ENGINE DIVISION COMPONENT MACHINING Over 2000 components are manufactured in-house at DLW.

These include ALCO turbo superchargers, lubricating oil pumps, cam shafts, cylinder heads, chrome plated cylinder liners, connecting rods and various gears. Our well-equipped Machine Shops have dedicated lines for operations like turning, milling, gear hobbling, drilling, grinding and planning etc. In addition, DLW is equipped with a variety of special purpose machines and a large number of state-of-the-art CNC machines to ensure quality and precision. Associated manufacturing processes like heat treatment and induction hardening are also carried out

in-house.

A completely new Chrome Plating Shop for Cylinder Liners has been set up with modern infrastructure like fume extraction system and Programmable Logic Controlled material movement system. Engine Assembly & Testing Pre-inspected engine block, crankshaft, camshafts, cylinder liners, pistons, connecting rods, cylinder heads, exhaust manifold, turbo-supercharger and all related piping is used in assembly of engine. Electrical machines like traction alternator, auxiliary generator and exciter are thereafter coupled on the engine. The complete power pack with electrics are tested on Computerised Engine Test Beds to verify horsepower output. Vital parameters of engine are checked to assure the quality of product. Only after the engine parameters are found perfect the power packs are cleared for application on locomotives.

Vehicle Division
Component Fabrication Precision cutting and forming of sheet metal is utilised for manufacture of superstructures including drivers cab, engine hoods, and compartments for housing electrical equipment. All activities connected with pipes like pickling, bending, cutting, forming and threading of pipes of various sizes are undertaken in another well-equipped work area. All electrical equipment is assembled in the fabricated control compartments and drivers control stands is done in another work area. Under frame Fabrication Under-frames are fabricated with due care to ensure designed weld strength. Requisite camber to the underframe is provided during fabrication itself. Critical Welds areas are tested radio-graphically. Welder training and their technical competence are periodically reviewed. EMD under-frame is fabricated using heavy fixtures, positioners to ensure down hand welding. Fixtures are used to ensure proper fitting of components and quality welding in subsequent stages. BOGIE MANUFACTURING Special purpose machines are utilised for machining cast and fabricated bogie frames. Axle and wheel disc machining is undertaken on sophisticated CNC machines. Inner diameter of wheel discs are matched with the outer diameter of axles and assembled on wheel press. The complete truck (bogie), including bogie frames, wheels and axles, brake rigging and traction motors are assembled which is ready for application to locomotive. LOCOMOTIVE ASSEMBLY Tested engines are received from Engine Division. Similarly under-frames are received from Loco frame Shop and Assembled trucks from Truck Machine Shop. Superstructures and contractor compartments 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. 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 painting. all locomotive systems are rigorous tested as per laid down test procedures before the locomotive is taken up for final painting and dispatch.