TABLE OF CONTENTS

1. Acknowledgment
2. Preface
3. Introduction to D.L.W.
4. Heavy Weld Shop
5. Heavy Machine Shop
6. Light Machine Shop
7. Rotor Shop
8. Heat Treatment Shop
9. Sub Assembly Shop
10.T.T.C.
11.Conclusion
 ♣ ♣
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 the working of the plant, from the
production shops.

I would sincerely like to thank Shri Ravi Shankar, Alok Singh

(CWI/TTC) and Mr. Sunil Kumar(JE/H.W.S.), Mr. Vinod
Kumar(JE/Rotor Shop) who was instrumental in arranging the
vocational training at DLW Varanasi, and without whose help and
guidance the training could not have materialized.

I express my deep sense of gratitude to Mr. R. R. Jha (Principal,

TTC) for given me such a great opportunity.
 ♣ ♣
The objectives of the practical training are to learn something about
industries practically and to be familiar with the working style of a
technical person to adjust simply according to the industrial
environment.

It is rightly said practical life is far away from theoretical one.

We learn in class room can give the practical exposure or real life
experience no doubt they help in improving the personality of the
student, but the practical exposure in the field will help the student in
long run of life and will be able to implement the theoretical
knowledge.

As, a part of academic syllabus of four year degree course in

Mechanical Engineering, every student is required to undergo a
practical training.

I am student of third year mechanical and this report is written

on the basis of practical knowledge acquired by me during the period
of practical training taken at Diesel Locomotive Works, Varanasi .
 Introduction to D.L.W.
Background – Diesel Locomotive Works (DLW) is production unit
under the ministry of railways. This was setup in collaboration with
American locomotive company (ALCO) USA in 1961 and the first
locomotive was rolled out in 1964. This unit produces diesel electronic
locomotives and DG sets for Indian railways and other customers in India
and Abroad.

Subsequently a contract for transfer of technology of 4000 HP

Microprocessor Controlled AC/AC Freight (GT 46 MAC) / passenger
(GT 46 PAC) locomotives and family of 710 engines has been signed
with electro motive division of general motors of USA for manufacture
in DLW. the production of these locomotives has now started and thus
DLW is the only manufacturers of Diesel Electric Locomotives with both
ALCO and General motors technologies in the world.

Brief History
• Set up in 1961 as a green-field project in technical collaboration with
ALCO/USA to Manufacture Diesel Electric Locomotives.

• First locomotive rolled out and dedicated to nation in January,1964.

• Transfer-of-Technology agreement signed with General Motors/ USA

in October,95 to manufacture state-of-the-art high traction AC-AC
diesel locomotives.

• A flagship company of Indian Railways offering complete range of

flanking products in its area of operation.
 • State-of-the art Design and Manufacturing facility to manufacture
more than 150 locomotives per annum with wide range of related
products viz. components and sub-assemblies.

• Unbeatable trail-blazing track record in providing cost-effective, eco-

friendly and reliable solutions to ever-increasing transportation needs
for over three decades.

• Fully geared to meet specific transportation needs by putting Price-

Value-Technology equation perfectly right.

• A large base of delighted customers among many countries viz. Sri

Lanka, Malaysia, Vietnam, Bangladesh, Tanzania to name a few,
bearing testimony to product leadership in its category.

SALIENT FEATURES:
Annual production capacity 125 Locomotives

Annual turn-over (Rs) 5000 million

Total number of staff 7223
Workshop land 89 Hectares
Township area 211 Hectares
Covered area in shops 86300 Sq.m

Covered area of other service buildings 73700 Sq.m

Electrical power requirement 3468 KVA
(Average maximum demand)
Electrical energy consumption (units/year) 19.8 million
Stand by power generation capacity 3000 KW
PRODUCT OF DLW:
DLW is an integrated plant and its manufacturing facilities are flexible in
nature. these can be utilized for manufacture of different design of
locomotives of various gauges suiting costomer requirments and other
products. the product range avilable is as under. :

• WDG4 4000 HP AC/AC Frieght traffic Locomotive

• WDP4 4000 HPAC/AC Broad Gauge High Speed
Locomotive

• WDG3D 3400 HP AC/AC Broad Gauge Mixed Traffic

Micro-Processor Controlled Locomotive.

• WDM3C 3300 HP AC/DC Broad Broad Gauge Mixed

Traffic Locomotive.

• WDM3A 3100 HP AC/DC Broad Gauge Mixed Traffic

Locomotive.

• WDP3A 3100 HP AC/DC Broad Gauge High Speed

Passenger Locomotive.

• WDG3A 3100 HP AC/DC Broad Gauge Freight

Locomotive.

• WDM2 2600 HP AC/DC Broad Gauge Mixed Traffic

Locomotive.

• WDP1 2300 HP AC/DC Broad Gauge Intercity Express

Locomotive.

• WDM7 2150 HP DC/DC Broad Gauge Mixed Traffic

Locomotive.
 • WDM6 1350 HP DC/DC Broad Gauge Mixed Traffic
Locomotive.

• WDS6 1350 HP AC/DC & DC/DC Broad Gauge

Shunting Locomotive.

