a lathe machine, milling machine, welding, and drilling
machine.
Material cost It is the cost of raw materials from which each component (packet) can be made
and other fasteners for the joining process.
Table 3. 2Cost analysis summary

Part Part name Material cost in birr Labor cost Machining and Total cost
no in birr power cost in birr
1 Ram cylinder 373.83
2 Plunger cylinder 14.06 and 7.19 Since the

and plunger company have
lath, milling,
3 Lever 1.55
1185 Drilling etc. 3074.44
machines so I
4 Reservoir 57.29
shouldn’t pay for
this process
5 Base 1193.46
6 Bolt 10.11
75
ENGINEERING
7 Circular rod 31.24
8 Iron plate 974.66
9 Iron ring 90.95
10 Bearing 320
Table 3. 3Result and Decision

Part name Results Decisions
Ram cylinder L 𝑡 𝐷𝑟 𝜏 𝜎𝑐 𝜏, 𝜎𝑐<20N/
23cm 6mm 102 mm 0.0943N 0.0943N 𝑚𝑚2 so, it is
/𝑚𝑚2 /𝑚𝑚2 safe.
Plunger 𝑡𝑝 𝜎𝑡 𝐷𝑝 𝑑𝑝 𝑊 𝜎𝑡 <120N/𝑚𝑚2
cylinder and 5 mm 0.0277 30 mm 20 mm 2 kg so, it is safe.
Plunger N/𝑚𝑚2
Lever 𝑣𝑟 L 𝑅𝑎 𝑀𝐵 𝑑𝑙
3 35 cm 1 kg 2.3 N-m 25 mm
Reservoir 𝑉𝑜 𝑑𝑟 𝑡𝑟 𝐷𝑟
1110c. 122mm 4mm 130mm
c
76
ENGINEERING
Base 𝑙×𝑏×𝑡 𝐴𝑐 𝐴𝑠ℎ 𝑊𝑏 𝜎𝑐 𝜏 𝜎𝑐 , 𝜏<20N/
200×150×25 30000 7068.58 0.039N 0.039 𝑚𝑚2
𝑚𝑚2 𝑚𝑚2 1195 /𝑚𝑚2 N/𝑚𝑚2 so, it is safe.
N
Bolt ℎ 𝜎𝑎 𝜎𝑚𝑎𝑥 𝜎𝑚𝑖𝑛 𝑑𝑐𝑖𝑛 𝑑𝑐𝑜𝑢𝑡
200 37.5 40 30 38mm 40mm
mm 𝑀𝑝𝑎 𝑀𝑝𝑎 𝑀𝑝𝑎
Circular rod H D 𝐴
200mm 50mm 0.283𝑚2
Iron plate 𝑤 𝑙 𝑡 𝐴
500mm 700mm 20mm 0.007𝑚2
Iron ring D 𝑡 L
400mm 100mm 800mm
parallel fillet S 𝑡 𝒍 A
welded joints
10mm 7.07mm 121.2 856.88
𝒎𝒎 𝑚𝑚2
Bearing Do Di W
62mm 30mm 16mm
3.12 Material selection
During the design process, the most challenging point is to select the appropriate material
for the specified component of the machine so to minimize these challenges during the
selection time consider the following points
 Considering the cost of the material

 Considering the machinability of the material
 Considering the availability of the material
 Its corrosion resistivity
Mechanical properties of the material such as strength, hardness, elasticity, malleability, ductility,
and so on. for the parts which will be subjected to comparison load the material that I have been
77
ENGINEERING
selected is cast iron because it has high strength for compression load and for handles which Small
torque is applied the material is steel.
Table 3. 4material selection
Part name Material Density of materials

Ram cylinder Cast iron 7300kg/𝑚3
Plunger cylinder Cast iron 7300kg/𝑚3
plunger Cast iron 7300kg/𝑚3
Lever Steel alloy 7850kg/𝑚3
Reservoir Cast iron 7300kg/𝑚3
Base Cast iron 7300kg/𝑚3
Bolt and Nut Steel alloy, bronze respectively 7850kg/𝑚3

