Supervised indutrial training report.pdf

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Industrial Training Report
Name : Muhammad Saqlain
Class Roll No : 19AU017
Industrial Training Course : Supervised Industrial Training
Training Period : 16 weeks
Training Organization : Pakistan Railway

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Abstract
The internships in companies are an important part of the students schooling at
graduate level. Students have to do internships in the company of their choice at the
end of their final year in order to get experience in a professional context. For the last
four months I have done my final year internship in PAKISTAN RAILWAY.
During my training I cover 10 departments/shops of Pakistan railway (Diesel
classified repair shop, E&DC shop, Tool shop, Rehabilitation shop, Power plant
shop, Foundry shop, Heat treatment shop, Roller bearing shop, Motor shop and
central laboratory).
During this period, I acquired knowledge on all tasks, how to repair, replace and
install mechanical parts and systems also assisted in providing the units the
functionality they need. I learned how to diagnose the faults in locomotive engines
and power vans. I also cover the foundry and heat treatment shops during this
training in which I learned detail knowledge of furnaces, their working and
processes.

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Acknowledgment
All the praise to Almighty Allah who bestowed me with the ability and potential
to complete this internship. Special thanks to the management and staff of all shops
of Pakistan railway for giving me a chance to engage in the practical aspects of my
course of study.
First and foremost, I want to thanks my supervisor Engr. Ahmad Neam, who helped
me in my work and my special thanks to all teachers and all staff of automotive
engineering & technology department for helping me and give me a lot of knowledge
of my field and teach me how to survive in the life.
I would also like to thank my families and friends for their help and support in this
work that always helped me and stood by me, and I have always appreciated it.

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Table of Contents
Abstract.................................................................................................................................... 2
Acknowledgment..................................................................................................................... 3
CH#1 Background of Training Organization............................................................................. 8
1.1 History & Background .................................................................................................... 8
1.2 Vision & Mission............................................................................................................. 9
1.3 Pakistan Railway Workshop Mughalpura, Lahore ......................................................... 9
1.4 Organogram ................................................................................................................. 13
CH#2 Schedule of Training & Duties, as Trainee.................................................................... 14
2.1 Training Schedule......................................................................................................... 14
2.2 Duties as a trainee ....................................................................................................... 14
Ch#3 Working Experience...................................................................................................... 23
Week 1 ............................................................................................................................... 23
Week 2 ............................................................................................................................... 23
Week 3 ............................................................................................................................... 24
Week 4 ............................................................................................................................... 24
Week 5 ............................................................................................................................... 24
Week 6 ............................................................................................................................... 25
Week 7 ............................................................................................................................... 25
Week 8 ............................................................................................................................... 25
Week 9 ............................................................................................................................... 26
Week 10 ............................................................................................................................. 26
Week 11 ............................................................................................................................. 26
Week 12 ............................................................................................................................. 27
Week 13 ............................................................................................................................. 27
Week 14 ............................................................................................................................. 27
Week 15 ............................................................................................................................. 28
Week 16 ............................................................................................................................. 28
Week 17 ............................................................................................................................. 28
Ch#4 Projects carried out....................................................................................................... 30
4.1 Projects ........................................................................................................................ 30
4.1.1 Installation the Auxiliary Drive on CAT C-175 Engine ........................................... 30
4.1.2 Replace piston and connecting rod....................................................................... 32
4.1.3 Making Gun metal by foundry process................................................................. 34

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4.1.4 Bushes heat treatment process............................................................................ 34
4.1.5 Replace wheel bearing.......................................................................................... 35
4.1.6 Engine overhauling................................................................................................ 37
4.2 Supervisory worker...................................................................................................... 38
4.3 Problem encountered & Problem solving process, approach ..................................... 39
4.4 Hand on skill acquired.................................................................................................. 41
4.5 How to improve productivity in an Organization ........................................................ 47
4.6 Quality management system in Pakistan railway........................................................ 48
4.7 Safety at work .............................................................................................................. 50
Ch#5 Conclusion..................................................................................................................... 52
5.1 Recommendation......................................................................................................... 52
CH#6 References.................................................................................................................... 53
Appendix ................................................................................................................................ 54

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Table of Figure
Figure 1 Pakistan railway......................................................................................................... 8
Figure 2 Locomotive workshop............................................................................................. 10
Figure 3 C&W workshop....................................................................................................... 11
Figure 4 Organogram ............................................................................................................. 13
Figure 5 Locomotive engine .................................................................................................. 15
Figure 6 E&DC shop ............................................................................................................. 16
Figure 7 Tool shop................................................................................................................. 17
Figure 8 Foundry shop........................................................................................................... 18
Figure 9 Rehabilitation shop.................................................................................................. 18
Figure 10 Power van.............................................................................................................. 19
Figure 11 Heat treatment furnace........................................................................................... 20
Figure 12 Roller bearing shop................................................................................................ 21
Figure 13 Motor shop............................................................................................................. 21
Figure 14 Engine details ........................................................................................................ 32
Figure 15 Removing damper.................................................................................................. 32
Figure 16 Pistons and connecting rods .................................................................................. 33
Figure 17 Furnase .................................................................................................................. 35
Figure 18 Quenching media................................................................................................... 35
Figure 19 Heating the bearing................................................................................................ 36
Figure 20 Removing bearing with hydraulic machine........................................................... 36
Figure 21 Hino bus engine..................................................................................................... 38
Figure 22 Completion letter................................................................................................... 54

