1. DIESEL LOCOMOTIVE WORKS (DLW) VARANASI (Uttar Pradesh)
PROJECT REPORT OF VOCATIONAL TRAINING

2. SIX WEEKS TRAINING REPORT -
DIESEL LOCOMOTIVE WORKS (DLW)
Submitted To: Submitted by :-
Mr. Suorbh Agrawal Ajeet Yadav
Lecturer of ME dept ( )
ME –VII-A

3. ACKNOWLEDGEMENT
I take this opportunity to express my heartfelt gratitude to the entire DLW team who helped me understand the basics of locomotives. I acknowledge with thanks the help extended by my project guides, Mr. N.N. Pathak (MMS) and Mr. Nizam (MGR). I am also very grateful to the many individuals, esp. Mr. U.C. Tiwari (Electrical Division) who offered me ideas, contacts and support along the way.
PUSHKAR PANDEY
Roll No

4. Certificate This is to certify that the project report of vocational
training entitled “DIESEL LOCOMOTIVE WORKS (DLW)” is done
by PUSHKAR PANDEY ( ). The matter embodied in
this project work has not been submitted earlier for the award
of any degree or diploma to the best of my knowledge and
belief.

5. About Diesel Locomotive Works Locomotives Produced By DLW
CONTENTS
Introduction
About Diesel Locomotive Works
Locomotives Produced By DLW
Products Of DLW
Innovations In Global Locomotives
Different Shop
Main Gauge Room
Maintenance Shop-II
Electronics Lab
Technology Leant
Engine Division
Reference

6. INTRODUCTION
•Diesel Locomotive Works (DLW) established in 30 April located in the city Varanasi (U.P.) in 300 hectares.
•Diesel Locomotive Works (DLW) manufactures the diesel electric locomotive engine (EMD and ALCO) and DG sets.
• Diesel Locomotive Works (DLW) Certification
ISO 9001 (International Organization for Organization)
ISO 14001
OHAS (Occupational Health And Safety Zone)

7. ABOUT DIESEL LOCOMOTIV WORKS ORGANISATION
A flagship production unit of Indian Railways offering complete range of products in its area of operation with annual turnover of over 2124 Crore.
State of the art Design and Manufacturing facility to manufacture
200 locomotives per annum with wide range of related products viz. DG Sets, Loco components and sub-assemblies.
Supply of spares required to maintain Diesel Locomotives and DG sets.
Unbeatable trail-blazing track record in providing cost-effective, eco-friendly and reliable solutions to ever increasing transportation needs for over four decades.
Fully geared to meet specific transportation needs by putting Price - Value -Technology equation perfectly right.

8. •1350 HP CAPE GAUGE LOCOMOTIVE VDM 4 •2300 HP CAPE GAUGE LOCOMOTIVE
PRODUCTS OF DLW
1-ALCO Product
•WDP3A 3100 HP PASSENGER LOCOMOTIVE
•1350 HP CAPE GAUGE LOCOMOTIVE VDM 4
•2300 HP CAPE GAUGE LOCOMOTIVE
•2300 HP METER GAUGE LOCOMOTIVE
•3000 HP CAPE GAUGE LOCOMOTIVE
2-EMD Product
•WDG HP GOODS LOCOMOTIVE
•WDP HP PASSENGER LOCOMOTIVE
3-DG Set (DIESEL GENERATING SET)

9. LOCOMOTIVES PRODUCED BY DLW
BROAD GAUGE MAIN LINE FREIGHT
LOCOMOTIVE: WDG 3A
TECHNICAL INFORMATION
Diesel Electric main line, heavy duty good service locomotive, with 16 cylinder ALCO engine and AC/DC traction with micro processor controls.

10. WDP4-4000 HP PASSENGER LOCOMOTIVE
State-of-Art, Microprocessor controlled AC-AC, Passenger Locomotive Powered with16-710G3B 4000HP Turbo charged Two Stroke Engine.
Fabricated rigid design under frame, two stage suspension, High Traction High Speed3 axle (HTSC) light weight cast truck frame attribute to high adhesion performance.
Wheel Arrangement
Co-Co
Track Gauge
1676 mm
Weight
123 t
Length over Buffers
19132 mm
Wheel Diameter
1092 mm
Gear Ratio
18 : 74
Maximum Speed
105 Kmph
Diesel Engine
Type: 251B,16 Cyl.-V
Train
Air
Min radius of Curvature
117 m
Fuel Tank Capacity
6000 litres
HP 3100
3100
Brake
IRAB-1

11. Diesel Engine:- Transmission:-
16 Cylinder 710 G3B, 2 stroke, turbocharged–after cooled.
Fuel Efficient Engine.
Injection System–Direct Unit Injector.
Compression Ratio – 16:1
Lube Oil Sump Capacity –1073 Lts.
Transmission:-
Electrical AC-AC.
4 Traction motor ( 3 in parallel per bogie).
Suspension– Axle hung / taper roller bearing.

