The document discusses Diesel Locomotive Works (DLW) in Varanasi, India which manufactures diesel locomotives. It was established in 1961 in collaboration with American Locomotive Company. DLW produces two types of locomotives - ALCO and GM locomotives. It exports locomotives to several countries. The document provides details on DLW's annual production, specifications of locomotives, and classification codes. It also describes the manufacturing process which involves various shops for machining, fabrication, assembly, testing and more.

1. Presentation on Industrial
Training
at
Manglesh Singh
Mechanical Engineering
Final Year
1350840049

2. o Production Unit under ministry of railways set up in Ancient city of temples,
Varanasi to Undertake indigenous manufacture of Diesel Locomotives.
o Set Up in Collaboration with American Locomotive Company (ALCO) in 1961.
o First Locomotive was rolled out in 1964.
o DLW got its first ISO certification in 1997. Recently DLW has obtained
“Integrated Quality and Environment Management system” certification based
on ISO-9001 and ISO-14001.
o Produces two types of locomotives
o ALCO loco
o GM loco
o DLW exports locomotives to Sri Lanka, Malaysia, Vietnam, Tanzania, Bangladesh.

3. GM (General Manager)
CME (G)
Chief Mechanical Engineer
CME (P)
Chief Mechanical
Engineer (Production)
Dy. CME
(Engine)
Dy. CME
(Block)
Dy. CME
(Loco)
Dy. CME
(Tooling)
Dy. CME
(Planning)
Dy. CME
(M&P)

4. Continued…
WM (Works Manager)
(AWM) Assistant Works Manager
SSE (Senior Section Engineer)
SE (Section Engineer)
JE (Junior Engineer)
MCM (Master Crafts Man)
FTR-I (Fitter-I)
FTR-II (Fitter-II)
FTR-III (Fitter-III)
Helper (Khalasi)

5. DLW’s annual production :250 locos
Cost of one loco :12 to 14 crore (GM loco)
8 crore (Alco)
Weight of one Loco :121 Ton
Fuel Consumption :At Full Load - 540 lit/hr.
:Idling- 40 lit/hr.
Max. Speed :160 Km/hr.
Dia of Wheel :1092 mm
Wheel to Wheel Distance :1596.5 mm
Length of Under Frame :1962 mm

6. Locos, except the older steam ones, have
classification codes that identify them. This code
is of the form:
“[ gauge ][ power ][load ][ series ][ sub type ]”
e.g. WDG5A

7. 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.

10. • The ALCO is a passenger/freight-hauling diesel-electric locomotive with
AC electric transmission designed by the American Locomotive
Company and produced under license by Diesel Locomotive
Works (DLW) of Varanasi, India for Indian Railways as their classes
WDM-2, WDM-3A/2C, WDM-3D and WDG-3A for operation in India.
• Power output
•2,600 hp (1,940 kW) (WDM-2)
•3,000 hp (2,240 kW) (WDM-3A/2C)
•3,100 hp (2,310 kW) (WDG-3A)
•3,300 hp (2,460 kW) (WDM-3D)

11. • The WDG4 & WDP4 series of DLW make locomotives are GM
(General Motor) locomotives.
• The GM locomotive is equipped with a microprocessor based
computer control system- referred to as EM- 2000 locomotive.
• The GM locomotives are also fitted with equipments like Engine,
Turbo super charger, Compressor, Alternator, Traction motors etc.
like those in ALCO locomotive but their designs are different.
• GM locos can produce power output up to 4500 hp.

14. Machining and Fabrication of Cylinder Block.
Machining : HMS
Fabrication: HWS

15. • Precision flame cutting by CNC
machines
• Thickness of plates: 80 mm
• 5 axis CNC machine
• This machine performs milling,
drilling, tapping and boring
operations in single setting.

16. Engine
DivisionEngine
Erection
Shop
Heat
Treatment
Shop
Engine
Test Shop
Rotor
Shop Sub
Assembly
Shop
Light
Machine
Shop
Turbo
Section

17. The shop deals with manufacturing of various components
required for the power pack unit such as cam shaft, connecting
rod, gear levers, piston pins etc.

18. This section deals with testing of functioning of
engine at various parameters.

19. This section involves hardening, tempering and stress
removal of various components including camshaft,
rocker arm, cam lobe etc.

20. This section involves assembly
of turbo-supercharger to the engine.

22. Fabrication of frames on which locomotives are
mounted.

23. Bending of various pipes used in
the locomotive frame.

24. • Machining and Assembly of Axle-Wheel.
• Mounting of traction motor on axle.

25. • Assembly of locomotive and loco-frame.
• Assembly of driver cabin with locomotives.

26. Flywheel
Valve
Water Pump

27. Rocker Arm
Head

28. Starter Motor
Arrangement of
starter motor
pinion and
Flywheel: As motor
starts and solenoid
actuates, pinion
shifts to mesh with
tooth on outer
periphery of
flywheel.