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Table of Table
Table 1 Training schedule...................................................................................................... 14
Table 2 Locomotive inspection schedule............................................................................... 42

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CH#1 Background of Training Organization
1.1 History & Background
Pakistan Railways is the national, state-owned railway company of Pakistan.
Founded in 1861 and headquartered in Lahore, it owns 4,800 miles (7,791 km) of
track across Pakistan from Torkham to Karachi and operates freight and passenger
service. Pakistan Railways was also known as the Pakistan Western Railway from
1947 to 1974.
Pakistan Railways is the national state railway company of Pakistan in Lahore. In
Pakistan Railways, industrial training was conducted in 14 workshops to recognize,
define industrial problems and uncover their root causes by manipulating relevant
technical literature and analytical tools.
Figure 1 Pakistan railway

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1.2 Vision & Mission
In 2014 the Ministry of Railways launched Pakistan Railways Vision 2026,
which seeks to increase the company's share of the transportation sector from four to
20 percent with the ₨886.68 billion (US$8.4 billion) China–Pakistan Economic
Corridor rail upgrade. The plan includes new locomotives, development and
improvement of current rail infrastructure, an increase in average train speed,
improved on-time performance and expansion of passenger service. The first phase
of the project was completed in 2017, and the second phase is scheduled for
completion by 2021. Pakistan Railways is an active member of the International
Union of Railways.
1.3 Pakistan Railway Workshop Mughalpura, Lahore
Pakistan railway Mughalpura workshop was established in 1908. This workshop
have 192 acres area. In this area 27 acres are covered area and 165 acres are
uncovered area. Total numbers of employees in this workshop are 3726 (2893 skilled
staff, 587 semi-skilled staff & 246 unskilled staff). This workshop have major 3
workshops.
I. Locomotive shop
II. Carriage & Wagon shop
III. Center Laboratory
Mughalpura workshop have following departments:
I. Mechanical department
II. Electrical department
III. Store department
IV. Civil engineering department

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Locomotive Workshop
In locomotive workshop repair, rebuild and testing of locomotive engines and
manufacturing the some components of locomotive. In loco workshop have
following shops:
 Diesel classified repair shop
 Machine maintenance shop
 Engine block shop
 Foundry shop
 Rehabilitation shop
 E&DC shop
 Tool shop
 Black smith shop
Figure 2 Locomotive workshop
Carriage & wagon workshop

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In C&W workshop maintenance, repair and manufacturing the bogie of goods
and coaches. In C&W workshops have following shops:
 Power plant shop
 Motor shop
 Tool Shop
 Welding shop
 Roller bearing shop
 Wheel shop
 Spring shop
 Paint shop
 AC repairing shop
 Bogie shop
 Heat treatment shop
 Black smith shop
Figure 3 C&W workshop

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Central laboratory
In central laboratory testing the materials, paint, fuels, lubrication oil, grease
and water. In central laboratory have following sections:
 Steel section
 Paint section
 Oil section
 Water section
 Non-ferrous section
 Textile section

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1.4 Organogram
Figure 4 Organogram

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CH#2 Schedule of Training & Duties, as Trainee
2.1 Training Schedule
Table 1 Training schedule
SR# Name of Shops Period of Training
1 Diesel Classified Repair Shop Loco 27-3-2023 to 15-4-2023
2 E&DC Shop Loco Shop 16-4-2023 to 22-4-2023
3 Tool Shop Loco Shop 23-4-2023 to 1-5-2023
4 Diesel Rehabilitation Shop Loco 2-5-2023 to 15-5-2023
5 Foundry Shop Loco Shop 16-5-2023 to 25-5-2023
6 Power Plant Shop C&W Shop 26-5-2023 to 10-6-2023
7 Heat Treatment Shop C&W Shop 11-6-2023 to 18-6-2023
8 Roller Baring Shop C&W Shop 19-6-2023 to 29-6-2023
9 Motor Shop C&W Shop 30-6-2023 to 19-7-2023
10 Central Laboratory MGPR 20-7-2023 to 22-7-2023
2.2 Duties as a trainee
My responsibilities
 As a trainee, it is my duty to actively participate in workshop and actively
listen to trainers.
 My responsibility should be willing to actively participate in practical
training.
 It is my responsibility to carefully follow the instructions of trainers and
mentors.

