INTRODUCTION
This report is a comprehensive summary of my industrial attachment at Royal Eswatini Sugar
Corporation (Mhlume fleet workshop). It outlines the activities, experiences and skills acquired
during my three-month internship, conducted from 02 June to 02 September 2025. The
internship was an integral part of my academic and professional development, aimed at
bridging the gap between theoretical knowledge and practical application in the field of
automotive engineering vehicles and machines maintenance and repair.
The main objectives of the industrial attachment were:
To achieve professional experience
To enrich my knowledge, skills and exposure
To understand the operation of a workshop
To develop inter-department communication
The scope of training covered a variety of tasks within the RES Corporation automotive
workshop, including routine servicing, fault diagnosis, component replacement, and
participation in team-based repair operations. The internship also involved professional
conduct, and standard safety and risk mitigation practices expected in a technical setting.
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COMPANY PROFILE
ROYAL ESWATINI SUGAR CORPORATION
Location
The Royal Eswatini Sugar Corporation limited is located in the north-eastern lowveld of the
Kingdom of Eswatini, in the Lubombo region
Physical address
RES Main Administration Building
King’s Road, off MR3 Road
Simunye in Eswatini
Contact information
RES Corporation
P.O. Box 1 Simunye L301
Phone: +268 2313 4000
Email: info@[Link]
Brief history
The Royal Eswatini Sugar Corporation was founded from two different companies which are;
Mhlume Sugar Company of 1958 and Simunye Sugar Mill of 1980. This two companies
merged together to form Royal Swaziland Sugar Corporation in 2002. In 2020, the company
changed its name to Royal Eswatini Sugar Corporation due to the the country’s official
renaming from Swaziland to Eswatini. The company was established as a joint venture between
the Government of Eswatini and private investors to develop Eswatini’s sugar industry and
support national economic growth.
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Mhlume Fleet Workshop Organizational Structure
Fleet Workshop manager
Haulage Forman Tractors Forman Vehicle Section Forman
Artisans Artisans Artisans
Qualified Handyman Qualified Handyman Qualified Handyman
Artisan assistants, Artisan assistants, Artisan assistants,
Apprentices and Interns Apprentices and Interns Apprentices and Interns
RES Corporation, Mhlume Fleet workshop core business and activities
The workshop maintains a robust fleet of agricultural and industrial vehicles, which requires:
Diagnostics & Repairs: On-site servicing of tractors, harvesters, and heavy-duty
vehicles.
Parts Sourcing & Inventory: Managing a supply chain for OEM and aftermarket
components.
Preventive Maintenance Programs: Ensuring uptime and safety across all mobile
assets.
Workshop Operations: Equipped garages for hydraulic, clutch, brake, PTO, and drive
system repairs—especially relevant to your internship experience.
Technical Training & Internships: Supporting engineering students and technicians in
hands-on automotive diagnostics and system design.
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ACTIVITIES CARRIED OUT
Daily activities
Begin everyday by cleaning and putting tools in place
Ensure proper demarcation of tasks and equipment in the workshop
Begin each and every week with prayer
Every Tuesday hold a meeting pertaining safety and wellness
Major tasks completed
TASK 1: Fuel injection timing (injector pump spill timing)
Date: 25 June 2025
Situation: After fitting New Holland TD5.110 injector pump which was from service, engine
crank but does not fires and run yet excellent fuel pressure supply is observed at all four fuel
injector delivery pipes
Possible causes
Injector pump delivers fuel too early or too late
Faulty or poor electric connection on shut off solenoid
Safety precautions
Disconnect the battery
Ensure the engine is cool
Clean the area around the pump to avoid contamination
Procedure followed
Removal
Remove valve cover
Rotate the crankshaft setting engine cylinder number one to TDC, end of compression
stroke (crankshaft pulley mark will align with the engine front cover mark and both
intake and exhaust valves on cylinder number one will be fully closed)
Reinstall the valve cover
Remove fuel lines and disconnect throttle linkages and wiring
Remove the fan belt and its tensioner
Remove front pump cover and loosen the nut assembling the pump with the timing gear
Unbolt the 3 bolts mounting the pump and carefully slide the pump out
Timing
Hold pump with vice and remove shut off solenoid
Pour diesel on shut off solenoid port and rotate pump to squirt diesel
When it squirts at cylinder number one delivery point, retard the pump, remove washer
and tighten the lock-bolt to lock pump
Reinstall the shut off solenoid
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Reinstallation
Note: The number 4 mark on the injector pump gear must be between the two 4 (4,4) markings
on the idle gear
Slide the pump aligning the gear and shaft into position
Torque load the shaft nut and the 3 mounting bolts evenly
Close the pump front cover
Reconnect all fuel lines, wiring and linkages
Unlock pump, insert washer and tighten lock bolt
Bleed air out of the fuel system
Reinstall the fan belt and the tensioner
Post-installation checks
Connect battery and start engine to check for leaks
Observe engine idle, check if engine runs rough or smokes excessively and throttle
response (if not satisfying, retard or advance the injector pump through the provision
of slots on the pump housing to get better performance)
Tools used
Ring and open end spanner 10,13,15,17,19 and 22 mm
Socket 13 mm
T-bar and extension
Drain tin
Jerry Fuel can
Challenges faced and solutions
Challenge: Difficulty locating or aligning timing marks accurately, leading to
guesswork or delays.