• YDM4 1350 HP AC/DC & DC/DC Broad Gauge Mixed

traffic Locomotive.

• EXPORT LOCO 2300 HP AC/DC Meter Gauge/Cape gauge Mixed

Traffic Locomotive.

• Diesel Generating Sets 800 KW to 2500 KW

• Spare Parts fot engines, locomotives and generating sets

STRATEGIES

Our Vision: "To be a World class manufacturer of Diesel Electric locomotive

Our Mission :"We shall achieve our vision through Continuous Improvement in
the areas of Product Quality, Research and Development, Supplier Partnership,
Human Resource Development and Team Work with emphasis on Core
Competence Leading to Customer Satisfaction And Business
Excellence."

Our Quality Policy: "We are committed to Excellence in all Activities and Total
Customer Satisfaction through Continuous Improvement in Quality of Products
And Services."

Our Quality Philosophy:

○ Quality is not controlled but produced;
○ Emphasis is on quality in all organizational processes;
○ Regular quality audit as per ISO procedures;
○ Top Management totally committed to quality in all activities;
 ○ Adoption of workers' participation and continuous improvement as a part
○ of quality philosophy;
○ Regular training schedules for all.

QUALITY ASSURANCE

Quality has been a crusade in DLW since its very inception. We

actively inculcate the primary importance of manufacturing a quality
product in all our workmen, supervisors and engineers from the day
they join DLW. Each of our workmen is continually trained and re-
trained in Quality aspects.
Modern instrumentation and machinery help the workmen in
maintaining a high standard of quality. Under ISO 9002 certification
scheme, all our jigs and fixtures, tools and gauges are calibrated
regularly according to a carefully worked out plan.
DLW has a fully equipped Gauge Room for calibration of gauges,
and a tool room for checking of jigs and fixtures. To supplement the
rigorous standards of certification for DLW's vendors, almost all
bought-out items are subjected to quality checks and certified by
our incoming inspection. Now DLW's Quality thrust has been
certified by an internationally accredited ISO certifying body, and
DLW is proud owner of ISO 9002 certificate for the entire range of
manufacturing activities.

HUMAN RESOURCES DEVELOPMENT

• Battery of highly skilled, motivated and trained man-power treated as the
most important organizational asset;
• People centric participative style of management with societal
orientation.
• Training forms a continuous part of organizational culture;
• Regular training courses conducted in functional areas as well as in
Quality Systems;
• Well equipped technical training center available for providing technical,
computers and managerial training inputs to new recruits at staff and
supervisors' level;
• Staff trained at General Motors, USA facilities as a part of new agreement
reached with them;
• Management totally committed to healthy Industrial Relations, Staff
welfare and Safety;
• Excellent industrial safety track record by adopting all round safety
measures and conducting regular safety audits;

EMPLOYEE BENEFITS
• DLW is committed to provide best possible staff welfare;
• Facilities and competent medical/ paramedical staff to meet any medical
emergency;
• A well equipped and modern 90 bed hospital with latest fully self sufficient,
and eco-friendly Township for employees sprawling over 211 hectares, in
the vicinity of work-place;
• Excellent educational facilities for wards of employees within campus;
 • It takes pride in making claim for having some of the best sports facilities
in town viz. Olympic size sports grounds, stadium, swimming pools, lush
green golf-course and other high-end sport facilities.

ENVIRONMENT & OUR SOCIETY

At DLW, we firmly believe that no organization can operate in vacuum and
therefore, we owe a lot not only to the environment we breath in but also to
the society we live in. Our environmental policy and other social goals
enshrine this commitment and are reflected in all our activities.

Environmental Policy
"We, at Diesel Locomotive Works, Varanasi, while carrying out Chrome-
plating and Wastewater Treatment will continually strive to minimize the
impact of our activities on the environment.
We will minimize the resource consumption and waste generated from these
shops to make our surroundings greener and cleaner.
We shall comply with all applicable environmental regulations.
We shall spread the message of environmental protection to the community
by disseminating our Environmental Policy to employees and to the public."

Our Societal Orientation

 Our untiring efforts to make our micro-environment cleaner and better speak
volumes about our commitment to society in general. This is evident from our
constant endeavor in spearheading many such projects e.g. adult education,
clean Ganga to name a few, through various social organizations.
 Value and Wealth creation not only for stakeholder but for whole society as a
dominant shareholder.
Direct employment to more than 7000 people and indirect to more than
55000 people through wide cross-section of dedicated suppliers/ ancillary units,
instilling a familial bondage among various stake

RESEARCH & DEVELOPMENT

• R & D - a Customer centric Activity Committed to Innovation and
Continuous Improvement;
• Highly skilled Manpower capable of handling complete R&D activities;
• A sophisticated design center with modern CAD/ CAE workstations
equipped with Unigraphics and Ansys;
• Back-up support from RDSO, a centralized R&D organization at corporate
level;
 • Several milestones in the past - an enviable pedigree viz.
○ original ALCO design made 7% more fuel efficient;
○ many design improvements leading to better performance,
incorporated in the original ALCO design;
○ many new designs for locomotives such as WDP1, WDG2, WDP2
to name a few;

R&D strategy aims at absorption of new technology, up-gradation of

existing processes, improvement in tool designs and machining facilities,
development of new products and special processes for world-class
quality - thus helping our customers to succeed..........