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 My responsibility to maintain records, prepare reports and documents their
learning experiences during the workshops.
 I should display a professional demeanors and positive attitude during the
workshop.
Diesel Classified Repair Shop, Loco Shop, MGPR:
 Retain maintenance of diesel locomotive.
 Overhaul and repair of diesel engines.
 Troubleshooting and diagnosing mechanical and electrical problems.
 Replacement and repair of damaged parts.
 Cleaning and servicing of fuel systems.
 Testing and calibration of locomotive components.
 Providing technical support and advice to locomotive operators.
Figure 5 Locomotive engine
E&DC Shop, Loco Shop, MGPR:
 Repair and maintenance of electrical and diesel components of locomotive.
 Troubleshooting and repair the electrical faults in locomotive.
 Manufacture and repair of electrical control panels and circuits.

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 Test and calibration of electrical equipment’s.
 Inspection of defective electrical and diesel components.
Figure 6 E&DC shop
Tool Shop, Loco Shop, MGPR:
 Machine tools maintenance
 Tools testing
 Tools fabrication
 Tools surface testing
 Tools inventory management

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Figure 7 Tool shop
Foundry Shop, Loco Shop, MGPR:
 Casting and pressing of various metal components used in railway
equipment’s
 Melting and pouring metal in molds.
 Sand preparation and mold making.
 Cleaning and finishing of casting.
 Quality control and inspection of castings.
 Repairs and maintenance of foundry equipment’s. .
 Collaborate with design and engineering department for new casting
requirements.
 Management of stocks of raw materials and finished castings.
 Research and development for improved casting techniques.

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Figure 8 Foundry shop
Rehabilitation Shop Loco shop
 Locomotive engine inspection
 Locomotive engine rebuild projects
 Welding and Fabrication
 Quality Assurance
 Record keeping
 Paint and refinishing
Figure 9 Rehabilitation shop

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Power Plant Shop, C&W shop, MGPR
 Repair of power vans
 Power van engine maintenance
 Troubleshooting
 Electric load testing
 Voltage testing
Figure 10 Power van
Heat treatment Shop, C&W shop, MGPR
 Material surface changing
 Annealing
 Tempering
 Normalizing
 Hardening the surface

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Figure 11 Heat treatment furnace
Roller Bearing Shop, C&W shop, MGPR
 Inspection and evaluation of the condition of roller bearings used in railway
cars.
 Carrying out maintenance and repair of roller bearings to ensure proper
function.
 Removal of roller bearings for cleaning and inspection.
 Lubrication of roller bearings with suitable grease.
 Reassembly of roller bearings after maintenance or repair.
 Carrying out tests and measurements to ensure the accuracy and efficiency of
rolling bearings.
 Replacement of damaged or worn roller bearings.
 Maintaining proper documentation of maintenance and repair activities.

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Figure 12 Roller bearing shop
Motor Shop, C&W shop, MGPR
 Railway buses repairing
 Troubleshooting
 Body repairing
 Buses maintenance
 Store parts of buses
Figure 13 Motor shop

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Central Laboratory:
 Sample collection and testing
 Quality control analysis
 Chemical analysis
 Material testing
 Environmental monitoring

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Ch#3 Working Experience
Week 1
 I visited Apprentice College to get our schedule.
 I went to Diesel Classified shop and submitted our training letter. Get
Attendance from the clerk. Then I have a introduce with Foreman and
workers.
 I visited shop and charge man gave us brief introduction about the
components of shop.
 I went to duty point of Engine Overhaul shop and visited the Site.
 I stayed at duty point and checked the repairing work.
 Study about different torque value of body truck parts.
Week 2
 I went to shop and worker gave the information about the overhauled
components.
 I inspected various tool used in the workshop.
 I inspected the various components of engine.
 I worked with the workers and reassemble the engine parts.
 I checked that how turbocharger is installed in the engine.
 I helped workers in changing the main gas kit of diesel engine.

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Week 3
 I helped workers in changing the main gas kit of diesel engine.
 I listed the cylinder firing order and the working of rocker arm and camshaft.
 I inspected the nozzles and crank case under the supervision of foreman.
 I inspected the Water pump and air compressor and gained knowledge from
the foreman.
 He told us about the purpose of this workshop and the tools used in the
workshop.
 We compiled our attendance sheet by signing it from foreman and submitted
to clerk office in Diesel classified shop.
Week 4
 I went to E & DC shop and submitted my schedule. And foreman gave the
introduction about this shop.
 I understood that which machine is used in different shop sections. I checked
the different operation like facing, turning process.
 I inspected different wrokpiece prepared in the shop. In grinding section, I
observed different operations done on the grinding machine.
 I compiled my attendance sheet by signing it from foreman and submitted to
clerk office in E & DC shop.
Week 5
 I went to Tool shop and submitted my schedule. And foreman gave the
 I observed the different operations performed in the lathe machine operations.
 I observed the different operations performed in the fitting machine section.
clerk office.

