This document provides an overview of the Diesel Locomotive Works (DLW) in Varanasi, India. It was established in 1956 to manufacture diesel-electric locomotives for Indian Railways. DLW produces around 250 locomotives annually and has various production shops that specialize in different components and assembly stages. Key shops include the block division, engine division, and loco division, which focus on fabrication, engine production, and final locomotive assembly, respectively. The document outlines the classification system for locomotives and describes some of the main production processes at DLW, such as sub-assembly, heat treatment, and engine erection.

1. K.N.G.D MODI ENGINEERING COLLEGE
DEPARTMENT OF MECHANICAL ENGINEERING
PRESENTATION ON : DIESEL LOCOMOTIVE WORK
SUBMITTED BY
SHUBHANKAR SINGH
ROLL NO.- 1319540087
SUBMITTED TO
NUPUR MEHTA
Asst. Professor

2. OUTLINE
 Introduction of DLW
 Classification
 Production Shop
 Sub Assembly Shop
 Heat Treatment Shop
 Loco Assembly Shop
 Engine Erection Shop

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

4. SOME FACTS ABOUT DIESEL LOCOMOTIVE
WORKS
DLW’s annual production - 250
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

5. Classification of locomotives
Locos, except the older steam ones, have classification codes that identify them. This
code is of the form
WDG5A “ [ gauge ][ power ][load ][ series ][ sub type ]”
•The first letter (gauge)
W- Indian broad gauge
Y- meter gauge
Z- narrow gauge(2.5 ft)
N- narrow gauge (2 ft)
 The second letter (motive power)
D- Diesel
C- DC electric (can run under DC traction only)
A- AC electric (can run under AC traction only)
CA- Both DC and AC (can run under both AC and DC tractions)
B- Battery electric locomotive (rare)

6. The third letter (load type)
G-goods
P-passenger
M-mixed traffic ; both goods and passenger
S-Used for shunting
U-Electric multiple units (E.M.U.)
R-Railcars
The fourth letter (series)
The series digit identifies the horsepower range of the locomotive.
Example for the series letter ‘3’ means that the locomotive has power over 3000 hp but less than 4000 hp.
The fifth letter (subtype)
an optional letter or number that indicates some smaller variations in the basic model.
For ex: ‘A’ for 100 hp,
‘B’ for 200 hp and so on……..

7. Production Shops
PRODUCTION
SHOPS
BLOCK
DIVISION
ENGINE
DIVISION
LOCO
DVISION

8. BLOCK
DIVISION
HEAVY
WELD
SHOP
HEAVY
MACHINE
SHOP
ENGINE DIVISION
LIGHT MACHINE
SHOP
SUB ASSEMBLY
SHOP
ROTOR SHOP
HEAT TREATMENT
SHOP
ENGINE ERECTION
SHOP
ENGINE TESTING
SHOP
LOCO
DIVISION
LOCO
TEST
SHOP LOCO
FRAME
SHOP
PIPE
SHOP
TRUCK
MACHIN
E SHOPTRACTI
ON
ASSEMB
LY SHOP
SHEET
METAL
SHOP
LOCO
ASEEM
BLY
SHOP
LOCO
PAINT
SHOP

9. Sub Assembly Shop
This shop deals with following section:-
 Turbo machining section
 Cylinder head & shot blast section
 Fuel pump, support, cam shaft ate section
 Cylinder head
 Turbo
 Governor, Water pump, Fan Drive, Lube oil pump, After Cooler assembly section.

10. Heat Treatment Shop
In this shop hardening, stress leaving, tempering, normalizing, carburizing, quenching, is done by help of
conventional & unconventional process. Here we are doing hardening of cam-shaft, connecting rod, piston
pin, different small components of cylinder head.
This shop is divided in two parts which are as follows:-
 Induction Section- Use for induction hardening
 Furnace Section- Use for overall process

11. Loco Assembly Shop
L.A.S. Operation:-
 Drive cap assembly, Air compressor assembly, Control stand assembly.
 Driver cap checking, Air brake piping.
 Long hood assembly, Buffer assembly, Radiator setting.
 Engine setting, Compressor setting.
 Long hood setting, Auxiliary generator assembly and setting Alternator part packing and assembly.
 Equipment assembly, Fuel oil parking, Lube oil piping, Engine water cooling piping.
 Driver sheet setting, Damper assembly, Air, duct setting.

12. Engine Erection Shop
Engine erection shop There are seven sections in this shop from 01 to 07 action have two or three station as
given below:-
• Station No. 1 to 4 in section 01.
• Station No. 5, 6, 6A and 6B are in section 02 to 03.
• Station No. 7 to 12 are in section 04 to 07.
• Station No.1 to 4 - Washing, debarring and panting.
• Station No. 5 - Cam shaft bush fitting cylinder head stud driving linear Sleeve and Liner pressing and
water testing.
• Station No. 6A - Piston Assembly.
• Station No.6B - Crank Shaft Assembly.
• Station No 6 - Piston Assembly Heads, Exhaust Manifold, water Connection, Air elbows, Nozzle and
water header Pipe-fitting.
• Station No.7 to 9 - Lowering engine block, oil catcher, Generator, Lube Pump and water pump fitting oil
• Station No. 10 - Cam shafts, gears, Control shaft, Turbo supper cooler, Oil Seal, Turbo super charger
application.
• Station No.11 & 12 - Fuel pump Support, Valve leaver, Governor

13. THANK YOU !