RECENT MILESTONES & FUTURE PLAN

MILESTONES ACHIEVED:
Transfer of technology (TOT) -- An added feather in the
cap:-
○ Agreement with General Motors of USA for technology transfer to
manufacture high horse-power GT46MAC 4000HP AC/AC locomotive in
India;
○ Only country outside North-America to have this bleeding edge
technology;
Many export/repeat orders complied successfully in recent past and many more
in the pipeline;
Supplied more than 400 locomotives to various non railway customers;
Emerging as a leading manufacturer of ALCO/ GM locomotives for developing
countries.
FUTURE PLANS :
• Assimilation of GM technology to manufacture their latest 710 series of
diesel electric locomotives;
• To emerge as a globally competitive locomotive manufacturer;
• To develop as an export hub for ALCO/ GM locos for Asian market;
• To follow an export led growth strategy through continuous improvement;
• Cost effectiveness and technology/ product up-gradation as a key to retain
global competitiveness by putting price-value-technology equation right.

ENGINE DIVISION
FABRICATION OF ENGINE BLOCK
Steel plates of sizes up to 80 mm thick
are ultrasonically tested before being
precision cut by numerically controlled
flame cutting machines. Fabrication of
engine block is completed by submerged
arc welding using semi-automatic welding
machines. Down-hand welding is ensured
using specially designed petitioners.
Special fixtures are used for making
down-hand welding possible in
inaccessible areas. Critical welds are
subjected to radiographic examination. All
welders are periodically tested and re-
qualified for the assigned job

MACHINING OF ENGINE BLOCK

The fabricated engine block is then taken up
for a variety of machining operations like
planning, enveloping and end drilling. All
these operations use heavy duty planers
and CNC drilling machines. V-boring of
cylinder liner bores is a process requiring a
high degree of precision and is undertaken
using a specially designed machine. Recent
addition of a Plano-milling centre has
provided further fillip to the quality and
speed of enveloping operation. 12 Cylinder
and 16 Cylinder Blocks have V angle of 45°,
whereas the 6 Cylinder Block is inline type.
COMPONENT MANUFACTURING
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 hobbing, 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.
All related 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

The engine block, crankshaft, camshafts,
cylinder liners, pistons, connecting rods,
cylinder heads, exhaust manifold, turbo-
supercharger and all related piping is
assembled to make a complete engine. This
is followed by mounting of electrical
machines like traction alternator, auxiliary
generator and exciter. This power pack is
tested for horsepower output and other
parameters of engine health on
computerized Engine Test Beds. Only after
the engine parameters are found perfect the
power pack is allowed to be moved to the
locomotive assembly area

VEHICLE DIVISION
UNDERFRAMES & SUPERSTRUCTURES
Precision cutting and forming of sheet metal is
utilized 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. In yet
another work area, all electrical equipment is
assembled in the fabricated control
compartments and driver’s control stands.
Under frames are fabricated taking all due care
to ensure designed weld strength. Care is
taken to impart the requisite camber to the
under frame during fabrication itself. Wherever
required, welds are tested radio graphically.
Welder training and their technical competence
is periodically reviewed.

BOGIE MANUFACTURING
Large special purpose machines are
utilized for machining cast and
fabricated bogie frames. In the same
work area, axle and wheel disc
machining is undertaken on
sophisticated CNC machines. Inner
diameter of wheel discs are carefully
matched with the outer diameter of
axles before the wheel discs are
pressed onto axles, at designated
pressure, using a specially designed
wheel press. The complete truck
(bogie), including bogie frames,
wheels and axles, brake rigging and
traction motors is assembled before
being sent onwards for locomotive
assembly.
LOCOMOTIVE ASSEMBLY & TESTING
Assembled and tested engines are receive in
this Shop from Engine Division. Also, under
frames, assembled trucks, 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 itself.
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.
Rigorous testing of all locomotive systems is
conducted as per laid down test procedures
before the locomotive is taken up for final
painting and dispatch.

OEM PARTS

We, at DLW, takes eminence and pride in building a long lasting relationship with
our esteemed customers: both internal and external. At DLW, this relationship is
seen as our life-long commitment to the customers. It offers wide range of
locomotives, their spare parts and related transportation services. Though,
organizational dynamism and vigorous pursuit of continuous improvement has
always driven us to offer the latest in technology, yet we continue to support our
older generation locomotives through a regular supply of spares. From complete
maintenance support including comprehensive parts, assemblies and product
upgrades, to training and customer service support, we believe in anticipating,
responding and exceeding customers' expectations better and faster than
competition, thus striving for customer delight.
Broadly our spares can be categorized as capital spares/ kits including
• Engines/ power packs;
• Transmission systems;
• Fueling systems;
• Brakes and draw gears;
 • Under-frame;
• Suspensions;
• Locomotive bogie/ truck arrangements.
• Replacement/ emergency spares including items those are normally
replaced in regular maintenance schedules
DLW manufactures more than 13000 items for all locos offered or being offered
from its stable. Any requirement of kits/ sub-assemblies/ spares for ALCO design
locomotives/ engines can be easily met at single destination. For the ease of
identification and computerization, each item has been assigned a unique part
number at DLW and needless to say that our part nos. have become trade
standards with their global acceptability. Enquiries are welcome on line or through
fax with details giving part nos. in case those are available.