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Week 6
 I went to Rehabilitation shop and submitted my schedule. And foreman gave
the introduction about this shop.
 Visual Inspection of crank shaft and balancing of crank shaft.
 Visual inspection of batteries and their rack in fuel tank.
 Visual study of accidental locomotive.
 Study of brake locomotive and their working procedure.
Week 7
 Visual inspection of engine and train body.
 Visual inspection of damage of bogie.
 Visual inspection of solving procedure.
 Study of locomotive beam and types used in advance locomotive.
 Visual study separating accidental locomotive and its rehabilitation.
 Visual study of basic operation of locomotive.
Week 8
clerk office in rehabilitation shop.
 I went to foundry shop and submitted my schedule. And foreman gave the
 Visual inspection of furnace and melting of iron.
 Visual inspection of furnaces used in this shop.
 I learned how to made sand mixture for casting.

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 I learned how to make brakes and door handle and AC vents from molten
metal.
Week 9
 Visual inspection of copper furnace and their material made.
 I studied melting temperature of different materials.
 I checked the hardness of material that made in this shop.
clerk office in Foundry shop.
 I went to Power plant shop and submitted my schedule. And foreman gave
 Inspection of Cummins generator used in power van.
Week 10
 I observed about the control system and circuit diagram of generator.
 Observe and inspect the control panel and their function.
 Study about the project workflow in power plant shop.
 I checked the voltage output of generator.
 I learnt about the dis assembling and overhauling of diesel generator.
 I learnt about the assembling of the diesel generator.
Week 11
 Inspection of coupler connection in power van.
 Learned the working principle of coupler.
 Inspection of wiring in power van.
 I learned the difference between Chinese and German power van.

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 I learned the safety factor of power plant shop.
clerk office in Power plant shop.
Week 12
 I went to Heat treatment shop and submitted my schedule. And foreman gave
 Inspection of different furnaces used in this shop.
 I learned about the shop projects workflow.
 Inspect the hardness of different materials.
 I learned the safety factor of heat treatment shop.
clerk office in Heat treatment shop.
Week 13
 I went to Roller Bearing shop and submitted my schedule. And foreman gave
 I learned about the dis assembling of different types of bearing from wheel.
 I gained knowledge about different types of bearing used in this Bogie.
 Learned about puller and pusher machine.
 I learned about the servicing of different bearings.
 I learned about the repairing process of bearing.
Week 14
 I learned the safety factor of roller bearing shop.

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clerk office in roller bearing shop.
Week 15
 I went to motor shop and submitted my schedule. And foreman gave the
 I learned about the repairing section of vehicle used in Pakistan railway.
 I learned the basic difference between petrol and diesel engine.
 I learned how to check radiator and also know how to visually inspection of
diesel buses.
 I learned how to disassemble the diesel engine for over hauling.
 I learned the sign of diesel engine may be week or need to be over hauled.
Week 16
 I learned how to adjust piston rings in diesel engine.
 I learned how to adjust the timing of diesel engine.
 I gained information of how to assemble the diesel engine after over hauling.
 I got information that how to inspect the diesel engine after over hauling.
 I learned the basic maintenance of diesel engine.
 I inspected the suspension of buses in motor shop.
Week 17
 In this shop, I inspected the electrical and brake system.
 I learned the safety factor of motor shop.
clerk office in motor shop.

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 I went to central laboratory MGPR and submitted my schedule. And foreman
gave the introduction about this lab.
 I learned about the material testing method and inspecting the projects of
steel section and testing method of oil and fuel used in Pakistan railway.
 I learned the safety factor central lab. I compiled my attendance sheet by
signing it from foreman and submitted to clerk office in central lab.

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Ch#4 Projects carried out
4.1 Projects
During my 16 week training I have got some projects by industrial trainer.
According to my training schedule, my duties are to go through dedicated workshops
and get knowledge about the working nature and equipment used in these workshop
and get myself familiar with the usage of multiple equipment and machines used in
these workshops. The following projects assigned by the trainer.
 Installation the Auxiliary Drive on CAT C-175 Engine
 Replace piston and connecting rod
 Making Gun metal by foundry process
 Heat treatment process of bushes
 Replace the wheel bearing
 Engine overhauling
4.1.1 Installation the Auxiliary Drive on CAT C-175 Engine
Followings are the steps of installation the auxiliary drive on locomotive CAT
C-175 engines.
 Gather all required resources (Auxiliary drive kit, Wishbone mounting kit,
Auxiliary mounting kit drawing, Wishbone mounting kit drawing, Tools).
 Remove jacket water and after-cooler pump flanges and bypass tube of
engine.
 Remove damper cover from engine.

