The document provides information about the Diesel Locomotive Works (DLW) in Varanasi, India. Some key points: - DLW is the largest diesel-electric locomotive manufacturer in India, producing locomotives since 1964. - It produces locomotives with power outputs ranging from 2,600-5,500 horsepower. Current models include EMD GT46MAC and GT46PAC locomotives under license from EMD. - DLW supplies locomotives domestically to Indian Railways and exports internationally to countries in Asia, Africa, and South America. It has an annual production capacity of 250 locomotives.

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1. INTRODUCTION
The Diesel Locomotive Works (DLW) in Varanasi, India, is a production unit owned
by Indian Railways, that manufactures diesel-electric locomotives and its spare parts. It is the
largest diesel-electric locomotive manufacturer in India.
Company
Founded in 1961, the DLW rolled out its first locomotive three years later, on 3 January
1964. It manufactures locomotives which are variants based on the original ALCO designs
dating to 1960s and the GM EMD designs of the 1990s. DLW has an annual production
capacity of 250 locomotives and plans to increase it to 275 based on the current demand.
Products
DLW locomotives have power outputs ranging from 2,600 horsepower (1,900 kW) to 5,500
horsepower (4,100 kW). Currently DLW is producing EMD GT46MAC and EMD
GT46PAClocomotives under license from Electro-Motive Diesels (formerly GM-EMD) for
Indian Railways .Some of its EMD locomotive products are WDP4, WDP4D, WDG4D,
WDG5 and others as of June 2015.
Market
Besides the Indian Railways, it regularly exports diesel-electric locomotives and has supplied
locomotives to other countries such as Sri Lanka , Malaysia, Bangladesh, Mali, Senegal,
Sudan ,Tanzania, Angola, and Vietnam and also to a few users within India, such as ports,
large power and steel plants and private railways.
Ancillary
In July 2006, DLW outsourced manufacture of some passenger and freight locomotives to
Parel Workshop, Central Railway, and Mumbai.

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Fig 1:DLW Workshop Gate
 BREIF CHRONICLE OF DLW
23 April 1956 Laying of foundation stone of factory by the first President of India
Late Dr. Rajendra Prasad.
August 1961 Diesel Locomotive Works came into existence.
January 1964 First Broad Gauge Locomotive (WDM-2) released by (Late) Shri
Lal Bahadur Shastri.
November 1968 First Meter Gauge Locomotive (YDM-4) released by (Late) Shri
Morarji Desai. (22 Nov.)
February 1975 First Broad Gauge Shunting locomotive (WDS-6) turned out.
January 1976 Locos exported to Tanzania.
March 1977 1000th
Locomotive turned out.
December 1977 First Diesel Generating Set Commissioned.
May 1984 Locos exported to Vietnam.
August 1994 First 3100 HP WDM-2C loco turned out.
April 1995 First 2300 HP WDP-1 Passenger loco turned out.
July 1995 First 3100 HP WDG-2 Freight loco turned out.
December 1995 Locos exported to Sri Lanka.
April 1996 Locos exported to Bangladesh.
February 1997 Awarded ISO-9002 Certification.
October 1997 Locos exported to M/s Puttalam Cement Company, Sri Lanka.
August 1998 First 3100 HP WDP-2 Passenger loco turned out.
March 1999 4000th
Locomotive turned out.

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August 1999 First PKD WDG-4 Locomotive turned out.
March 2001 Awarded ISO-14001 Certification.
April 2002 First DLW built 4000 HP WDG-4 Loco turned out.
June 2002 First DLW built 3300 HP WDG-3C Freight Loco turned out.
June 2005 2.4 MW Diesel Generating Set commissioned.
September 2005 Certified for OHSAS- 18001:1999
November 2006 First IGBT based WDG-4 loco turned out.
January 2007 5000th
Locomotive turned out.
November 2008 Locos exported to Mozambique.
October 2010 First Dual Cab WDP-4D loco turned out.
February 2012 First 5500 HP WDG-5 locomotive manufactured.
November 2012 First Dual Cab WDG-4D loco turned out.
January 2013 Enter into Golden Jubilee Year.
April 2013 Special WDP4D locomotive turned out equipped with new features.
April 2013 DLW bagged the shield of Best Production Unit of Indian Railways.
July 2013 1000th
High Horse Power Locomotive turned out.
January 2014 Golden Jubilee Locomotive WDP4B ‘PRATEEK’ turned out.
September 2014 7051st
Locomotive turned out.
December 2014 Inauguration of Expansion Project of DLW by Hon’ble Prime
Minister Shri Narendra Modi.
April 2016 First Vacuum type Bio-Toilet equipped WDG-4D loco turned out.
October 2016 Dedication of the first phase of Expansion Project of DLW to the
Nation by Hon’ble Prime Minister Shri Narendra Modi.
December 2016 2000th
HHP loco flagged off by MoSR.
February 2017 First electric loco WAP-7 turned out.
March 2017 Obtained certification of ISO 50001: 2011, for Energy Management
and GreenCo Silver Rating under the GreenCo Green Company
Rating System.
March 2017 First High Horse Power loco dispatched to Non-Railway customer
(M/s.OPGC).
March 2017 Highest ever Annual outturn of 334 locomotives including 317 HHP
and 2 electric locomotives.
April 2017 DLW bagged the Best Production Unit Shield 2016-17 of Indian