Solution: Cleaned the area thoroughly and marked key points with chalk or marker for
visibility.
Challenge: doubt and Lack of confidence slows progress
Solution: Broke the task into a checklist and Communicated clearly with mentors/
artisans for the clear step by step procedure.
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Task 2: Hydraulic system diagnose
Date: 11 July 2025
Situation: New Holland TT75 implements lift arms does not lift yet a little bit of movement is
observed
Possible causes
Low or contaminated hydraulic oil
Clogged hydraulic filter
Faulty hydraulic pump
Internal damage within hydraulic cover
Relief valve malfunction
Safety precautions
Relieve system pressure before disconnecting any hydraulic lines
Shut off the engine and disconnect the battery before performing any maintenance and
hydraulic work
Procedure followed
Check hydraulic oil level
Connect a pressure gauge on the SCV’s couplers to check for hydraulic pressure
(obtained 1.7 MPa) and compare to repair manual (1.5 to 1.8 MPa)
Adjust the rate of drop by centralizing the relief valve switch
Check for any disturbance in the rock shaft mechanism
Remove hydraulic cover to check for any damage within the hydraulic cover
Findings
The connecting rod between the piston and lift arms is broken
Figure:01, shows the hydraulic system cover with the piston and the con-rod.
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Possible causes
Implement lifting system overload
Sudden shock loads and impact
Recommendation
Conduct implement lift test and compare with power produced by the machine
Tools used
Hydraulic pressure gauge
Ring and open spanner 24 and 17 mm
Socket 24 mm, extension and T-bar
Hydraulic engine hoist
Challenges faced and solutions
Challenge: Lack of a hydraulic pressure gauge with the perfect calibration range.
Solution: Borrowed one from SD General spares.
Challenge: The mushroomed hydraulic piston head jams inside the cylinder during
removal
Solution: Outsourced it to Manzana Engineering for proper removal
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COMPETENCY DEVELOPMENT
During my internship at RESC, I developed and refined several key competencies:
Diagnostics and Repair: Gained hands-on experience troubleshooting hydraulic lift
issues, clutch systems, adjustments and settings, system components replacements and
basic electrical systems
Preventive Maintenance: Applied structured routines for servicing heavy machinery,
aligning with safety protocols and manufacturer guidelines.
Teamwork and Communication: Collaborated with technicians and supervisors,
improving peer-to-peer technical instruction and learning to communicate clearly under
pressure.
Safety Awareness: Practiced risk mitigation strategies, including hazard identification
and reinforcing academic safety modules.
These competencies align with academic learning outcomes in mechanical systems analysis,
technical communication, and applied safety engineering.
PROBLEMS ANCOUTERED SOLUTIONS
Technical Challenges:
Hydraulic system complexity: Faced difficulty diagnosing intermittent lift failures.
Solved by referencing manuals, consulting senior technicians, and applying systematic
pressure testing.
Ignition timing issues: Encountered timing misalignment in older tractor models.
Resolved through careful observation and drive key orientation checks.
Workplace Challenges:
Resource limitations: At times, lacked access to specific tools or parts. Adapted by
improvising with available resources and learning alternative diagnostic methods.
Communication gaps: Initial difficulty understanding workshop jargon. Improved by
asking clarifying questions and documenting terms for later review.
LESSONS LEARNT
Technical Lessons:
Importance of root cause analysis over quick fixes.
Value of structured troubleshooting and proper tool use.
Work Ethics & Time Management:
Learned to prioritize tasks based on urgency and safety.
Developed discipline in maintaining daily logs and schedules.
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Teamwork & Industry Standards:
Understood the importance of clear communication and mutual respect in workshop
environments.
Gained insight into professional expectations, including punctuality, accountability, and
continuous learning.
RECOMMENDATIONS
To the Company:
Consider offering short induction sessions for interns on workshop terminology and
tool orientation.
Improve access to updated manuals and diagnostic tools for newer machinery.
To the Institution:
Increase pre-attachment practical exposure, especially in diagnostics and safety
procedures.
Encourage students to practice technical reporting before internships begin.
Update machines in the workshop to familiarize students with machines found in
companies.
To Future Students:
Arrive prepared with basic tool knowledge and safety awareness.
Keep a daily logbook and ask questions, curiosity leads to mastery.
Respect workshop culture and learn from every technician.
CONCLUSION
My internship at Royal Eswatini Sugar Corporation (Mhlume fleet workshop) was a
transformative experience that bridged academic theory with real-world practice. It
strengthened my technical confidence, deepened my understanding of mechanical systems, and
reinforced the importance of safety and communication in engineering environments. This
attachment has laid a solid foundation for my career in automotive engineering and has inspired
me to pursue further specialization in diagnostics and sustainable mechanical solutions.
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REFERENCES
RESC service charts
New Holland TD5 series repair manual (TD5.75, TD5.90, TD5.100, TD5.110)
New Holland 10 series repair manual (5610, 6610)
New Holland TT series (TT4.90, TT55, TT65, TT75)
Bell 1734 tractor repair manual
APPENDICES
The industrial attachment, supervisor’s confidential report
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