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 Remove paint from the ID of the damper bore and front face of damper
washer.
Warning: Don’t use a grinding wheel or similar tool.
 Lay auxiliary drive bracket on engine rails and mark holes.
 Mount auxiliary drive bracket.
 Use 4 bolts and washers for install stub shaft on to damper. Use 600 ft-lb
torque wrench and torque bolts to 400 ft-lbs.
 Measure stub shaft run out with dial indicator.
 Measure run out of front face of damper washer with dial indicator.
 Mount coupling hub and taper lock bushing to stub shaft.
 Set spacer plates and shims required. Place .120" shim and .030" shim on the
mounting holes closest to the engine. Place a .060" shim .030" shim on the
mounting holes away from the engine.
 Build auxiliary drive shaft assembly.
 Lift auxiliary drive shaft assembly and place onto bracket.
 Torque all set screws on thrust collars and bearings.
 Measure dynamic run out of hubs.
 Install radiator to engine rails.
 Loosen idler and install belts.
 Install coupling.
 Tension drive belts.
 Reinstall jacket water and after cooler pump flanges and bypass tube.
 Belt guard and coupling guard installation.
 Inspection required after moving engine or radiator.

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Figure 14 Engine details
Figure 15 Removing damper
4.1.2 Replace piston and connecting rod
Followings are the procedure of replacing piston and connecting rod:
 Install a new piston pin bearing in connecting rod and remove old piston pin
bearing as follow:
 Heat length of connecting rod to a temperature of 175 to
260˚C.

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 Use tool to remove old bearing and install new bearing at same
time.
 Allow the connecting rod and the bearing to cool on room
temperature.
 Use a pin boring machine to machine the bore of the piston pin bearing to
correct diameter.
 Check the clearance between the ends of piston rings.
 Install oil ring spring with tooling in the oil grooves of the piston.
 Use tooling for install the intermediate piston ring with the side that has
identification.
 Use tooling for install top piston ring with the side that has identification.
 Position piston rings and the gap are 120 degree from each other.
 Put piston crown in position on piston skirt.
 Put the piston in position on connecting rod.
 Apply clean engine oil to piston pin and install the piston pin.
 Install the retainer rings with tooling. Make sure that retainer rings are fully
seated in the grooves of piston.
 Install connecting rod bearing in connected rod and connecting rod cap.
 Make sure that bearings are installed so that bearing tabs fit into the notches
in the connecting rod and in connecting rod cap.
 Install dowel in connecting rod cap.
 Install the pistons and connecting rod.
Figure 16 Pistons and connecting rods

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4.1.3 Making Gun metal by foundry process
Followings are the procedure of making gun metal:
 Making mold patterns.
 Making mold cavity.
 Put following material in the furnace:
 Copper 85.5%
 Tin 7%
 Zinc 5%
 Lead 2%
 Ni 0.5%
 On the furnace and liquefied the material by heating at temperature 1050 to
1200˚C.
 Liquid is poured in to a prepared mold cavity.
 Allow to solidify.
 Product is taken out of the mold cavity.
 After take out from mold cavity, trimmed and made to shape.
4.1.4 Bushes heat treatment process
 Take the bushes.
 Putting the bushes on furnace.
 On the furnace and give the temperature 800 to 850˚C.
 After heating on this temperature take out the bushes from furnace.
 Quench the bushes in water for 15 to 25 minutes.
 After soaking period putt the bushes again in furnace.
 Give the temperature 400 to 425˚C.
 After heating on this temperature, take out the bushes from furnace.
 Allow the bushes to cool in air for 15 to 25 minutes.

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Figure 17 Furnase
Figure 18 Quenching media
4.1.5 Replace wheel bearing
Following are the process of replacing the bearing wheel:
 Heat the wheel bearing.
 After heating the bearing attach hydraulic bearing remover machine with
bearing.
 Give the hydraulic pressure 40Psi for few seconds and then low pressure at
15 to 20Psi.

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 Remove bearing slowly at 15 to 20 Psi pressure.
 After removing bearing clean the surface.
 Heat new bearing at 120˚C temperature in oil tub.
 Install new bearing.
Figure 19 Heating the bearing
Figure 20 Removing bearing with hydraulic machine

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4.1.6 Engine overhauling
Following are the steps of engine overhauling:
1. Remove engine
 Remove engine cover.
 Drain the coolant and radiator hoses.
 Remove the radiator and fan.
 Loosen the alternator, the tension assembly and belts.
 Remove all electrical connection to the motor.
 Remove bolts that attach transmission bell housing to the engine.
 Use the hoist to remove the engine.
2. Disassemble the engine block
 Check for any sign of overheating, cracking and scratching on engine
block.
 Inspect the external components.
 Remove the exhaust manifold.
 Disassemble the rest of the engine.
 Check the cylinder bores.
 Remove pistons and rod assemblies.
 Remove and inspect the crankshaft.
 Remove the brackets, guide pins and everything else attach with the
outside of engine block.
 Finish the disassembly.
3. Disassemble the cylinder head
 Compress the valve springs.
 Remove the valve from head.
 Check each valve head.
 Recondition the worn valve guide.
4. Reassemble engine block
 Clean removed components.
 Clean the engine block.
 Install crankshaft and main caps.
 Install timing chain or belt to specification.