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Railways for second successive year.
 ORGANISATIONAL STRENGTH
 A flagship production unit of Indian Railways offering complete range of products
under one roof in its area of operation with annual turnover of more than Rs 4800
Crore
 State of the art design and manufacturing facility to manufacture 200 Diesel Electric
Locomotives per annum for meeting transportation needs of Indian Railways, Non-
Railway Customers (NRC) and Export
 Manufacturing 2.4 MW Diesel Generating sets as per demand
 Maintenance support by way of providing spares to Zonal Railways, Non-Railway
Customers and Export as per demand
 Unbeatable trail-blazing track record in providing cost-effective, eco-friendly and
reliable solutions to ever increasing transportation needs for over fivedecades
 Fully geared to meet specific transportation needs by putting Price - Value -
Technology equation perfectly right
 A large base of delighted customers among many countries viz. Myanmar, Sri Lanka,
Malaysia, Vietnam, Bangladesh, Tanzania, Angola, to name a few, bearing testimony
to product leadership in its category
 DLW has successfully started manufacturing of electric locomotive
 PRODUCT
One of the product made by DLW is-
WDP3A 3100 HP PASSENGER LOCOMOTIVE
High power-high speed dual cab Passenger Locomotive. Powered with 3100 HP, 4 stroke,
fuel efficient diesel engine. Fabricated Under frame and two stage suspension, 3-axle,
flexi-coil MK-V bogies, excellent riding quality.
The locomotive is powered with DLW make 251C up rated 16 cylinder fuel efficient
engine with Napier NA 295 IR model or ABB VTC 304-VG 15 model turbo super charger

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and a large after cooler for better cooling of the engine inlet air.
The locomotive is equipped with AC-DC transmission consisting of a directly coupled self
ventilated BHEL make TA10102 model traction alternator.This engine develops 3100HP
at 1050 RPM under standard condition.
Diesel Engine Transmission
 16 Cylinder 251 B- (Up rated)
Engine, 4 stroke, turbocharged
 Fuel Efficient Engine
 Injection System Direct Injector
 Governor Woodward
 Compression Ratio- 11.75:1
 Lube Oil Sump Capacity 1025 L
 Electrical AC-DC
 6 Traction motor ( 3 in parallel per
bogie)
 Suspension Axle hung / nose
suspension
 Gear Ratio 22:61
Truck Brakes
 Fabricated flexi coil MK-V CO-
CO Bogie
 Adhesion 0.25
 Panel mounted IRAB-I System
 Air , hand
 Pure air brake
General Characteristic
1. Installed Power
2. Axle Load
3. Gauge
4. Wheel arrangement
5. Wheel diameter
6. Height
7. Width
 3100 HP
 19.5 T
 1676 mm
 Co-Co
 1092 mm
 4081 mm
 3000 mm

