- The Diesel Locomotive Works (DLW) in Varanasi, India manufactures diesel-electric locomotives and spare parts. It produces high horsepower locomotives ranging from 2600hp to 5500hp. - In a diesel-electric locomotive, a diesel engine drives an electric generator that provides power to traction motors, with no mechanical connection between the engine and wheels. - The presentation covered the objectives, nomenclature, and process for assembling the truck machine components of DLW locomotives, including fitting wheels and axles, traction motors, and attaching the axle-wheel assembly to the truck frame.

1. PRESENTATION ON PRACTISE SCHOOL-1
at
DIESEL LOCOMOTIVE WORKS, VARANASI
PRESENTED BY
GAURAV MISHRA (2014BTECHME005)

2. CONTENTS
• About the company
• Introduction to Diesel locomotive
• Objectives
• Nomenclature of Diesel Locomotive
• Truck Machine Assembly

3. About DIESEL LOCOMOTIVE WORKS (DLW)
• The Diesel Locomotive Works (DLW) in Varanasi, India, is a production unit owned by
Indian railways.
• It manufactures diesel-electric locomotives and its spare parts.
• It was established in collaboration with Alco (American locomotive company) USA since
1961.
• Further technology agreements from the manufacturer GM-EMD (General Motors-Electro
Motive Diesel).
• DLW today produces high horse power (HHP) locomotives ranging from 2600hp to 5500hp.
• DLW has costumers like NTPC, Coal India, Indogulf etc.
• It also supplies locos to other countries like Sri Lanka, Vietnam, Malaysia, Tanzania,
Bangladesh.
• DLW annually produces 310 locomotives.
• DLW is the largest diesel-electric workshop in the Asia & second largest in the world.

4. What is a Locomotive.?
• As the word defines, “loco” in Latin English
means place and motive means move by the
change of position.
• Hence locomotive is a railway vehicle that
provides power for the motion of train.
• Locomotives in India are working on
electricity and diesel fuel.
• DLW produces diesel locomotives only.

5. How does a Diesel Locomotive Works.?
In a Diesel-Electric Locomotive, the diesel engine drives an electric generator or alternator whose
output provides power to the traction motors there is no mechanical connections between engine and
the wheels.

6. SOME FACTS ABOUT DIESEL-ELECTRIC
LOCOMOTIVE
 DLW’s annual production - 300+
 Cost of one loco - 12 to 14 crore (EMD)
 Weight of one loco - 121 Tonnes
 Fuel Consumption: At Full Load - 540 liter/hour
At Idle Load - 40 liter/hour
 Max Speed - 160 Km/hr
 Diameter of wheel - 1092±0.5 mm
 Wheel to Wheel Distance - 1596±0.5 mm
 Length of Under Frame - 19962 mm

7.  The first letter (gauge)
• W-Indian broad gauge (The "W" Stands for Wide Gauge - 5 Feet)
• Y-meter gauge (The "Y" stands for Yard Gauge - 3 Feet)
• Z-narrow gauge (2 ft. 6 in)
• N-narrow gauge (2 ft.)
 The second letter (motive power)
• D-Diesel
 The third letter (job type)
• G-goods
• P-passenger
• M-mixed; both goods and passenger
Nomenclature of Diesel Locomotive

8.  The forth letter (horse power)
• 3 – 3000 HP
• A – 100 HP more
• 4 – 4000 HP
• B – 200 HP more
• 5– 5000 HP
For example,
WDM3A:
"W" means broad gauge
"D" means diesel motive power
"M" means suitable for mixed(for both goods and passenger)service
"3A" means the locomotive's power is 3,100 HP ('3' stands for 3000 HP, 'A' denotes 100
HP more)

9. OBJECTIVES
• To study the process used in axle- wheels assembly
• To study the process used traction motor assembly
• To study the process used in truck frame assembly of WDG4/WDG4D/WDP4D
HHP Locomotive

10. TRUCK MACHINE ASSEMBLY
OF WDG4/WDG4D/WDP4D
HHP LOCOMOTIVE

11. STATION 1- Wheel and Axle Machining section
Wheels and Axle are machined on CNC Turret lathe machines

12. STATION 2- Wheels and Axle Assembly Section
Wheel, Bull Gear, Bearings, Suspension tube and other parts are fitted on the axle by
interference fitting by applying a load of 85-130 tonnes

13. • Roller taper bearings, Bull gear, and other parts are fitted on the axle, after heating them
to a temperature about 150-200ºC
• After fitting of these components, journal bearings are fitted on the both end of the axle.
• Traction Motor is fitted on the suspension tube to provide final rotational drive to
wheels.

14. STATION – 3 Traction Motor Assembly
Pinion is installed in traction
motor using ram pump
Traction motor is fitted on the suspension tube
and pinion & bull gear are aligned

15. STATION – 4 Truck Frame Assembly
Axle-wheels assembly is fitted on the
truck frame
Axle box, Vibration Damper, Suspension coil and brake
rigging components are fitted on the frame

16. Air-powered Piston Cylinder connected with Brake shoe(pad) by mechanical
linkage is fitted on the truck frame

17. THANK YOU