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 Install new pistons, rings, gaskets and seals.
 Install head gasket.
 Install a new valve train.
5. Reinstall the engine
 Mount engine back in to the hoist.
 Reconnect the all external components and electrical connection to the
engine.
 Test the engine.
Figure 21 Hino bus engine
4.2 Supervisory worker
The supervisors overall role is to communicate organizational needs, oversee
employee’s performance, provide guidance, support, identify development needs,
and manage the reciprocal relationship between staff and the organization so that
each is successful. And also doing following works.
 Managing workflow.
 Training new hires.
 Creating and managing the team schedules.
 Reporting to HR and senior management.

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 Evaluating performance and providing feedback.
 Identifying and applying career advancement opportunities.
 Helping to resolve employ issue and disputes.
4.3 Problem encountered & Problem solving process, approach
The following problems I encountered them and provide a complete solution
with fixing their malfunction.
Engine overheating: Engine temperature is high then normal operating temperature.
Diagnosing:
 Check the coolant level.
 Check the lube oil pressure.
 Check cooling system.
Result:
Water pump defected or not working.
Solution:
Change the water pump.
Difficulty in starting: Engine are cranking but not start or same time start but
suddenly off.
Diagnosis:
 Check the fuel level.
 Check fuel system.
 Check air cleaner.
 Check injection pump.
 Check starting motor and circuit.

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 Check battery are charged or discharged.
Result:
 Air cleaner are choked.
Solution:
 Replace the air cleaner element and clean the air cleaner.
Turbocharger loose the power: Turbocharger no charge the cylinder properly and
not properly working on high speed.
Diagnosis:
 Check the air cleaner.
 Check the exhaust gases leakage.
 Check air leakage from intake manifold.
 Check the turbocharger.
Result:
 Turbocharger defective.
Solution:
 Replace the turbocharger.
Problem: Low idle speed irregular
Diagnosis:
 Check adjustment of idle button.
 Check injectors.
 Check injection timing.
 Check fuel delivery.

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 Check feed pump.
 Check governor.
Result:
 Incorrect injection timing.
Solution:
 Set the correct injection timing.
Engine has low power
Diagnosis:
 Check injector nozzle.
 Check injection pump over flow valve.
 Check fuel pump.
Result:
 Injector nozzle pressure spring broken.
Solution:
 Replace the nozzle pressure spring.
4.4 Hand on skill acquired
I acquired following hand on skills from this training.
 Punctuality and time management skills
 Professionalism and positive attitude
 Organizational abilities
 I learn about locomotive inspection schedule and its process or parameters.
 Servicing the air cleaner elements.

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 Replacing the engine oil filter.
 Oil change.
 Engine speed sensor clean.
 Replacing the fuel filter element.
Locomotive inspection and maintenance schedule
Maintenance of locomotive is a complete job. Following are a table in which
there is a complete schedule of its inspection and time taken to complete.
Table 2 Locomotive inspection schedule
Inspection Schedule Time Completion
A-Schedule (After every trip) 1 hours
B-Schedule (Monthly) 2 hours
C-Schedule (After every 3 months) 8 hours
D-Schedule (After every 6 months) 8 hours
E-Schedule (After every 9 months) 8 hours
F-Schedule (After every 1 years) 16 hours
Inspection Parameters
Following are the parameters which are inspected during inspection process:
A-Schedule
 Fuel oil & lube check.
 Expresser discharge valve.
 Flexible couplings bubbles.
 Turbo run down test.
 Primary and secondary all oil, air and fuel filters are checked.

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B & C-Schedule
 All the works done of A-schedule.
 All cylinder head valve loch check.
 Sump examination.
 Main bearing temperature checked.
 Expresser valve checked.
 Lube oil filter changed.
 Strainer cleaned.
 Expresser oil changed.
D-Schedule
 Run engine; check operation of air system safety valve and expresser
crankcase lube oil pressure.
 Stop engine; carry out dry run operational test, check FIP timing and
uniformity of rack setting and correct if necessary.
 Tighten all air and exhaust elbow bolts and check valve clearance.
 Remove crankcase cover and check for any foreign material. Renew gaskets.
 Clean strainer and filters, replace the paper elements.
 Compressed air and vacuum system checked.
 Radiator fan check.
 Roller bearing axle boxes checked. Check for lose bolts, loss of grease and
sign of overheating.
 Renew of airflow indicator valve.
 Carry out blow bye test and gauge wheel wears.
F-Schedule

