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Presented by:

Abhishek Raj091603mechanical

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INTRODUCTION TO DLWDiesel locomotive Works ,Varanasi is a Production Unit of Locomotives under government of india ,Ministry of Railway withISO-9001, ISO-14001 & OHSAS-18001 certification.

It is spread over 300 hectares in the midst of city Temples , Varanasi.DLW has been manufacturing High quality Locomotives ( bothALCO& EMD type) & Diesel Generating Sets for Indian & Globalmarket.

It annualy manufactures 200 locomotives &Annual turnover is 1151 crores.

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TRUCK MACHINE SHOPBogies works as a leg of locomotive.It bears load of loco U/F, power pack , super structure andother accessories of locomotive.Two bogies are used in one locomotive.

TYPES OF TRUCK FRAME A. According to wheel arrangement bogie are to two type mainly.

* Bo-Bo Bogie ( Bi axle bogie, axle independently driven ) it contain 2axle 4 wheels, 2 TM.* Co-Co Bogie ( Tri axle bogie, axle independently driven ) it contain 3axle 6 wheels, 3 TM.B. According to truck frame manufacturing method.* Cast steel type truck frame such as YDM4, WDM2, WDS6, WDG4,

WDP4.* Fabricated truck frame such as WDG3A, WDM3D, WDP2, WDP1

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Main Items of Boggie

Axle

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Axle wheel assly .

ASSEMBLED WHELL & AXLE

Mounting pressure for Gear 50-115 TonesMounting pressure for Wheel. 80- 130 Tones

Mounting Pressure for journal bearing 50 TonesUniform rise in pressure to be maintained

Back lash clearance between Pinion andBull Gear should be in the range of 0.016"

to 0.024"

Axle, wheel & Gear assembly with

Traction Motor.

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Assly. Of axle wheel with truckframe

Primary suspension system

After axle-wheel is assembled withtruck frame , suspension systems areinstalled .

Top view of EMD Bogie

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Heavy Machine Shop

Engine crankcase After Normalising

Engine crankcase is manufactured firstlyby cutting the steel plates using plasma &laser cutting , and then it is welded inheavy weld shop to manufacture enginecrankcase .

After welding , weld joints areRadiographically & hydrolically tested.Now it is Heat treated in Heat Treatmentshop to normalise the crankcase .After Normalising , it is send to HeavyMachine shop , where it is given closetolerances upto 1 thou, on portal milling

machine , Planar machines & Angularboring Machine.

Plasma arc cutting

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Machining of crankcase on PortalMilling Machine

Machining of crankcase on Angularboring Machine.

Tool Magazine for portal milling

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ENGINE SHOP

Main Parts of EMD Engine

Oil Pan

Crankcase

Crankshaft

Power Assl.

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Cylinder Head Piston Assly .

Alternator Complete AsslyOf Power pack

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LOCO ASSEMBLY SHOP

All the piping systems forbrake & coolling of tractionmotor , fuel tank , MainReserviors etc are installed inthe loco Frame at the LocoFrame shop, and then Locoframe is transferred to LAS.Complete Superstructure ,

which possess driver cab ,longhood , shorthood etc istaken from sheet metal shopto LAS .Once engine , compressor,ECC, etc are installed on theunderframe , superstructureis joined at it.

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Mounting of Underframe +engine +othr accessories on boggies .

Once a Locomotive is assemledcomletely Except mounting on

boggies, it is shifted forPainting to Loco Paint Shop.From Loco Paint shop , It Isagain taken to Loco assembly shop, where it is mounted on

boggies.Now loco is completely assembled. So it is proceded fortesting to Loco Test Shop.If at LTS , any part is found

faulty , it is sent back to thecorresponding shop. After loco is tested , it is ready for the service.

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THANK YOU