HEAVY WELD SHOP

This shop mainly deals with the fabrication of the engine block and
base (B.G. & M.G.) Turbo support. After cooler housing items. The engine
block is the principal, structural member of the diesel engine. It is composite
weldment with heavy plates thickness varying from 16 mm to 75 mm and
steel forgives conforming to specification is 2062.
The spine being the most highly stressed item as we can say spine of
the cylinder block is made out of one piece bitted 5”x 7” thickness
confirming to is 1895. The billet foundation plate and cylinder walls are
built around the steel forging saddles to form the air chambers which ensure
the maximum rigidity for successful fabrication of cylinder block special
attention is paid to the following aspects cylinder block special attention is
paid to the following aspects.
1. Inspection standard
2. Proper materials
3. Proper electrodes and flux
4. proper welding technique
5. welfare of staff

SEQUENE OF FABRICATION OF ENGINE BLOCK

1. Set up of saddles foundation plates and spine on special fixture and
weld saddles spine founded on rails.
2. Set up welding of out side cylinder wall.
3. Set up of middle dock (Tack welded) with respect to target.
4. Remove can bearing shim from saddle face.
5. Intermediate machining operation remark in middle deck and chamber
at top of spline.
6. Set up of inside wall and deck welded with spline.
7. Lay out of plane height.
8. Intermediate machining operation
Machine height of out side wall and inside wall with respect to
marking and camber.
9. Set up of top deck (Both side) and lifter block (G.E. side only) for
filament of eye bolt and tack weld.
10.All in side (8x2 Beal welds) welding in done by sub are method.
11.Back gauging of saddle to foundation rail joint.
12.Lay out for bearing.
13.Set up for cam bearing with respect to pay out Si No.12.
 14.Welding of the cam bearing and saddle with foundation rail bottom
side (back gauge portion)
15.Set up of cam bearing rids and weld.
16.Say out for 8” machining.
17.Intermediate machining operation.
18.Flame cut counter of foundation plate to give relief clearance to free
movement of counter with respect to crank shaft.
19.Set up of the side sheets and sub arc weld of side sheets and top deck.
20.Set up of full control compartment sheet and weld.
21.Intermediate machining operation mills both and to lay out for end
plates considering total length and machining allowance.
22.Hydrostatic test of water compartment.
23.Set up of top end plates and weld.
24.Set up of top deck center and weld.
25.Stress relieving weldment.
26.Kerosene oil test for control shaft compartment.
27.Shot plast.
28.Final debarring.
Note: Saddle out side and inside walls foundation rail are x ray joints.
ELECTRODE

Saddle, spline and foundation plates are sledded on a rotary fixture E

6020 electrodes 6.3 mm and 5 mm of M/s A Par Pvt. Ltd. Bombay and
celorex of M/s Advani or Liken capable of giving X-Ray quality joints
are being used for the welding.
The coating is such that a stage containing iron oxide, manganese
oxide and silicon is usually produced other constituents containing the
 oxides of aluminum manganese of sodium are prevent to modify the slag
ferromanganese in the main de-oxygen and sodium silicate is used as the
binder. In most cases core wire is of remounted steel.
CARE OF ELECTRODE
Saddle spline rotary fixture E-6020 electrodes 6.3 mm and 5 mm.
Arc welding electrodes require special care in handling and storage to
That the flux coating may retain its original strength of bonding over
Long periods and give satisfactory welds on use so there electrodes are Kept
in a store maintains its room temperature at least 10 to 20 c
Higher then the out side temperature. When the storage atmosphere
In humid the moister gets deposited in the minute pores of the flux
Coating.
Stocking electrodes certain directly on the floor should be Avoided as
also putting too many of them once above the other because the electrodes at
the bottom may get crushed. Due to the weight above. It is good practice to
stock. Electrodes shelves separately according to their sires types and
batches.
FLUX: - In D.L.W. auto melt gr I flux of advance linken (P) LTD. Bombay
In used. The flux in a mixture of power of deter mined practical size
and each particle in chemically basic in character these particles are
not fused. the flux in heated period to use in on over at 250 c for O2
hours as moisture flux generated the hydrogen in the arc and cause
cold cracks in the weld deposit and in the heat effected zero.
WIRE:-Wire used in the sub are welding is the auto melt gr. A cold copper
Coated size 5m.m. with low carbon content confirming to IS 2879
 Manufactured by M/S Advani lincon P. ltd. Bombay. The chemical
composition of the wire in carbon 0.08% m.m. 0.46% P.0.018%
S0.022%.

STRESS RELIVE OF CYLINDER BLOCK.

After completion of welding the cylinder block in then stress relieved
at the temp. Ranging from 115 F obtating total timing 28 Hrs ie.
(1) Pre heat time 14 Hours.
(2) Soaking time 04 Hrs and
(3) Cooling time 10 Hrs in stress relative’s furnace capable to
accommodate to B.G. block at a time. As the engine block in
machined to very close tolerances. It is necessary that all
stresses developed during the fabrication stages are completely
relieved before machining. This would ensure a longer life in
service without any distortion which would normally result on
account of very alternating stresses that the engine block is
subjected to during its service.