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 Repeat of all items of trip and monthly schedule.
 Testing of all valves of compressed air or vacuum system. Repair if
necessary.
 Reconditioning, calibration and checking of timing of FIP is done. Injector is
overhauled.
 Cleaning of bull gear and overhauling of gear-case.
 RDP testing of radiator fan, greasing of bearing, checking of shaft and
keyway.
 Checking of push rod and rocker arm assembly. Replace it if bent and broken.
 Checking clearance of inlet and exhaust valve.
 Examination of piston for cracks, renew of bearing shell of connecting rod
fitment.
 Checking the connecting rod elongation.
 Checking the crankshaft thrust and deflection. Shims are added if deflection
is more than the tolerance limit.
 Main bearing is discarded if it has embedded dust, give evidence of fatigue
failure or is wearied.
 Install new gasket in the intake manifold.
 Overhauling of exhaust manifold.
 Checking of cracks in crankcase, lube oil header, jumper and tube leakage in
lube oil cooler.
 Overhauling of lube oil system.
 Overhauling of fuel system.
 Check the rack setting, governor to rack linkage, fuel oil high-pressure line.
 Check the cooling system.
 Complete overhauling of water pump.
 Water and oil seal renewal.
 Complete overhauling of expresser.
 Complete overhauling of turbo supercharger.
 Overhauling of after-cooler.
 Rear T/motor blower bearing are check and changed.
 Air intake filter and vacuum oil bath filter are cleaned and oiled.
 Clean the axle box housing.

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 Wheels inspection for fracture or flat spot. Wheel are turned and gauged.
 Check the brake parts for wear and lubricate the slack adjusters.
 Check the traction motor and repair it.
Servicing the air cleaner element
 Remove the cover.
 Remove the primary air cleaner element.
 The secondary air cleaner should be removed.
 Cover the turbocharger air inlet with tapes in order to keep dirt out.
 Clean the inside of air cleaner cover and body with a clean and dry cloth.
 Remove the tapes for the turbo charger air inlet.
 Install a new primary air cleaner element.
 Install the air cleaner cover.
Replacing the engine oil filter
 Connect a hose to drain for collect the oil.
 Open drain valve and remove plug for allow the oil to drain.
 Clean the plug and install the plug.
 Close the drain valve.
 Disconnect the house to drain.
 Be alert to the spring force. Gradually loosen the bolts but do not remove it.
 Before removing the bolts, pry cover loose or tap the cover with a rubber.
 Remove cover and spring.
 Remove O-ring seal, retainer and oil filter elements.
 Clean cover, spring, O-ring seal and retainer.
 Clean the inside of the oil filter housing.
 Ensure that the new oil filter elements are in good condition.
 Install new oil filter elements.

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 Install new O-ring seal if the old seal is damaged.
 Install retainer, spring and cover. Ensure that the retainer and spring are
properly seated.
 Start the engine and check the oil leakage.
Oil change
 Remove the oil filler cap.
 Fill the crankcase through the oil filler tube only.
 Clean the oil filler cap and install the oil filler cap.
 Close the fuel supply line and crank the engine until the oil pressure gauge
indicates 70kPa (10Psi).
 Open the fuel supply line.
 Cool the starting motor for two minutes before cranking again.
 Start the engine.
 Operate the engine at low idle for two minutes.
 Ensure that the lubrication system has oil and the oil filters fill with oil.
 Ensure that the oil level at the full mark on the low idle.
 Stop the engine and allow the oil to back into the sump for a minimum ten
minutes.
 Check the oil level.
Engine speed sensor clean
 Remove engine speed sensor (crankshaft position sensor).
 Inspect the condition of the end of the magnet.
 Look for signs of wear.
 Clean any debris from the face of the magnet.
 Check the tension of the slip head. Gently extend slip head minimum 4mm.
 Install the engine speed sensor.

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Fuel primary filter replace
 Turn off the engine.
 Disconnect the battery.
 Shut off the fuel tank supply valve to the engine.
 Close drain valve.
 Remove bolt, O-ring seal, case and element.
 Clean the case with nonflammable solvent.
 Change the element.
 Install the new O-ring seal if the old seal is damaged.
 Install the case and the bolts.
 Tighten the bolt to 25 ± 5 N-m.
4.5 How to improve productivity in an Organization
Following ways to improve productivity in an organization.
 Encourage learning opportunities
 Provide employees with technology
 Emphasize organization culture
 Strengthen communication protocols
 Identify and align goals with performance
 Streamline your workflows
 Give your people power to work remotely
 Give the right task to right people
 Make boosting work place morale a priority positive attitude and involvement
of management
 Proactive employ
 Good working condition
 Tool and equipment to rise productivity

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 Availability of input supplies
4.6 Quality management system in Pakistan railway
In 1947, there were almost 8,122 km railway tracks. Pakistan railway track is a
public sector that was known as Pakistan Western Railway back then. It is also
considered the predominant mode of transportation in Pakistan. When it was at its
peak in the year 1950- 1960, handled 73% of the freight traffic. It was approximately
4% less than 2011. But the Pakistan railway quality management has been critical
over the past years due to the deteriorating quality of services, which ultimately
cause a decreased number of passengers.
Due to poor quality management, Pakistan received a setback as a catalyst for
economic development. The reason was also that the government didn’t invest
properly in the infrastructure of the railway of Pakistan. There is a lack of human
resource management and a lot of involvement in nepotism and political
agendas. There is a huge involvement of personal interests by the government,
which is a bad example of quality management in Pakistan.
It is required of quality management to be more responsible towards the quality of
services and employees. But due to personal and political interest by the government,
it creates indignation and a feeling of job security among employees. Therefore the
Lack of management quality in Pakistan railways has destroyed the effectiveness of
work in railways.

