This summer training report focuses on locomotive manufacturing at Diesel Locomotive Works in Varanasi, emphasizing the complexities and operations of the plant. It acknowledges various personnel for their support during the training and outlines the structure and services of Indian Railways, including production facilities. The document includes detailed descriptions of different locomotives and associated technologies, as well as various operational chapters regarding locomotive works.

1. i
A
Summer Training Report
On
Locomotive Manufacturing Workshops
At
“DIESEL LOCOMOTIVE WORKS, VARANASI”
Submitted in partial fulfilment of the requirements for the
degree of
Bachelor of Technology in Mechanical Engineering
Submitted By
NAME
ROLL NO.
DEPARTMENT OF MECHANICAL ENGINEERING
NOIDA INSTITUTE OF ENGINEERING AND
TECHNOLOGY
GREATER NOIDA, UTTAR PRADESH
DR. A.P.J. ABDUL KALAM TECHNICAL UNIVERSITY,LUCKNOW
DECEMBER,2017

2. ii
ACKNOWLEDGEMENT
I would sincerely like to thank the employees and the officers of DLW, VARANASI
for their help and support during the vocational training.Despite their busy schedules,
they took time out for us and explained to us the various aspects of theworking ofthe
plant from the production shops.
I would sincerely like to thank Mr. Arun Yadav (SSE/LTS), Mr. Vipin Srivastava
(JE/LFS), Mr. Arvind Kumar (JE/EES), Er. Ravi Gupta (JE/HMS) who was
instrumental in arranging the vocational training at DLW Varanasi, and without
whose help and guidance the training could not have materialize.
A special gratitude I give to Mr. Saurobh Poddar , whose contribution in stimulating
suggestions and encouragement, helped me to coordinate my project especially in
writing this report.
I express my deep sense of gratitude to Mr. S.P.Singh(Principal, TTC) for given me
such a great opportunity.
NAME
ROLL NO.
7th Semester,B.Tech
Department of Mechanical Engineering
Noida Institute of Engineering & Technology,Greater Noida

3. iii
LIST OF ABBREVIATIONS
Abbreviation Stands For
ALCO American Locomotive Company
SSE Senior Section Engineer
JE Junior Engineer
DLW Diesel Locomotive Works
CE Chief Engineer
CEE Chief Electrical Engineer
GTO Gate Turn-Off
NR Northern Railway
IGBT Insulated-Gate Bipolar Transistor
HP Horse Power
TTC Technical Training Center
M/C Machine
MTBF Mean Time Between Failure
MS Mild Steel
R&D Research & Development
GM General Motor
AL Aluminium
O/P Output
LFS Loco Frame Shop
KMPH Kilometre Per Hour

4. iv
HMS Heavy Machine Shop
LTS Loco Test Shop
EES Engine Erection Shop
ISO International Organization for Standardization
GA Grinding Allowance
ER Eastern Railway
ECR East Central Railway
ECoR East Coast Railway
AC Alternating Current
DC Direct Current
MA Maintenance Area
NER Northern Eastern Railway

5. v
ABSTRACT
Indian railways has one of the largest and busiest rail networks in the world Indian
Railways is the state-owned railway company of india.It comes under the Ministery of
transporting over 18 million passengers and more than 2 million tones of freight daily.
Its revenue is Rs.107.66 billion. It is the world’s largest commercial employer, with
more than 1.4 million employees. It operates rail transport on 6,909 stations over a
total route length of more than 63,327 kilometer (39,359 miles).The fleet of Indian
railway includes over 200,000 (freight) wagon coaches and 8,000 locomotive.It also
owns locomotive and coach production facilities .It founded in 1853 under the East
India Company.
India Railway is administrated by the Railway Board Indian Railway is divided into
16 zones.Each zone railway is made up of acertain number of division .There are a
total of sixty-seven dividions.It also operate the Kolkata metro.There are six
manufacturing plants of the Indian Railway. The total length of track used by Indian
Railway is about 108,805km.While the total route length of the network
63,465km.About 40% of the total track kilometer is electrified & almost all electrified
section use 25,000V AC. Indian railway uses four rail track gauges.
The GM Locomotives have been included in the Diesel Locomotive fleet of Indian
railway. Production of GM locomotive has already started in DLW, Varanasi. The
4000 HP, computer controlled GM locomotive has a large number of special and
improved features vis-a-vis the Alco design diesel locomotive presently running in
Indian railway. All those in the field of diesel locomotive need to get acquainted with
the GM locomotive. This book “Introduction hand book on GM locomotive” prepared
by the CAMTECH has been prepared with the purpose of disseminating the
introductory information to all those in diesel loco maintenance field.