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 DIFFERENT DEPARTMENTS
 DESIGN OFFICE:
Prepare diagram of each part and sent to Material Control & inform timely in any change in
any parts to relative department.
 MATERIAL CONTROL OFFICE:
Prepare material list which consist of diagram and quantity of each part and sent to store
department for purchase.
 STORE DEPARTMENT:
After receiving material list, Store Department scrutiny the material list, take Funds & vetting
(careful inspection) from Account Department & then issues tenders. Open Tenders &
Purchase Order issued. After Receiving of Materials inspection is done by Inspection
Department.
8. Overall Length (Over Buffer
Beam)
9. Weight
10. Max tractive effort
11. Maximum speed
12. Fuel tank capacity
13. Locomotive Control
 17900 mm
 117 T
 29.25 T
 160 Km ph
 5000 l t s
 E-Type Excitation
Fig 2:
WDP3A-3100 HP GOODS
LOCOMOTIVE
WDP3A-3100 HP GOODS
LOCOMOTIVE
TRACTIVE EFFORT & SPEED
CHART,
BRACKING EFFORT & SPEED
CHART

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 INSPECTION DEPARTMENT:
After receiving of Material, Inspection is done by Inspection Department .If material is OK ,
then Receipt Note is issued by Store Department and sent to Accounts Department for
payment to firm. If material is not OK, then material is returned to the firm.
 ACCOUNTS DEPARTMENT:
Check all the purchase, given concurrence for purchase, vetted material list, Requisition &
payment to firms.
 PLANNING OFFICE:
Prepare JPO, Monthly Production Program, Scheduling, Processing, Rate Fixing, Issue Work
Orders, Schedule Orders, Issue Job card& other Production Documents. Preparing DLW
Budget& sent to Railway Board.
 PROGRESS OFFICE:
After opening of work orders ,collect the production documents from PCO and hand over to
user shop ,draw the material from Depot & given to the shop & hand over the ready-made
material of shop to user shop/store. After completion of work, close the work order.
 PRODUCTION SHOPS:
Production shops are divided in three divisions-
1. Block Divisions
2. Engine Divisions
3. Loco Divisions
 BLOCK DIVISIONS:
 Heavy Weld Shop
 Heavy Machine Shop
 ENGINE DIVISIONS:
 Engine Erricsion Shop
 Engine Test Shop
 Light Machine Shop
 Sub Assembly Shop
 Rotor Shop

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 Heat Treatment Shop
 LOCO DIVISIONS:
 Loco Frame Shop
 Pipe Shop
 Truck Machine Shop
 Traction Assembly Shop
 Sheet Metal Shop
 Loco Assembly Shop
 Loco Paint Shop
 Loco Test Shop
 SERVICE SHOPS:
 Maintenance Area-1,2,3
 Tool Room
 Central Transport Shop
 PERSONNAL DEPARTMENT:
Prepare payment of Staff, Leave Record, Personal Record of every employee, Housing
allotment, Welfare of staff, etc.
 HEALTH DEPARTMENT:
Having facility of Indoor & Outdoor patients.
 CIVIL DEPARTMENT:
Maintenance of colony quarters, up gradation of facilities in quarters , sanitation etc.
 ELECTRICAL DEPARTMENT:
Maintenance of Lighting in quarters ,and in workshop, electrical works in locomotives etc.
 TECHNICAL TRAINING CENTRE:
Provide training to all employee at time to time refresh update their knowledge.
 RESEARCH & DEVELOPMENT:
1. R&D –a Customer centric Activity Committed to Innovation and Continuous
Improvement.
2. Highly skilled Manpower capable of Handling complete R&D activities.

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3. A sophisticated design centre with modern CAD/CAE workstations equipped with
Unigraphics and Ansys.
4. Back-up support from RDSO, a centralised R&D organisation at corporate level.
5. Several milestone in the past –an enviable pedigree viz.
 Original ALCO design made 7% more fuel efficient.
 Many design improvements leading to better performance ,incorporated in original ALCO
design.
 Many new designs for locomotives such as WDP1,WDG2,WDP2, to name a few.
Fig 3: Digrammatic Representation of Diesel Electric Locomotive

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2. HEAVY MACHINE SHOP (HMS)
This shop carries out the machining of cylinder block (M.G. & B.G.) main base, saddler Main
bearing caps, Splines, Turbo Super, Charger, Lube Oil, Fuel Oil & Water header) cam
bearing housing.
 OPERATION:-
Planning, Milling, Drilling, Tapping, Boring Honing, Serration milling etc.
Types of Machine provided in the shop are:-
i. Double Housing planned machine (32”, 24‟, & 16‟).
ii. Radial drilling machine.
iii. Radial drilling machine Travelling type.
iv. Boring Machine
v. Angular Boring Machine (Excello)
vi. Tracer Planner machine.
vii. Hill Acme koing structural milling machine.
 TOOLS USE:-
1. O.K. Tool (Rough & Finish)
2. C.C. Milling cutter (4”, 9”, & 10”)
3. Boring Tipped Tool (Rough & Finish)
4. Honing Stone (For hand honing)
5. Drill, Reamer, Top (Various Seizer)
6. Serration Cutter.
Fig 4: Micron meter
 MEASURING INSTRUMENT
1. Dial Bar gauge

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2. Micron meter (outside and depth)
3. Vernier Height gauge.
4. Vernier calipers
5. Mandrill or optical shad drill machine EX-
 CELLO ANGULAR BORING MACHINE:-
Motor R.P.M. in constant, Spindle, speed is control by clutch systems.
 H.M.T. ANGULAR BORING MACHINE :-
Spindle speed is directly controlled through motor. (Coated carbide is used in H.M.T. angular
Boring machine) cylinder block made of fabricated class II material except main
bearing cap as it made class IV material. The machining of cyl. Block is complicated and
challenging job. It required great skill and knowledge. After duly fabricated, stress
relieved and shot blasted the block is subjected to layout to ensure availability of adequate
machining allowance, where necessary and to provide guide liner for subsequent machining
the weight of the block is 6.02 tons approx. (Fabricated Material) After completion of all
operations as per drawings the black subjected to inspection in addition to stage inspection
dimension live radial distance between center of crank bore and com bore, distance between
center of com bore and liner seat etc. are checked at this stage the weight of the black is 05.02
tons apprx. 01 ton of material removed by the machining and than blank is block send for
assembly.
Fig 5: Angular Boring Machine

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2. LOCO ASSEMBLY SHOP
I. Component Fabrication
Precision cutting and forming of sheet metal is utilised for manufacture of superstructures
Including drivers cab engine hoods, and compartments for housing electrical equipment. All
activities connected with pipes like pickling, bending, cutting, forming and threading of pipes
of various sizes are undertaken in another well-equipped work area. All electrical equipment
is assembled in the fabricated control compartments and driver's control stands are done in
another work area.
II. Underframe Fabrication
Underframes are fabricated with due care to ensure designed weld strength. Requisite camber
to the underframe is provided during fabrication itself. Critical welds are tested radio-
graphically.
Welder training and their technical competence are periodically reviewed. High Horse Power
(HHP) underframe is fabricated using heavy fixtures, positioners to ensure down hand
welding. Fixtures are used to ensure proper fitting of components and quality welding in
subsequent stages.
III. Bogie Manufacturing
Special purpose machines are utilized for machining cast and fabricated bogie frames. Axle
and wheel disc machining is undertaken on sophisticated CNC machines. Inner diameter of
wheel discs are matched with the outer diameter of axles and assembled on wheel press. The
complete truck (bogie), including bogie frames, wheels and axles, brake rigging and traction
motors are assembled which is ready for application to locomotive.
IV. Locomotive Assembly
Tested engines are receive from Engine Division. Similarly under frames are received from
Loco frame shop and assembled trucks from Truck machine shop. Superstructure
compartments and contractor compartment are received from respective manufacturing and
assembly shops of Vehicle Division. Important alignments like crank shaft deflection,
compressor alignment and Eddy Current clutch/radiator fan alignment are done during
assembly stage. Electrical control equipments are fitted and control cable harnessing is
undertaken. The complete locomotive is thus assembled before being sent onwards for final
testing and spray painting. All locomotive are rigorous tested as per laid down test procedures
before the locomotive is taken up for final painting and dispatch for service.

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Therearestep by step process for the assembly of the locomotive. There is a sequence for
assembly. In LASElectricalcontrolequipmentisfittedandcontrolcableharnessingisundertaken.The
completelocomotiveisthusassembledbeforebeingsentonwardsforfinaltestingandspraypainting.Tested
enginesarereceivedfromEngineDivision.SimilarlyunderframesarereceivedfromLocoframeshopand
assembledtrucksfromTruckmachineshop.Superstructurecompartmentsandcontractorcompartmentare
receivedfromrespectivemanufacturingandassemblyshopsofVehicleDivision.Importantalignmentslike
crankshaftdeflection,compressoralignmentandEddyCurrentclutchradiatorfanalignmentaredoneduring
assemblystage.
Fig6:SideviewofGMLocomotiveDieselEngine
OperationinLAS:
1 . D r i v e c a p a s s e m b l y AircompressorassemblyControlstandassembly
2 . D r i v e r c a p c h e c k i n g Airbrakepiping
3 . L o n g h o o d a s s e m b l y BufferassemblyRadiatorsetting
4 . E n g i n e s e t t i n g Compressorsetting
5 . L o n g h o o d s e t t i n g AuxiliarygeneratorassemblyandsettingAlternatorpartpackingand
assembly
6 . E q u i p m e n t a s s e m b l y FueloilparkingLubeoilpipingEnginewatercoolingpiping
7 . D r i v e r s h e e t s e t t i n g DamperassemblyAirductsetting

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3. LPS (LOCO PAINT SHOP)
In loco paint shop, generally painting of locomotives is done after final assembly .After
painting, it goes to LTS (Loco Test Shop) for final inspection & after which it is delivered
to its destination.
 SAFETY PRECAUTIONS:
1. Every worker should wear PPE’s (Proper Protection Equipments) and then do his
work.
2. While doing spray painting, compressed air pressure should being 4-5 kg/cm2 range.
3. Before starting spray painting, check whether (spray painting gun, nozzle/cap, pan
haze connector, suction haze filter) are tight or not and tighten it. Remove old cotton
cloth from suction haze assembly and tie/fasten it with new cotton cloth.
4. After completing the spray painting operation, close the compressed air connection,
while cleaning airless painting spray gun .Remove painting gun & lock the trigger.
5. While cleaning spray gun of PFT painting device, properly close the knob tightly and
even close the compressed air supply.
6. While painting or while cleaning, make sure that nozzle of spray gun should not be
towards your face or towards anyone else.
7. After completing the work, workers should ensure that compressed air pipe should be
placed properly on the floor near air point.
 WORKING IN LPS:
1. Cleaning and masking inner & outer area of the engine by compressed air& thinner.
2. Cleaning, sanding, dusting by compressed air and primer painting by Epoxy Zinc
Phosphate on outer side of Loco.
3. Doing H.R gray painting inside as well as applying Epoxy putty on outer parts of
Locos.
4. Masking, sanding, dusting through compressed air and finish painting inside driver’s
cabin.
5. Sanding, cleaning through compressed air and Epoxy Surfacer painting on outer areas
of Loco.
6. Sanding, cleaning through compressed air and P.U finish painting (2 coating) of1st
Border area and then masking & marking.

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7. Sanding, cleaning through compressed air and P.U finish painting (2 coating) of2nd
Border area and then masking & marking.
8. Sanding, cleaning through compressed air and P.U finish painting of rest outer portion
of Loco (single coating).
9. Sanding, cleaning through compressed air and P.U finish painting of rest outer portion
of Loco (double coating).
10. Sanding, cleaning through compressed air and P.U finish painting of both bogies.
11. De masking of both inner & outer areas of Loco.
12. Pipe marking (colour coding) ,stencil work ,DV Hood ,net painting, face setting &
door lock painting ,touch up painting & applying Decol.
F
Fig 6: Painting of a Locomotive

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4. SAS (SUB-ASSSEMBLY SHOP)
SAS or Sub assembly shop of workshop is a place where assembly of different parts are
carried out. It mainly concerns with the assembly of cylinder –piston arrangement and all
other necessary accessories that are required for proper working of cylinder piston
arrangement.
There are basically four assemblies which are carried out in SAS shop. These are:
1. Power Assembly
2. Water pump Assembly
3. Clutch drive Assembly
4. Rocker arm Assembly
5. Valve bridge Assembly
6. OST Assembly
DETAILED ASSEMBLY WORK:
a) Carrier assembly:
Different parts are carrier, insert bearing &piston pin. Apply lube oil on insert bearing
surface &piston pin. Then assemble both parts into carrier.try to keep the pin hole, piston
cooling hole, and insert bearing round punch mark aligned for proper flow of lube oil.
Put retainer plate &lock the insert bearing from both sides with specified bolts. Keep in
mind that rod &pin bolt hole should remain in vertical position. Mount fork/blade to
piston pin and assemble it with specified bolts.
b) Piston assembly:
Clean the piston carefully before assembly. Apply lube oil on thrust surface and thrust
washer. Fit trust washer in piston and fit the complete power assembly to piston. Then
open this assembly from one end to fit into the piston rings.
c) Liner assembly:
Clean the surface with air& apply lube oil. Keep in mind while fitting piston rings :
 First-Second= 180 degrees
 Second-Third=90 degrees
 Third-Fourth=180 degrees
 Fourth-Fifth=90 degrees

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 Fifth-Sixth=180 degrees
Apply lube oil to piston& piston rings. Carefully put gasket over liner water
holes.
d) Cylinder head assembly:
Clean the cylinder head & other parts like exhaust valve spring sheet, sheet lock by
compressed air. Put plate at one end of cylinder head & exhaust valve and then fit
bottom plate Lock it from both sides. Fit spring in exhaust valves. Press spring over
hydraulic press machine. See that lock does not come out.
e) HHP Power assembly:
Assemble cylinder head over liner stud &assemble all other accessories compound.
Assemble all other parts with the help of specified bolts .
 Leak Test
Fill the water through dummy plate. Fit leak test gauge outlet end. Maintain 80 psi air
pressure. Then after one and half hours cal inspector to check whether leakage or not.
Inspector permits where the assembly is proper or not.
In an EMD diesel engine, since two power assemblies share a common connecting-rod
journal, and since the power assemblies are directly opposite each other rather than staggered
as in a typical V-type engine, two different power assemblies are required in a single engine.
The difference between the two assemblies is in the connecting rods. One connecting rod "big
end" has to fit inside that of its companion rod and the two types are referred to as "blade
rods" and "fork rods". The "fork rod" is logically the "master" as only it has a "rod cap", in
this specific case referred to as a "basket", whereas the "blade rod" is logically the "slave" as
its "big toe" is designed to fit completely within, and is guided by, and is retained by the
"fork", and both are retained by the single "basket".
Several situations can require power assembly replacement. Most are due to failure within the
power assembly itself such as a dropped valve, broken piston or internal coolant leak. Less
common are replacements to repair catastrophic failures such as broken connecting rods or a
"hydro-locked" power assembly that has been broken or knocked out of the cylinder block
when the cylinder filled with coolant during engine operation and the inability of the piston to
compress the liquid caused catastrophic failure. Complete power assembly replacements,

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where all of the assemblies in an engine are replaced, are least common and are normally
done as part of a comprehensive engine overhaul.
In a normal in-service power assembly replacement situation, the replacement will follow an
inspection of the engine specifically performed to find internal engine failures. With the
engine crankcase access and cylinder block airbox covers removed, a visual inspection of the
engine's rotating and reciprocating assemblies can be performed. The use of a fiber
optic endoscope (flexible borescope) may facilitate this inspection and evaluation, but this is
not a requirement, nor is it a part of EMD's maintenance program.
The engine airbox covers (the upper covers observed on the side of an EMD engine - they
cover the "airbox" that allows air to flow through the cylinder block to the power assemblies)
are removed to allow visual inspection of the inside of the cylinder liners and the piston
crowns, skirts and rings. The crankcase access covers (the lower covers observed on the side
of an EMD engine) are also removed to inspect for coolant leakage, damaged components
and excessive wear. A proper inspection requires filling and pressurizing the cooling system
to check for leakage from the power assemblies.
To inspect the engine, it can be manually "barred over" with a lever, but manual engine
rotation is slow and inefficient. In some applications manually barring the engine over can be
difficult or impossible. The preferred tool for engine rotation is an electrically powered,
hydraulically operated "turning jack". The turning jack uses a hydraulic cylinder and ram
assembly that automatically advances to engage a hole in the flywheel. When the ram reaches
its limit, it automatically retracts and advances again to engage another hole. The engine is
then progressively rotated through its cycle and can be rotated in either direction by installing
the jack on either side of the engine. Not only is a turning jack faster and more efficient, it is
also safer since there is no risk of a barring lever coming loose and causing injury or damage.
Also, with a turning jack, there is no need for the mechanic to be in physical contact with the
engine at any point during the inspection process.

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5. EES (ENGINE ERICCSION SHOP)
In Engine Ericcsion Shop, the assembly of crankcase, cylinder and other accessories &
mountings are done. Assembly of cylinder is done in SAS shop. Crank case from machine
shop arrives in EES .First of all, crank case is washed in crank case washer.
Then nut bolts and other accessories are mounted in it. Then crank shaft and oil pane are
attached .
Fig 7: Loco Engine Assembly
Then camshaft and other mountings like OSTD, Governor, Water pump, lube oil tank, Filter,
Exhaust, Turbo jet etc are mounted on engine. After full& final assembly of engine is done
before it is sent to ETS (Engine Test Shop) for final testing.
Fig 8: Diagrammatic and Real representation of Locomotive Engine

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A turning jack also allows a complete top deck and crankcase inspection to be performed by
one mechanic in minutes, and inspecting the engine with the components in motion produces
a better inspection. Rocker arm rollers can be inspected for proper rotation, potential
valvetrain problems such as insufficient or excessive clearance can be observed, piston ring
movement in the ring grooves indicating excessive groove wear can be observed, broken
valvesprings can be more easily seen, and so on. A turning jack also allows the mechanic to
observe the flywheel timing marks while the engine is rotating to time the engine properly for
maintenance or post-repair engine valve-train and fuel-system adjustments.
Claims of power assembly replacement being possible with "ordinary tools" in a "few hours"
are subjective, as the tools necessary are hardly "ordinary" in typical mechanic shops and
actual repair times can vary widely depending on the situation. At the minimum, large
sockets and high-capacity torque multipliers are necessary to enable the large nuts retaining
the hold-downs to be removed and retorqued to proper specifications. Various other special
tools, while not strictly required, make the job much easier. Additionally, there are special
tools required for adjustment of the fuel system after assembly replacement.
As far as repair time goes, power assembly replacement is typically performed by at least two
mechanics so the labor involved is at least twice the repair time required. If the engine comes
in for inspection or repair "hot", the unit may need to cool for several hours before repairs can
begin. If parts are not readily available, the delays will increase. Typically, for a power
assembly replacement in an engine cool enough to work on and with the proper tools and
necessary parts readily at hand, two mechanics can replace a power assembly properly and
safely in a 4-hour period. Rarely are major repairs involving expensive engines and
components and significant safety hazards rushed to create "efficiency" at the expense of
safety and reliability.
The quality and layout of the work area also has a big effect on the time required and the
quality of the work. Proper equipment and tools make the job "easy". Poor working
conditions and having to make do without the appropriate tools and equipment can make the
replacement process a nightmare. The aforementioned "barring over" with a lever versus
having a turning jack is a good example of being properly equipped. A properly equipped
repair shop for mobile equipment (locomotives) or individual engines (rebuild/overhaul shop)
or the area where stationary engines are permanently installed (marine applications where the
engine cannot be practically removed for service or electrical power plants, etc.) will be

21. 21
equipped with sufficient overhead lifting equipment to allow the assemblies to be safely and
efficiently handled, removed and installed.
Although the components are large and heavy and specialized tools are required, the
replacement process is straightforward and simple. The engine coolant is drained, the rocker
arm assembly and fuel system components are removed, the connecting rod is disconnected
from the crankshaft, the power assembly hold-downs (commonly called "crabs") are
removed, the cooling system plumbing is disconnected, the lifting fixture is installed and the
power assembly is lifted out of the cylinder block. The process is reversed to install the
replacement power assembly.
Following installation of the replacement assembly, all hardware is torqued to specs, the
cooling system is refilled, the engine crankshaft is properly timed to allow the valves and fuel
injector of the new power assembly to be adjusted, the valve train and fuel injection system is
adjusted using appropriate gauges, the fuel system is primed and the engine is started and
checked for proper operation and leaks within the cooling system, if any, are identified. As in
any other situation where an engine is rebuilt, there is a "break-in" period for replacement
power assemblies that should include operating the engine at varying speeds and loads for a
specified period of time to seat the cylinder rings before the engine is placed into normal
service.

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6. CTS (CENTRAL TRANSPORT SHOP)
CTS or Central Transport Shop is a shop where maintenance is done of vehicals used in
entire DLW. From the cars of officials to vehicals used in lifting materials and material boxes
.Examples are jumbo trucks, fork lift truck.
1. FORK LIFTER TRUCK
It is a diesel run vehical which works on hydraulic principle (Pascal law) to carry out lifting
function. It is mainly used for lifting material boxes upto 2 tones. It is diesel operated
vehical.
Fig 9: Fork lifter
2. JUMBO TRUCK
It is a battery run vehical used for material handling. It has a flat platform over its chasis to
make room for material to be carried. It is of two types.
Fig 10: Jumbo truck