KEROSINE OIL TEST-

Check that there should not be any leakage at the bottom side of the
fuel control compartment welding joint after powering kerosene oil. The
engine block is then shat blasted at pneumatic compressed air a pressure of
75ibs/sgu.inch.
DEBURING-
It is to be ensured that the completes (welding) weldment is free of
any spatter welding defects and sharp corrosion of important welded joint
have been ground then the cylinder block is marked and handed over for
machining operation to H.M.S.
DESINING RECOMBINATION FOR CAMBEARING SUPPORT
Earlier design of cam bearing support welded with cylinder side waits
then welded with the ribs (3/4”Th welded grc) due to heavy vibration and
less welding area development of cracks wire observed in the com bearing
supports. (Mainly upper portion)
To over come the problem of cracks and strengthen new design of
cam bearing are welded all round with the ribs and then ribs are wide with
the side cylinder wall.
Hydrostatic test
Water compartment are fully filled with water and after air light
covering are pressure of 75 lbs/squ inch minimum is maintained for about
half on hours. It there is any leakage in welds arranged welded and water
listed.
Heavy weld shop
1. Heavy weld shop ha three important sections.
2. Flame cutting, grinding and straightening section.
3. Cylinder blocks fabrication section.
4. Main base, turbo support and miscellaneous section.
Flame cutting, grinding and straightening section
All the flame cutting items required for the B.G. & M.G. engine for
block, base & turbo support are cut in the section by flame cutting machine.
For all cutting of different types of items. The different types of plates are
use as per their specification and thickness. Following important items are
cut here.
Spline, top deck, middle deck side sheet, main base and plates top rail
cross web, back, plate, centers block flanges levers etc.
In grinding section above items are deslaged and ground by pneumatic.
Grinder.
 In straighten section important items of cyl-block main base and turbo
support are straightened.
Cylinder block fabrication section
The following components for B.G. Cylinder block assly are required.
1. End seal
2. Side plate L.S & R.S.
3. Angle L.S. & R.S.
4. Foundation plate L.S. & R.S.
5. Saddle machined inters main bearing I no.
6. Saddle machined gen end I no.
7. Saddle machined centre main bearing I no
8. Spline I no
9. Cyl side wall out side L.S. & R.S.
10.Cyl side wall in side G.S. & R.S.
11.Middle deck L.S. & R.S.
12. Cam bearing (inter, gen and & frill end ) 18 nos
13. Cam ribs 18 nos
14.Top deck L.S. & R.S. and top deck centre
15.Weld strip (gen-end) R.S. & L.S.
16.Plate ( water compt drive)
17.Frill end plate.
18.Self cont. compt L.S. & R.S.
19.End plate ( gen end)
20.Cover (cont compartment )
21.Diaphragm
22.Lifter block ( gen end)
Sequence of Fabrication Assembly:
 Setting of saddles on the fixtures as per drawing with the foundation
plat L.S. & R.S. and one spine on the top of the saddle. Tacked and welded
all these with each other burn run of the saddle with spline, clean and grind
the opening of the spline, then set and face the out side and inside walls L.S.
& R.S. both sides of the saddle burn run off and clean grind of the wall
opening
After that setting up the middle deck weld from bed bottom side of
deck and lifter block weld 16 beets all welding as quality. Saddle to
foundation plate, saddle to spline and saddle to out side wall welding is
check as joints.
Arc wilding done machine on the cylinder block where the welding by
machine is called submerged are welding. Copper coated mild steel class II
were with flux is used.
After x-ray welding test, the assembly is sent for lay our of cam bearings in
marking section. The cambering are set up tack and weld with the cam ribs
and water compartment plates. After that again x-ray text of bottom plates is
done. Then burn opening and Skelton grinding operation is done. Then send
this block assembly in the machine section for 8 machining of side sheet. Set
and weld the side sheets on the 8 machining. Weld fuel self compartment on
the positioned welding machine. Weld side sheet foundation rails. Side sheet
to cam ribs. Out side wall of full self compartment. After that the block
assembly is again sent to M/C section. For end milling to maintain the length
of the block as per marking and size. Then hydraulic water test is done at 75
P.S.I.
At last set up the end plates (gen and free end) both side of the block
assembly, tack and then setup the top deck centre in the centre of the block
and weld it by sub are welding M/C
After complete fabrication the block is sent to H.T.S. sec. for stress reliving
to 700 c then shot blasting the block and sent the machine section for final
machining.
Main base fabrication
The following components are required for the assly of main base.
1. Side sheet L.S. and R.H.
2. Pipe assembly with plates
3. Engine mount free end and gen end CH/RH
4. Rib (engine mount free end & gen.end)
5. Top rail
6. Bottom. Plate (Gen end, free end & centre)
7. Plug L.O. drain.
8. Cross web G.A. 1,2,3,4,5,6,7,8, & 9
9. Cross web auxiliary assembly
10.End plate free end & gen end.
11.Oil drain compartment.
12.Pad
13.Brass engine mount free end.
14.Brass engine mount gen end.
15.L.O. suction pipe (sub. Assembly)
Sequence of Fabrication:-
Setting top rails on the fixture and mach the centre of the fixture. Set
the side sheet R.S. & L.S. with the cross webs to maintaining the width of 31
¾ of main base, tack and weld with cross webs. After that bottom plates gen
end and free end are set up. Tacked and weld on its proper place. Then set
and tack and weld the end plates gen end & free end with lo suction pipe. at
post L.O. drain plug is set up and dip strike on it proper place. Engine mount
free end and generator end CH/RH, T, welding is to be completed.
After fabrication, the main base is sent to H.T.S. for stress reliving at 700 c
temperature and cooled in furnace. Then shot and de burn. Then sent to
machine section for complete machining.
TURBO SUPPORT FABRICATION:-
It is the support for turbo which is mounted on cylinder block on free end
side. Following components are required for it.
1- Flange bottom 2
2- Back plate 1
3- Side plate l.s 1
4- Side plate R.H 1
5- Flange oil catcher 1
6- Top plate air chamber 1
7- Front wall air chamber 1
8- Bottom Plate 1
9- Centre Plate 1
10- Back wall pt. 1
11- Side plate R.S 1
12- Partition plate 1
13- Patch plate 2
14- Gasket 4
15- Pipe segment 1
16-Cover 1
17-Ribs 1
18-Flange 1
19-Side pipes
2
 20-Side plate air chamber 1