Circular rod Cast iron 7300kg/𝑚3
Iron plate Cast iron 7300kg/𝑚3
Iron ring Steel alloy 7850kg/𝑚3
Bearing Steel alloy 7850kg/𝑚3
3.13 Working principle

The brake drum lifter i s mechanically operated and works when the person applies small
force to a machine it moves on land by its four wheels or bearing attached to the base. After
pushing of brake drum lifter to the specified place we must pump the plunger cylinder by using
a lever up to the height of the drum brake of the car. Then we insert the brake drum into the iron
ring, iron ring holds the drum by using the three nuts on the surface of it. Then the person
pulls the machine to its specified area and services the car.
Generally
• First, fill the oil into reservoir with a filler
78
ENGINEERING
• Push the machine to the car that needs wheel service
• Pump the oil into the plunger cylinder by using the lever up to the height of the brake
drum of the car
• Insert the brake drum of the car into the iron ring
• Tight the iron ring using the bolt-on brake drum of the car
• Pull the machine to the specified position
• After finishing of wheel service again push the machine to the car
• Finally, install t h e brake drum of the car
79
ENGINEERING
12
figure3. 15 assemble drawing of brake drum lifter
Part no part name
1. Ram cylinder 7. Nut

2. Plunger cylinder 8. Circular rod
3. Plunger 9. Iron plate
4. Lever 10. Iron ring
5. Reservoir 11. handler
6. Base 12. Bearing/wheel
68
Chapter Four
4. Overall Benefits Gained During the Internship Program
4.1. Practical and Interpersonal
During those three months of the internship program, I was able to bridge the gap between
student life and professional life. This internship program provided me with a platform to
introduce myself in a professional field.
In overall within three months I had the opportunity to improve my practical skills, theoretical
knowledge, my interpersonal communication skill, team playing skill, leadership skill, etc. I also
had the opportunity to understand work ethics and gain great knowledge of entrepreneurship
skills. On the next page, I will try to describe what I have learned in the different aspects that I
have mentioned before.
4.1.1 Theoretical Knowledge

The internship had many benefits in this regard because as I all know my knowledge is
mainly based on theory thus it was necessary by any means to change or interpret the theoretical
knowledge i n to a practical one.
The internship was very helpful in upgrading my theoretical knowledge As an example, in

theory, I have learned that seals are used to protect fluids from leaking or I use different kinds
of lubricants for different parts or about the details of the braking system, but in practice, I
install the seals or I change the lubricants which are the greases or the oils or I carefully check
and make different amendments for the braking systems including disassembling the springs,
the brake shoe/ganacha, the wires which go straight to the sensors in the cab which does the
purpose of sensing whether the friction material is worn out or not.
Let’s again take for example the differential. Theoretically, I have learned about the differential
to be the most important and the most affecting component of the vehicles and it does the
function of giving different rotational speeds to the half shafts provided that the torque on both
shafts is the same and at the end, it facilitates for the effective turning of the wheels. In practice,
what I first did was to prove whether the theories are applied to the vehicles. During practice, I
have performed on every single component of the differential which are, the crown gear, the
pinion gear, the spacers, the four identical bevel gears, etc.
69
JIMMA UNIVERSITY DEPARTMENT OF MECHANICAL ENGINEERING
Additionally, the internship also helped me in how I can relate my knowledge to the
working environment and I think that this is very important for my future in that I won’t be
new to a working environment.
4.1.2 Practical Skill

By working in a such big company I have improved my practical skill in many sectors of work
in the ERA company.
Some of the practical skills I have improved in the internship program are; -
 Understanding of setting out work for car maintenance

 Preparation and evaluation of weekly schedule.
 The internship has increased my knowledge of trucks and manpower
management which is a crucial thing in maintenance work.
figure4. 1 Team Work on the Motor
4.1.3 Leadership Skills