6. vi
TABLE OF CONTENTS
Contents Page No.
First page … i
Acknowledgement … ii
List of Abbreviations … iii
Abstract … iv
Table of Contents … vi
List of Figures … ix
List of Tables … x
CHAPTER:1
1.1.Introduction to Diesel Locomotive Works (DLW) … 1
1.2.About the company … 1
1.3.About the plant … 2
1.4.Wheel Arrangement … 5
CHAPTER:2
2.1.Classification of Locomotive … 6
2.2.Salient features … 8
2.3.Products Of DLW … 8
2.3.1.WDG2 Locomotive … 9
2.3.2.Broad Gauge Main Line Locomotive WDG 3A … 10
2.3.3.Locomotive WDM3D … 11
2.3.4.Broad Gauge Shunting Locomotive WDS6AD … 13
2.3.5 .WDG4 - 4000 HP Goods locomotive … 14
2.3.6.1350 HP Meter Gauge Locomotive YDM4 … 16

7. vii
2.3.7.What is a diesel locomotive? … 17
2.3.8.Why was diesel engine developed? … 18
2.3.9.What Makes A Diesel Locomotive Work? … 18
2.3.10.The ‘Diesel Advantage’ … 19
CHAPTER:3
3.1.The Transmission system … 20
3.2.The Electric Transmission … 20
CHAPTER:4
4.1.Engine Erection Shop (EES) … 22
4.2.Washing … 23
4.3.Debarring … 23
4.4.Panting … 23
4.5.Piston Assembly … 23
CHAPTER:5
5.1 Loco Testing Shop (LTS) … 25
CHAPTER:6
6.1.Locomotive Frame Shop (LFS) … 30
CHAPTER:7
7.1.Heavy Machine Shop (HMS) … 32
7.2.Operations performed in HMS … 32
7.3.Type of the machines provided in the shop … 32
7.4.Tool used … 32
7.5.Measuring instrument … 33

8. viii
7.6.Ex-cello angular boring machine … 33
7.7.HMT Angular boring machine … 33
7.8.Machines available in HMS for block … 34
CONCLUSION … 36
REFERENCES … 37

9. ix
LIST OF FIGURES
Fig No. Title Page No.
Fig1.1 Diesel Locomotive Works,Varanasi … 1
Fig2.1 WDG2 Locomotive … 9
Fig2.2 WDG3A Locomotive … 11
Fig2.3 WDM3D Locomotive … 12
Fig2.4 WDS6AD Locomotive … 13
Fig2.5 WDG4 Locomotive … 14
Fig2.6 YDM4 Locomotive … 16
Fig3.1 Transmission system … 21
Fig4.1 Engine erection shop … 22
Fig4.2 Piston assembly … 23
Fig4.3 Piston Cylinder … 24
Fig5.1 Diesel engine … 25
Fig5.2 Electric engine … 26
Fig5.3 LTS shop … 27
Fig6.1 Loco frame shop … 30
Fig6.2 Lifting of frames … 30
Fig6.3 Loco frames … 31
Fig7.1 Angular boring machine … 33
Fig7.2 Automatic Boring Machine … 35

10. x
LIST OF TABLE
Table No. Title Page No.
Table2.1 Technical Information … 10
Table2.2 Technical information … 11
Table2.3 Technical Information … 12
Table2.4 Technical information … 13
Table2.5 Diesel Engine and Transmission … 15
Table2.6 General Characteristic … 15
Table2.7 Trucks And Brakes … 16
Table2.7 Technical Information … 14
Table7.1 List of machines … 34