PROCEDURE OF FABRECATION
1. Dressing and setting of flange bottom and back plate on support.
Welding of the flange from the centre of fixture.
2. Setting and tacking of back plate, buck wall and portion plate.
3. Tacking of right side plate on back plate.
4. Welding of 2” I.P.S extra heavy coupling on left side and its setting
and tacking on back plate.
5. Grinding ,dressing , setting & tacking of centre on side plate
R.S.&L.S
6. Setting & tacking of flange oil catcher.
7. Marking and gas cutting of 4 ¼ “dia hole in bottom plate and welding
of ring on the hole of the plate.
8. Setting and tacking of above bottom P.t. on top plate on fixture.
9. Setting and tacking of side R.S
10.Dressing of back wall and its setting and tacking.
11.Setting and tacking of front and bottom plate & front wall.
12.Setting and tacking of pipe segment cover.
13.Inspection hole cutting in front wall.
14.Setting and welding of flange and side piece.
WELDING PROCESS
(1) Out side bottom plate, top plate, centre plate to side plate both
sides an rest welding is down from bottom is top in sequence
numbest for inside welding bottom pt, top plate and rest, from
bantam is tip is done.
 (2) In this operation the support is clamped on positioned with top
plate and all the rest wadding is completed. After these
gauging
Is done on flange oil catcher. Then later welding is done and
base is welding.

HEAVY MACHINE SHOP

SHOP No. – 04
This shop carries out the machining of Cyl. BLOCK (M.G. &
B.G.) main base, saddler Main bearing caps, Splines, Turbo Super
Charger, Lube Oil, Fuel Oil & Water header) com bearing housing.
OPERATION:-
Planning, Milling, Drilling, Tapping, Boring Honing, Serration
milling etc.
Types of Machine provided in the shop are :-
Double Housing planned machine (32”, 24’, & 16’).
Radial drilling machine.
Radial drilling machine Traveling type.
Boring Machine
Angular Boring Machine (Excello)
Tracer Planner machine.
Hill Acme koing structural milling machine.
TOOLS USE :-
1. O.K. Tool (Rough & Finish)
 2. C.C. Milling cutter (4”, 9”, & 10”)
3. Boring Tipped Tool (Rough & Finish)
4. Honing Stone (For hand honing)
1. Drill, Reamer, Top (Various Seizer)
2. Serration Cutter.
MEASURING INSTRUMENT
1. Dial Baar gauge
2. Micron meter (out side and depth)
3. Vernier Height gauge.
4. Vernier calipers
5. Mandrill or optical shad rill machine
EX-CELLO ANGULAR BORING MACHINE :-
Motor R.P.M. in constant, Spindle, speed is control by clutch
system.
H.M.T. ANGULAR BORING MACHINE :-
Spindle speed is directly controlled through motor. (Coated
carbide is used in H.M.T. angular Boring machine)
Cyl. Block made of fabricated class II material except main
bearing cop as it made class IV material.
The machining of cyl. Block is complicated and challenging job.
It required great skill and knowledge. After duly fabricated, stress
relieved and shot blasted the block is subjected to layout to ensure
availability of adequate machining allowance, where necessary and
to provide guide liner for subsequent machining the weight of the
block is 6.02 Tons approx. (Fabricated Material)
After completion of all operations as per drawings the black
subjected to inspection in addition to stage inspection dimension live
radial distance between center of Crank bore and com bore, distance
between center of com bore and liner seat etc. are checked at this
stage the weight of the black is 05.02 tons apporx. 01 ton of material
removed by the machining and than blank is block send for assly.

Main dimension of cyl. Block.

1. Did of com bore = 4.750” to 4.7515”
(B.G. & M.G.)
2. Did of blank bore = 9.0355” to 9.0370”
(M.G. & B.G.)
3. Did of liner bore = 10.750” to 10.752” (Upper)
(B.G. of M.G.)
= 10.621” to 10.623 (Lower)
4. Did of thirst Collar = 10”
5. Thickness of thrust bearing = 4.247” to 4.249”
6. Thickness of the plate = free end = ”
= gen. End = 1”
7. Radial distance between the centers of crank of
Cam bore = 10.499” to 19.501”
8. Distance of liner seat from center of crank
Bore = 32.480” to 32.485”
9. Total length of the M.G. black = 106.370”
= 106.380”
10. Total length of main Bush B.G. = 172.380”
B.G.= 172.370”
11. Total length of main Bush M.G. = 117.130”
= 117.120”
12. Total length of B.G. Black = 161.625”
= 161.630”

Main parts of the Cyl. Block (B.G.)

(I) Foundation Rail (R.S. AND L.S.)
(II) Saddle ( 9 Nos)
(III) Spline
(IV) Inner well (R.S. and L.S.)
(V) Other well (R.S. and L.S.)
(VI) Top deck (Middle)
(VII) Top deck (R.S. and L.S.)
(VIII) Side sheet (R.S. and L.S.)
(IX) Com bearing (16 Nos)
(X) Cop (9 Nos.)
(XI) Rib (16 Nos.)
(XII) Bottom Deck. Or Middle deck
(XIII) Fuel self comport.
Main parts of the Cyl. Block (M.G.)
1. Foundation Rail (R.S. and L.S.)
2. Saddle – 7 Nos. (One Center)
3. Top deck
4. Middle deck.
5. Side sheet (R.S. and L.S.)
6. Cam. Bearing 6 Nos.
 7. Cap – 7 Nos.
8. Ribs – 10 Nos.
9. Fuel self comport.
10. Inner wall (R.S. and L.S.)

Horizontal Boring Machine :-

MW :- (no): 2155 & mw No. : - 2154
Cam and Crank.
Boring of cylinder block crank and cam.
Method:-
Load the block on fixture.
For checking weather there is any gap
Or not put the filler of size 0.001” to
0.0015” in side location pad. If there is
No gap then start work otherwise tight
The fixture and recheck till no gap situation.
Boring of Cam Bore: (LS & RS):-
This is done in three steps:
(a) Rough Bore: - Do this in one pass
R.P.M.: 35 Feed: 6 mm/min.
(b) Semi Finish Boring: - Do this in one pass
R.P.M.: 35 Feed: 6 mm/min.
(c) Finish Boring : Do this in one pass
Pass No. Bore No. R.P.M. Feed
1. 1, 4, 7, 10
2. 2, 5, 8, 224 25mm/min
3. 3.6.9.
Boring of Crank Bore: This is also in three steep.
(a) Rough Boring: Do this in three pass.

Pass No. Bore No. R.P.M. Feed

1. 1, 4, 7, 14 5 mm/min
2. 2, 5, 8,
3. 3, 6, 9
(b) Semi Finish Boring: Do in one pass
R. P. M.: 14 Feed: 5 mm/min
(c) Finish Boring: Do in one pass
R. P. M.: 140 Feed: 25 mm/min
Tool:-
Two tools are used for boring both tools are fixed in slot of
boring bar. Due to spindle rotation boring is done. Tool movement
and machine action is governed by G Code and M Code respectively.
Absolute mode and incremental modes are used for tool movement.
Single point cutting tool (two) is first fitted in devise block then in
boring bar.
Cutting Oil:
Boring finishing operation cutting oil is used for smooth
operation
Fixture: J/F No. : FB (E) 15/2
Different – Different tools are used in different step of Boring!
Crank:-
Rough Boring : 8.880”
Semi Finish Boring : 8-997”
 Finish Boring : 9.035”
Cam:
Rough Boring : 4.700”
Semi Finish Boring : 4.720”
Finish Boring : 4.750”
Maximum removal of metal takes place in rough boring.
For making thrust (Cutting)
Tool Size : 10”
R.P.M. : 14
Feed : 22.86 mm/min
(.09”/min)
Tool material used in rough and semi finish boring is high speed steel
and in finish boring amended carbide.
Angular Boring Machine:-
M.W. No. : 1263
Angular Boring
Boring of Top deck bore and middle deck bore:-
Method:-
Load the block on fixture.
For checking weather there is any gap or not put the filler of the size
0.001” to 0.0015” in side location pad. If there is no gap then start
work otherwise tight the fixture and recheck till no gap situated.
Boring of Top deck Bore:
Tool:-
There are 18 tools are used. I tool in each side. Each are
adjusted automatically for rough cut and finish cut. During rough cut,
finish tool remains idle and during finish cut, rough tool remains idle.
7 tools are fixed in each side in boring bar and two are replaced
according to demand of boring.
Different tools which are used are as follows:-
1. M.I.D. Counter Insert No – TPUN – 160308
2. Rough – snmm – 190612 (weight) 190616 (yellow)
3. Liner seat rough TNMG 220412
4. T/D Chamfer P.G. 002 (only for 1263 m/c)
5. Liner seat finish – TPUN – 110308
6. Micro boring tool OOC No. 10A2LB
7. Counter insert wide no. – PNUN – 160402
8. T.I.D. Counter No. (Rough) – 1263 (N.C.)TN – 28
(TNUN 220 412)
9. 2187 M/c. – MIS Counter No. TNMM – 160408
 LIGHT MACHINE SHOP