12. DIFFERENT SHOP
Fitting shop
Machine shop
LAS (Loco Assembly Shop)
HWS (Heavy Welding Shop)
RS (Rotor Shop)
MGR (Main Gauge Room)
MSS (Maintenance Shop)
MA-II (Maintenance-II )
TMS (Truck Machine Shop)

13. MAIN GAUGE ROOM METROLOGICAL TERMS:-
ACCURACY : It is difference between mean value and true value of measurement.
PRECISION : This is the measure of repeatability.
RANGE : It indicates size value between which the measurement may be made on
the given instrument .
RESOLUTION : This is the minimum possible read out of instrument.
SENSITIVITY : This is the ability of measuring device to detect small difference in the quantity being measured.

14. ENVIRONMENTAL CONDITION IN MGR
Temperature in MGR shall be maintained by M & P staff within 20°C ± 2°C.
All measuring instrument should be callibrated before use by reference standard or as stipulated in three literatures in the MGR.
EQIPMENT
APPLICATION
ELECTRONIC TORQUE TESTER
FOR CALLIBRATION AND INSPECTION OF TORQUE WRENCHES.
DRUM MICROMETER
FOR CALLIBRATION OF ALL TYPE DIAL INDICATOR .
ACCURACY
TESA MICRO-HITE
TWO COORDINATE MEAN OF MEASURE RELATIVE HEIGHT , ANGLE & CENTER DISTANCE OF REFERENCE TO BORE .
ACCURACY /0.001µm.
ELECTRONIC HEIGHT MASTER
FOR CALLIBRATION OF SLIP GUAGE WITH STANDARD.
ACCURACY – ”/0.001µm.
UNIVERSAL GUAGE CALLIBRATOR MACHINE
FOR CAALIBRATION OF ALL TYPE NORMALINE ASSUMING INSTRUMENT LIKE O.S & I.S MICROMETER,DIALS,DIAL BORE GAUGES.
SUPER MICROMETER
FOR CHECKING OF PLAIN PLUG & THREAD PLUG GAUGE . ACCURACY –
SURFACE ROUGHNESS MEASURE MACHINE
FOR CHECKING OF SURFACE ROUGHNESS.

15. MAINTENANCE SHOP-II
Maintenance shop is the combination of many shops. The shops which come under the maintenance shop-2 are:-
1. Assembly shop
2. Machining shop
Daily care:-
Check all the safety guard before switch on the machine.
Do not by-pass any safety interlocks on the machine.
Check oil level for lubrication and hydraulic system.
Check and lubricate work holding.
When shutting down/change shift then clean the machine.
Keep tool bars/registers on disc clean and protected against damage.
Do not use compressed air for cleaning the machine tool.

16. ELECTRONICS LAB
Lab developed with the principle of providing of repairing and maintenance of the cards which are for the running of the CNC machine. One of the most important equipment used in lab for this purpose is QT 200.Details of this testing machine are given in the next sectionElectronics .

17. I.D.F (Internal Distribution Frame):-
Battery Charger:-
Operate at 230 V AC and then converts V DC and provide to the exchange battery is connected in parallel, as soon as electricity goes it get connected with exchange. In complete battery there is negative and positive plate. All negative plates are joined with the help of a solder at terminal post, which is called negative terminal and vice versa.
The negative and positive plates are kept in such a manner that every positive plates in between two negative plates. In this way numbers of negative plates are more in number comparison to positive plates.
Positive plates and negative plates are very close to other. To avoid mixing plates kept away by using separator of wood rubber. Positive material get collects under the battery.
I.D.F (Internal Distribution Frame):-
The cables which are coming out of exchange are terminated at I.D.F. In IDF the number are connected in series wire and thus it makes easier to find out the number when complication arises.
In R.T. exchange there are two type of IDF:-
1. Crone type install in the well by the tata.
2. Install just decide the MDF that tag block type.

18. TECHNOLOGY LEARNT Fitting tools
•Measuring tools: Steel Rule, Inside Caliper, Outside Caliper, Vernier Caliper and Micro meter.
•Holding device: Parallel Jaw Vice
•Cutting tools: Hacksaw, chisel and files
•Striking tools: Ball peen hammer, straight peen hammer, cross peen hammer.
•Marking tools: Scriber, Divider and Center Punch

19. REFERENCES www.dlw.indianrailways.gov.in

20. THANK YOU