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Poor quality management has severely affected long-term arrangement and their
enforcement. They are doing persistent changes in the placement of senior servants.
Their quality management remains an unsolved issue; their primary concerns are the
current administration of PR states.
The physical infrastructure of railways is no longer productive and disrupts the
productivity of work. The primary concern of the infrastructure of railways includes
current administration, maintenance, and repair expenditures that are affecting
operation costs. The reason behind the dispute within PR’s operations was
locomotives with operational status.
Poor quality management is causing Travelling without ticket frequently. Quality
management is not so responsible for checking the tickets and providing authentic
tickets to passengers. There are a lot of unethical activities going on in Pakistan
Railways. The railway’s unethical activity is occurring with all support of ticket
verifiers and railway police. This is the failure of quality management. Quality
management needs to increase monetary gain and to increase monetary gain, they
need to improve the administration against all these leaks.
In the year 2015-16, there were almost 90,510 cases reported without ticket
passengers. In the year 2016-17, there were almost 66,602 cases reported without
ticket passengers. In the years 2017-18, there were almost 42,206 cases reported
without ticket passengers. These figures show that the quality management
department is somehow trying their best to improve the services and working on their
ticket problems. This article sums up the current condition of the Pakistan Railway
and also suggests some solutions to implement Quality in the department.

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Implementations of quality management are poor and almost 70% of carriages are
out of service. Passengers train, freight and cargo train are spare because of shortage
of locomotives. But In 2014, management tried to improve the duty hours of the
Badami bagh cargo train increased up to 6 days a week. It generated almost 37, 0000
per day revenue.
The major earning of railways is from freight services but there’s a lack of freight
trains in Pakistan. The tracks are over-aged and trains cannot maintain the average
speed of 120 km/h speed in some sections like Karachi-Lahore. There is no proper
time management due to passengers don’t feel satisfied. A lot of passengers
complain about the low quality of services provided by Railway.
The quality management department claims that they maintain the quality but still
there are certain gaps. Benchmarking can be used to fix the problems. Benchmarking
is the process of learning, adapting from other organizations to improve the
performance of the company. Pakistan can benchmark Japan and Indian Railway
Models.
4.7 Safety at work
 Be alert from any situation.
 Use safety shoes with soles.
 Wear the gloves, glasses and helmet while welding.
 If welding on height, a signboard must be installed below.
 Keep clean the work area.
 Don’t wear loose clothes.
 Use the right tools for work.

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 Do not try to stop the machine with your hands.
 Place all scraps in the scrape container.
 Do not clean your clothes and body with compressed air.
 During overhead cranes and shunting, keep whistling continuously.
 In case of injury, seek immediate medical first aid.

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Ch#5 Conclusion
16 weeks industrial training in Pakistan railway was a huge success and a great
time of acquisition of knowledge and skills. This training focused upon increasing
our knowledge and interest into word the production of railway carriage & wagons
and Loco workshops. Because it is most efficient and necessary needs to people in
these days so its production at most efficient method with minimum cost and in
proper sequence with less wastage.
The overall working experience in each shops or workplace was kind of intellectual
and diversified. It increasing my practical skills that are the main thing which I learnt
in training session. I am sure that the practical skills and knowledge got from this
industrial training program will definitely help me during my professional life ahead.
Finally, I would like to thanks my instructors and all the person of this organization
who had helped me a lot during my training/internship.
5.1 Recommendation
 Invest in training and skill development.
 Workshop should be equipped with modern and advanced machine and tools.
 Implement effective inventory management system.
 Pakistan railway should introduce standardized repair and maintenance
procedures for these workshops.
 Improve communication channels between departments.

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CH#6 References
https://www.railways.gov.pk/SiteImage/Downloads/Workshop.pdf
http://www.sisubil.no/php/datafilr_for_verk/Cat_manuals/SISU%20repair%20manua
ls/CYLINDER%20BLOCK/Pistion%20and%20connetion%20rod%20assembleSMC
S_1225_016.pdf
https://www.ieacooling.com/wp-content/uploads/2018/12/iom-newlogooverlay-
c175-093014-8401748.pdf
https://www.cat.com/en_US/products/new/power-systems/electric-power/diesel-
generator-sets/1000028916.html

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Appendix
Figure 22 Completion letter

Supervised indutrial training report.pdf

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