During the three months at the Ethiopian Roads Authority, I have developed my leadership
skills. Achieving leadership skills requires a high-level commitment to learning from each
experience I face. I have observed that a good leader is a well principal individual who is
focused on a common goal and eliminates excess fear and doubt from his employees and works
for the common good all.
During these times I have been able to observe that one should have great skills to be a leader
these are;
70
 Communicate effectively
 Take ownership and responsibility
 Great listener
 Encourage others through positivity
 Good management skill
 Commitment, integrity, and passionate
4.1.4 Work Ethics- Related Issues

The ethics of work is the most important thing in harmonizing the work atmosphere. It is this
work ethic that keeps the workers/employees in their peaceful daily routine at the workplace.
Possessing a good work ethic encompassing honesty, self-motivation, initiative and a positive
attitude will serve you well in all aspects of your life. In addition to the above work ethic points,
I can think of some common work ethics which include respecting one another, being punctual,
showing good hospitality to all the customers and also keeping and using the company’s
resources wisely and properly and of course lots of other values. High-quality core values based
on the moral virtues of hard work and perseverance are intrinsic to determining your value to an
employer and your self-image. Being productive and working hard is evidence of an individual’s
high standards and principles, displaying the level of integrity in his/her character. Practicing a
good work ethic is an ongoing character-building trait.
Possessing a good work ethic means not being a clock watcher, doing whatever it takes to
accomplish a goal, and taking pride in one’s activity and achievements. Persons with a good
work ethic compete only with themselves and continually strive to do better. There are many
advantages to having a deep commitment to personal responsibility. Among those advantages.
 Opportunities for advancement

 Enhancing professional image
 Being viewed as an asset
 Serving economic turndowns
 Future career potential
71
4.1.5 Entrepreneurship Skills

Application of energy and passion toward the creation and implementation of new ideas and
creative solutions. Essential in gradients includes the willingness to take calculated risks in terms
of time, equity, or career, the ability to formulate an effective venture team; the creative skill of
building a solid business plan; and finally the vision to recognize opportunity where others see
chaos, contradiction, and confusion.
During my internship experience, I developed the five levels of entrepreneurial development.
 The self-employed mindset
 The managerial perspective
 The attitude of the owner (leader)
 The entrepreneurial investor
 The true entrepreneur
And also I have developed characteristics that are found in all successful entrepreneurs.
These are
-Confident -Gregarious
-Team player -A Leader by example
-System-oriented - Dedicated
- Not afraid of risk -Feels a sense of ownership
-Able to communicate -Passionate about learning
-Grateful -Optimistic
72
Chapter five
5 Conclusion and Recommendation
5.1 Conclusion
During my stay at ERA, I have gained an understanding of how to interpret and apply my
theoretical knowledge in practical situations. I also understand that it is difficult to directly apply
my theoretical knowledge to practical problems in industries or projects like this one because it
needs some experience to apply theoretical knowledge to practical problems, and from the intern
program I can tell that I got some of these experiences. I am sure that I will have more
confidence working as an employee in factories after graduation.
 An internship is a position that allows a student to gain professional experience in an
occupational area they are considering. Typically, the experience has a level of
responsibility that allows a student to develop new skills in the field and offers the
student training and supervision that facilitates learning.
 Operating on an existing manual liner extractor was challenged. Because it takes much
time and human power. Therefore, I do this project to eliminate those problems.
 At last not list I can conclude that my four months of stay in ERA were very fruitful and
beneficial to my future carrier .and also the project I designed going to help for solving
problems during replacing drums and brake shoes. That is by using the work tool I can
easily remove or replace the drum without any challenge or problem. The machine also
avoids loss of energy, time-consuming, noise, wearing materials, and so on. Especially, I
have designed it to minimize the problems that are challenging ERA in replacing the
drums and brake shoes.
73
5.2 Recommendation
 I recommend to interns that; ERA has different problems starting from the layout up to
the internal components of machines therefore it’s better to propose a solution or modify
the parts based on their field of study which the company accepts like metal, mechanical
engineering in order the company to be productive.
 I recommend the company that; one of how students may bridge their learning in the
classroom with professional practice is through student internship for the students to
propose a solution they need facilities like internet access, safety materials, and others
therefore the company should be responsible for all the facility requirement
 The company should allow a budget for the projects that the interns might do and assist
them in any way that they may need.
 Sometimes the preventive maintenance of machines does not properly do on time
because the employees did not consider the machine only their target is to accomplish
the work task in the given period.
 There are many cars which are not used by the company so they should remove from
the working area.
 The company should change the proposed projects into real parts.
 And the internship time was not that much enough to get the required thing so I will
recommend to my campus to give more time for the student. But I will understand that
the pandemic disease covid-19 has a great influence on the academic calendar.
74
Reference
[1] Beer, Ferdinand, P., “Mechanics of Materials”, Second Edition, McGraw-Hill, Inc.: Santa
Fe, NM 1992.
[2] Design dimension of screw threads, bolts, and nuts according to IS41 (part iii 1997 table 11.1)
[3] from Engineering material.
[4] Mechanical Engineering Shigley’s Mechanical Engineering Design, Eighth Edition Text: by
Budynas−Nisbett.
[5] R.S. Khurmi, J.K. Gupta, a textbook of machine design, 2002, 13th edition & fifth edition.
75
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INTERNSHIP REPORT ETHIOPIAN ROADS AUTHORITY (ERA)

