This contains DLW Introduction and detail of 4 shops alloted during my training

1. PRESENTED BY
RAVI KUMAR JAISWAL
1303340839

2.  DIESEL LOCOMOTIVE WORKS (DLW), Varanasi (India) an ISO
9001:14001 & OHS 18001 certified production unit owned by Indian
Railways, it is a central unit of Govt. of India (ministry of Railway).
 It was laying of foundation stone of factory by the first president of
India Late Dr. Rajendra Prasad in 1956 & Diesel Locomotive Works
came existence in 1961.
 To meet the increased transportation needs of the Indian railways it
was established in near ancient city varanasi collaboration with
ALCO( American Locomotive Company), USA in 1961.
 First locomotive rolled out and dedicated to nation in January, 1964.

3.  Got its first ISO certification in 1997 and ISO-9001 and ISO-14001 in
December 2002.
 State of the art Design and manufacturing facility to manufacture
200 locomotive per annum with wide range of related products viz.
DG Sets , Loco components and sub-assemblies.
 A large base of delighted customers among many countries viz.
Myanmar ,sri lank, Malaysia, Vietnam, Bangladesh, Tanzania,
Angola, to name a few bearing testimony to product leadership in its
category.
 At present the latest locomotive produced by DLW; i.e. WDG 5 has
capacity upto 5000 HP & trying to make it 5500 HP.
 First loco realesed by late lal bahadur sastri in 1964 ,WDM2

4.  DLW’S annul Production -275
 Component are manufacture -2000
component
 Cost of one LOCO -25
crore(EMD)
 Weight of one LOCO -121 ton
 Fuel consumption at full load -540 lit/hr
 Fuel consumption at idle load -40 lit/hr
 Max. Speed -160km/hr
 Dia. of wheel -1092mm

6. 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)

7. • 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……..

8.  WDG5 5500 HP AC/AC Freight operation
 type locomotive
 WDG4 4000 HP AC/AC Freight Traffic
 Locomotive
 WDP4 4000 HPAC/AC Broad Gauge High
 Speed
 WDG3D 3400 HP AC/AC Broad Gauge Mixed Traffic
 Micro-Processor Controlled Locomotive.
 WDP3A 3100 HP AC/DC Broad Gauge High Speed
 passenger Locomotive
 WDM2 2600 HP AC/DC Broad Gauge Mixed Traffic
 Locomotive
 YDM4 1350 HP AC/DC &DC/DC Broad Gauge Mixed
 Locomotive
 WDP4D 4400 HP ac/ac Broad Gauge High Speed

10. BLOCK DIVISION
ENGINE DIVISION
LOCO DIVISION

11. •BLOCK DIVISION:
1.Heavy Weld Shop
2.Heavy Machine shop
•Engine Divisions:
1.Light Machine Shop
2.Engine Erection Shop
3.Engine Testing Shop
4.Sub Assembly Shop
5.Rotor Shop
6.Heat Treatment Shop
Loco Divisions:
1. Loco Frame Shop
2. Pipe Shop
3. Truck Machine Shop
4. Sheet Metal Shop
5. Traction Assembly Shop
6. Loco Assembly Shop
7. Loco Test Shop
8. Loco Paint Shop

12. SAS LAS
LPS
HMS
My four week training was confined to four
different sections

13.  Wheel and Axle assembly
 Brake rigging assembly
 Traction motor & gear case assembly

16. Animated View

17. This shop carries out the machining of
Cylinder BLOCK main base, saddler Main
bearing caps, Turbo Super Charger, Lube Oil,
Fuel Oil & Water header) com bearing housing.

18.  Planning,
 Milling,
 Drilling,
 Tapping,
 Boring Honing,
 Angular Boring,
 Serration milling etc.

22. • Tested engines are receives from Engine Division.
• Similarly under frames are received from Loco frame
shop and assembled trucks from Truck machine shop.
• Super structure 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.

23. • 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.

29. After the Loco (engine) is made they are sent for
final work of painting. Loco painting is done by
spray paint. Skilled workers are employed who
can make markings take shape and size under
consideration.
In loco paint shop the loco is spray painted by the
air tight paint booth.

32. In DLW, Loco Paint Shop is divided into different- different section, which under
section different -different portion painted for a specified colours.
BODERING:
Deep Yellow colour are used for WDG4. And Dazzling white, Golden yellow
colour are used for WDP4.
FINISHING:
Sky Blue Colour are used for WDG4. And French Blue colour are used for
WDP4.
FOR TRUCK PORTION:
Black paint used in both WDG4 & WDP4.
In DLW, Two types paint are used:-
1. Enamel Paint
2. Poly vinyl Paint
For safety purpose from dust particle used glass, rubber, builder plates,cables. And
resist from dust particle, Loco is spry by EZP (EPOXY ZINC PHOSPHATE).
Epoxy Surface:-
It is a process in paint (epoxy paint) is used for fill up all the gaps properly.

36. THANK U !