This summer training report summarizes the student's experience at Diesel Locomotive Works in Varanasi. DLW was established in 1956 to manufacture diesel-electric locomotives for Indian Railways. It produces 250 locomotives annually and was set up in collaboration with ALCO to meet India's growing transportation needs. The report describes DLW's production process including welding, bogie assembly, axle and wheel assembly, and locomotive testing. It also outlines the objectives of preventive maintenance and types of machinery used such as mills and cranes.

1. 
Summer training report
on
dieSel locomotive workS varanaSi
Submitted to- Submitted by-
MECHANICAL ISHANT GAUTAM
DEPARTMENT B.TECH (M.E) 4th
Year.
TITM, MEERUT ROLLNO-
1232140025

2. DLW, was founded by Late Railway Minister Mr. Lal Bahadur Shastri on 23
April 1956. It is spread in 300 acres area at Varanasi.
It is a production unit owned by Indian railways , for which it manufactures
diesel–electric locomotives and its spares parts.
To meet the increased transportation needs of the Indian railways it was
established in collaboration with ALCO( American Locomotive Company),
USA in 1961.
 DLW rolled out its first locomotive three years later, on January 3, 1964. It
manufactures locomotives.
introduction

3. 
 DLW’s annual production - 250 Loco
 Cost of one loco - 12 to 14 crore (EMD)
8 crore (Alco)
 Weight of one Loco - 121 Ton
 Fuel Consumption; At Full Load - 540 lt/hr.
Idle Load - 40 lt/hr.
 Max. Speed - 160 Km/hr.
 Dia of Wheel - 1092 mm
 Wheel to Wheel Distance - 1596.5 mm
 Length of Under Frame - 19962 mm
Some factS about
dieSel electric
locomotive

4. 
 In a diesel-electric locomotive, the diesel engine drives an electrical generator or
alternator whose output provides power to the traction motors. There is no
mechanical connection between the engine and the wheels.
dieSel electric locomotive

7. welding Shop
Welding is a process which produces joining of materials
by heating them to suitable temperatures with or
without the application of pressure and with or without
the use of filler material.
Welding is used for making permanent joints.
It is used in the manufacturing of automobile bodies,
aircraft frames, railway wagons, machine frames,
structural works, tanks, furniture, boilers, general repair
work and ship building.

8. Shielded Metal Arc Welding [SMAW]
Submerged Arc Welding [SAW]
Gas Shielded Metal Arc Welding [MIG]
Flux Cored Arc Welding [FCAW]
Shielded Metal Arc Welding [SMAW]
Submerged Arc Welding [SAW]
Gas Shielded Metal Arc Welding [MIG]
Flux Cored Arc Welding [FCAW]
Types Of Welding Used in dlWTypes Of Welding Used in dlW

9. bOgie assembly shOp
 A bogie is a wheeled wagon or trolley. In
mechanics terms, a bogie is a chassis or
framework carrying wheels, attached to a
vehicle.
 Usually the train floor is at a level above the
bogies, but the floor of the car may be lower
between bogies.

10. bOgie assembly (emd)
 Wheel and Axle assembly.
 Brake rigging assembly.
 Traction motor & gear case assembly.
 Bearing adopter assembly.
 Final assembly.

11. axle, Wheel & axle bOx assembly
These wheels are having wear adapted profile to RDSO drawing.

12. axle, Wheel & gear assembly WiTh
TracTiOn mOTOr

13.  PRESS BULL GEAR ON AXLE.
 SHIFT ABOVE ASSEMBLY AT BEARING HOUSING
FITTING STAND.
 FIT THE BEARING HOUSING AND BOLTING .
 ASSEMBLE SEAL , CAP AND TAPER ROLLER BEARING
 BOLTING .
 NOW, SHIFT THIS ASSEMBLY ON WHEEL & AXLE PRESS
MACHINE.
assembly prOcess:

14. Break down of machine can occur due to the following two reasons:
Due to unpredictable failure of component which cannot be prevented.
Due to gradual wear and tear of the parts of the machine which can be prevented by
regular inspection known as preventive maintenance.
prevenTive mainTenance
Also termed as “planned maintenance” or “systematic maintenance” .
An extremely important function for the reduction of the maintenance cost and to
keep the good operational condition of equipment.
breakdOWn mainTenance
mainTainance area

15. 
To obtain maximum availability of the plant by avoiding break down and
by reducing shut down period to a maximum.
To keep the machine in proper condition so as to maintain the quality of the
product.
To ensure the safety of the workers.
To keep the plant at the maximum production efficiency.
To achieve the above objectives with most economical combination.
objective of preventive maintenance

16. 
1. Heavy Machine Shop
2. Light Machine Shop
macHine SHop

17. 1. Conventional machine
2. NC machine
3. CNC machine
1. conventional macHine:
It is a simple machine which is now an old technique.
2. numerical control macHine:
Numerical control is defined as a system in which the actions of the machines
are controlled by the insertion of the numerical data. In other words number
controls the action.
typeS of macHineS

18. cnc milling macHineS
CNC mills can perform the functions
of drilling and often turning.
CNC Mills are classified according to
the number of axes that they possess.
A standard manual light-duty mill is
typically assumed to have four axes:
Table x.
Table y.
Table z.
Milling Head z.

19. 
loco & engine teSt
SHop

20. 
lubricating oil teSting
 Lubrication is done for better performance of the engine parts.
 testing is done by checking the circulation of lubricant oil.
 For rotating parts checking is done by seeing the returning path of the oil
i.e. checking not only the forward path but also the returning path.
 RR40 is used as lubricating oil.
typeS of teSting

21. 
 Water acts as a coolant for moving part of the engine because constant
movement or rotation causes various parts to heat up and water
working as coolant cooled down the concerned part.
load teSting
For load testing electrical load is provided to the engine. If there is
any abnormal sound then the engine is again tested for lubrication so
that any flaw which is there can be removed.
water teSting

22. Fork liFt truck
Forklift is a powered
industrial truck used to lift
and transport materials.

23. 
HYDrAulic lADDEr

24. crAnEs
A crane is a lifting
machine, generally
equipped with
a winder, wire
ropes or chains and sheav
es, that can be used both
to lift and lower materials
and to move them
horizontally.