HARAMAYA INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

HOSTING COMPANY: ETHIOPIAN ROAD AUTHORITY

INTERNSHIP DURATION: THREE MONTHS

DEPARTMENT OF MECHANICAL ENGINEERING

Name of student ID Signature Date

Dawit Mesfin 0546/10

Name of advisor Signature Date

n Number of threads in engagement,

D Outside or major diameter

dr the inner diameter of the ram cylinder

Dr the outer diameter of the ram cylinder

P the pressure acting on the cylinder

t the thickness of the ram cylinder

dp inside dia of plunger cylinder Dp

Dp outside dia of plunger cylinder

tp thickness of plunger cylinder

σt permissible tensile strength

1.1 Brief History of Road Building in Ethiopia...................................................................................1

2.4.6 Engine Assembling Order...............................................................................................27

3.12 Material selection.......................................................................................................................65

figure2. 1 gear box.................................................................................................................................18

figure3. 1 removing brake drum by using curved metal........................................................................46

figure4. 1 Team Work on the Motor......................................................................................................70

1.1.1. Organizational Background of ERA

A) First highway program (1951-1957)

B) Second Highway Program (1957-1966)

C) Third Highway Program (1965-1968)

D) Fourth Highway Program (1968-1973)

E) Fifth Highway Program (1974-1976)

According to proclamation No 133/1978, the reestablished Ethiopian Roads Authority included

1.2 Services provision of the company

1.4 Institutional Set-up

 Asphalt road construction

1.5 Vision of ECWC

1.6 Mission of ECWC

 To engage in domestic and overseas construction works as a contractor in constructing,

1.8 Equipment and Technology Capacity

1.9 Main Objective of ECWC

 Making strong bond of corporation, customers, and end users

1.10 Main Customer of the Services

1.11 End Users of the Services

1.12 Organizational Structure and Arrangement of ERA

Chart 1.1. Organizational Structure and Arrangement of ERA

The corporation has ten divisions to fulfill the goals

 Road Construction Division

Corporate Planning and Business Development Department Main functions:

o Annual operational management

Road Construction Division Main functions:

o Enabling the Ethiopian Road Construction Corporation’s Road construction projects

Equipment Management and Maintenance Department Main function:

Purchase and Supply Department Main function:

o Conducting single and collective purchases and distribution of purchased items

Finance Management Department Main functions:

Human Resource Management Department Main functions:

o Planning and implementing the corporation’s human resource requirements and

ICT and Organizational Development Department Main functions:

o Implementing and regulating new changes to the corporation

Internal Auditing Services Department Main functions: