DIESEL LOCOMOTIVE WORKS (DLW)

1. MAHARISHI MARKANDESHWAR UNIVERSITY
TRAINING FROM:-
DIESEL LOCOMOTIVE WORKS
VARANASI
BY:-
MOHD ANAS ZAMAN ANSARI
ROLL NO. 75134017
B-TECH (ME)-5TH SEM

2. ABOUT THE DLW
• DLW was founded by the Late Railway Minister Mr. Lal Bahadur
Shastri on 23 April 1956.
• It is the production unit owned by Indian Railways, it manufactures
diesel electric locomotive and spare parts.
• To meet the increased need of transportation of Indian Railway it
was established in collaboration with ALCO (American Locomotive
Corporation) in 1961 and EMD (Electro Motive Diesel) in 1990, USA.
• DLW rolled out his first locomotive three years later on 3 January
1964.
• DLW is supplying locos to Zonal Railways, PSU and other countries
like Vietnam, Srilanka etc.
• At present the latest locomotive produced by DLW ; I e. WDG-5D
has capacity up to 5500HP.

3. DIESEL LOCOMOTIVE WORKSHOP
• DLW’s annual production 320 locos
• Cost of one loco 14 to 18 crore (EMD)
Weight of one loco 126 Ton
• Fuel Consumption(at full load) 540 lit/hr.
• Maximum speed 160 km/hr.
• Dia of wheel 1092mm
• Wheel to wheel distance 1596.5mm
• Length of under frame 19962mm

4. POWER PACK
BACK ENDFRONT END
RIGHT
BANK LEFT
BANK
STRAINER
MAIN
LUBE OIL
PUMP
SCAVENGIN
G PUMP
WATER
PUMP
GOVERNO
R
LUBE OIL PAN
CRANKCASE
TURBO
SUPER
CHARGER
EXHAUST
MANIFOLD

5. ASSEMBLY
• Oil pan is kept on metallic stand and fit white colour silicon seal in
oil pan face groove.

6. ASSEMBLY
• Power assembly received from SAS
consist of following components.
Cylinder
head
Cylinder
liner
Piston

7. COMPLETE
POWER ASSEMBLY

8. ASSEMBLY
• After fitment of Power Assemblies, fuel Injectors are
also fitted in cylinder head.

9. ASSEMBLY
• An electro-hydraulic speed control (governor) maintains
the engine speed selected by the operator.

10. ASSEMBLY
• Primarily used to increase engine horsepower and provide
better fuel economy through the utilization of exhaust gases
• When the engine approaches full load, the heat energy in the
exhaust, which reaches temperatures approaching 538°C
(1000°F) is sufficient to drive the turbocharger without any help
from the engine. At this point, turbocharger drive is
mechanically disconnected from the engine gear train.

11. ASSEMBLY
•. After cooler are assembled along
with the turbocharger.
• It is used for bringing down the
temperature of compressed air
received from turbocharger.

12. ASSEMBLY
• Further accessories, assemblies and components fitted on power
pack:
Vibration damper, fuel oil header, water header, pumps: lube oil
water scavenging, governor , piston cooling pipe, lube oil filter,
fuel oil filter and exhaust manifold.
• After complete assembly of power pack, it is tested on engine test
bed, where following connections are done:
Mechanical connections:
Water connections, fuel connections, lube oil connections, engine
to alternator.
Electrical connections:
Connections from Alternator to Load Box.
Lube oil circuit, fuel oil circuit, water circuit are also inspected
Now Power Pack is ready for testing on test bed.

13. TESTING OF POWER PACKS
During testing following parameters are measured .
• Engine speed
• Fuel consumption
• Low water pressure indicator
• Main lube oil pressure
• Fuel inlet pressure
• Alternator current
• Alternator voltage
After successful testing of power pack, power pack is sent to Loco Assembly Shop
for further fitment.

14. MAJOR ASSEMBLIES
ENGINE FROM ETSHOP
UNDER FARME FROM L F SHOP
BOGIE FROM T M SHOP
LONG HOOD FROM L A SHOP
CAB FROM LF SHOP
ALTERNATOR FROM T A SHOP
CCB FROM T A SHOP
(Computerized Control Brake)

15. ENGINE
• V16 cylinder, 4500 HP

16. UNDER FRAME
• Milling operation on mounting pad of Engine and Alternator.
• Fuel oil piping.

17. BOGIE
• Co-Co Bogie.
• High speed high traction three axle
• Bogie contain axle, wheel, traction motor and gear box.
Bogie
Traction
motor
Gear box
Axle
Sand pipe

18. LONG HOOD AND CAB
D B Hood
Engine Over
Hood
Cooling
Compartment

19. ENGINE SETTING
• Engine and compressor setting on under frame.
• Torque mounting bolt of engine.
Rear Bolts 650 lbs
Front Bolt 450 lbs

20. ALTERNATOR ASSEMBLY
• Alternator, Dustbin pump, Axillary
motor assembly.

21. EQUIPMENT RAKE
• Water tank
• Lube oil cooler
• Fuel oil filter
• Lube oil filter

22. READY FOR LOCO TEST
• Now this loco is ready for loco test
• From loco test shop loco is sent to paint shop.

23. READY TO USE

24. Thank you