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Main parts of battery operated vehicles:
 Motors:
Electric cars have traditionally used series wound DC motors, a form of brushed DC electric
motor. Separately excited and permanent magnet are just two of the types of DC motors
available. More recent electric vehicles have made use of a variety of AC motor types, as
these are simpler to build and have no brushes that can wear out. These are usually induction
motors or brushless AC electric motors which use permanent magnets. There are several
variations of the permanent magnet motor which offer simpler drive schemes and/or lower
cost including the brushless DC electric motor.
 Motor controllers:
The motor controller regulates the power to the motor, supplying either variable pulse width
DC or variable frequency variable amplitude AC, depending on the motor type, DC or AC.
 Battery:
Most electric vehicles today use an electric battery, consisting electrochemical cells with
external connections in order to provide power to the vehicle.Battery technology for EVs has
developed from early lead-acid batteries used in the late 19th Century to the 2010s, where
most batteries used in EVs today are lithium-ion batteries.
3. DIESEL VEHICALS
Other vehicles like Ambulance, Bolero, Pitch roller, Truck, Tempo, cranes, tractors and many
more came for servicing and maintenance. Most of the vehicles work on four stroke diesel
engine that are: suction, compression, power, exhaust stroke.
Diesel is taken as main fuel and air is taken from atmosphere, is filtered and supplied to the
cylinder for combustion. The power obtained is not only utilised in running the vehicles but it
also runs accessories like compressor, pump etc.
 Four-stroke engines
Like a gasoline engine, a diesel engine usually operates by repeating a cycle of four stages or
strokes, during which the piston moves up and down twice (the crankshaft rotates twice in
other words) during the cycle.
1. Intake: Air (light blue) is drawn into the cylinder through the open green air inlet
valve on the right as the piston moves down.
2. Compression: The inlet valve closes, the piston moves up, and compresses the air
mixture, heating it up. Fuel (dark blue) is injected into the hot gas through the central

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fuel injection valve and spontaneously ignites. Unlike with a gas engine, no sparking
plug is needed to make this happen.
3. Power: As the air-fuel mixture ignites and burns, it pushes the piston down, driving
the crankshaft (red wheel at bottom) that sends power to the wheels.
4. Exhaust: The green outlet valve on the left opens to let out the exhaust gases, pushed
out by the returning piston.
 Two-stroke engines
In a two-stroke diesel, the complete cycle happens as the piston moves up and down
just once. Confusingly, there are really three stages in a two-stroke cycle:
1. Exhaust and intake: Fresh air is blown into the side of the cylinder, pushing the old
exhaust out through valves at the top.
2. Compression: The inlet and exhaust valves close. The piston moves up, compresses
the air, and heats it up. When the piston reaches the top of the cylinder, fuel is injected
and spontaneously ignites.
3. Power: As the air-fuel mixture ignites, it pushes the piston down, driving the
crankshaft that sends power to the wheels.
Two-stroke engines are smaller and lighter than four-stroke ones, and tend to be more
efficient since they produce power once during each rotation (instead of once during every
two rotations, as in a four-stroke engine). This means they need more cooling and lubrication
and suffer higher wear and tear.
 NOTE: HYDRAUIC PRESSING MACHINE
This machine is installed in CTS. It is mainly used for RIM fitting & dismantling on
solid types. It has capacity from 80-100 tonnes. It takes electrical supply 415V at 50
Hz. The pump of machine works at 10-17 litres per minute. The motor works at
5.5kW at 1440 rpm.It is manufactured by PES hydraulics India pvt. Ltd.

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CONCLUSION
As DLW focuses not on quantity ,but on quality & satisfaction of its customers .It has always
been in top of public sector companies. Last year DLW has won second consecutive time
“Best Production Unit Shield of 2016-2017” of Indian Railways.
As vision of DLW is
"To be a world class manufacturer of reliable, cost-effective, state of the art Diesel - Electric
locomotives."
And mission of DLW is
"We shall achieve our vision through
♦ Focus on quality for sustained and continuous improvement in reliability &
performance on the product leading to
customer satisfaction.
♦ Developing core competence with due emphasis on innovation, human resource
development and team work.
♦ Achieving environmental excellence by prevention of pollution, reduction of emissions,
energy conservation and
preservation of natural resources.

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BIBLIOGRAPHY
1. www.dlw.indianrailways.gov.in
2. www.irfca.org
3. www.cris.org
4. www.scrib.com