This shop deals with the matching of various small components

required for the power pack unit such as, cam shaft, connecting rod, liners,
gears levers, F.P. Support, Piston pin, nuts and bolts bushes, various shafts
etc.
The light machine shop divided into the following section:-
1. Econometric section
2. Grinding section
3. Gear section
4. Cam shaft section
5. A.T.L. section
6. Belching section
7. Connecting rod section
8. Lathe section
9. Liners section
10. Drilling section
11. Milling section.
Connecting rod section:
In this section the connecting rod is made. All the machining
operations of the connecting rod. Completed here with the help of various
types of machine. The connecting rod has two parts, one is cap and other is
rod. The material of the connecting rod is steep forging. In B.G. 16 per loco
and in M.G. 6 per loco.
Main dimensions
1. crank bore (big bore) =6-411” to 6.421”
2. piston pin bore (small bore)=3.998” to 3.999”
3. Distance Between Two = 20.995” to 21.000” bare centre
4. Rod Thickness = 3.020” to 3.022”
5. Weight = 32 Kg 950 gram to 32 Kg gram.
6. Pressure Torque = 150 P.S.I.
1. Econometric section :-
This section manufacturing various sizes etc.
Machine provided: - econometric machine, do-all machine, belt
grinding machine (for control shaft feed)

2. Gear- Section: -
This section deals to making various gears impeller such as : cam
shaft gear, crank shaft gear, extension shaft gear, impeller gear (follower
& drive) and broaching Machine Provided :-
(a) gear hobbling machine
(b) gear shaving machine
(c) V.T.L. machine
(d) Radial drilling machine
(e) Broaching machine & (F) centre mill M/C
1. Grinding Section: -
In this section the various small components are grinding as per
required finishing after machining operation and each components having
grinding allowance (G.A.) main piston pin, impeller and fuller and
follower gear, pin valve guide, various studs. Cam roller, seat (V/C Q ‘X’
head) spider various bushes etc.

Machine provided
(a) cylindrical grinding machine
 (b) internal grinding machine
(c) centre less grinding machine
(d) thread rolling machine
(e) universal grinding machine
(f) external grinding machine
2. Camshaft section –
This section making cam shaft (both B.G. & M.G.) with completed
machining operation by various special type of machine. In B.G. 08 nos
per loco and in M.G. 03 per loco.
Machine Provided
1. Centre mill machine
2. Auto lathe machine
3. Gun drill machine
4. External grinding machine
5. Lathe machine
6. Cam grinding machine
7. Radial drilling machine
8. Cam angle checking machine
9. Magna flux machine
Cam shaft length size (B.G.)
Cam shaft no. Do all size milling size?
16 B731 73 39 29/32” 39.656”
74 37 1/8” 36.875”
75 39 3/8” 39.125”
76 47 11/32” 47.093”
77 43 3/32” 42.843”
78 37 1/8” 36.875”
 79 47” 46.750”
80 38 17/32” 36.281”
Cam shaft length size (M.G.)
Cam shaft no. Do all size Milling Size?
16B 95 33 3/8” 33.125”
96 32 7/8” 32.625”
97 41 13/32” 41.156”
Cam angle
Air cam 7 angle 315.769” 315-46
Fuel cam 7 angle 327
Ex. Cam 7 angle 238.936 238-56
Air cam 8 angle 45.769 45-46
Fuel cam 8 angle 57
Ex. cam 8 angle 328.936 328-56
05. Automatic Turret Lathe (A.T.L) Section:-
This section manufacturing various types of small components for
Power pack engine such as:
Lock spring seat (V/L & X-Hd) spewing seat. Ball end, cup end ad.
Screw (X-HD & V/L) cop screws L.A.S. retainer, spring lever, F.P. inlet,
Porg Bkt. piston pin liner sleeve, body outer ring spicier etc. machine
provided.
1. M.T.L. ( Bar type , chuck type)
2. U.T.L.
The A.T.L. section is the vital section of this shop. Maximum small
components are manufacturing in the section
06. Benching Section:
 In this section the benching operation of the entire component which
are manufacturing in the shop are done here. In the benching section.
There hawing hand cutter maching and belt grinding machine, with the
half of these machine bar removing from all the components.
07. Cyl. Liner Section:
In this section .cycle liner machine operation have done here by the
various type of m/cs. the material of the cyl. Liner is spe. Cast iron and
the set the per loco is in B.G. 16 and in M.G. 6 cylinder.
Main Dimension:-
1. Length 21 15/16 + 1/64
2. Inside dia rough honing -9.010”
3. Inside dia finish honing – 9.015”
4. Out side dia – 10.00”
5. Dia of groove – 10.749 to 10.750”
Machine provided:-
1. Shot blast machine.
2. Vertical boring machine
3. Auto lathe machine.
4. Honing machine.
5. Cylindrical grinding machine.

08. Lathe section:

This section deals various types tropical small components are
manufacturing. Centre lath machines oar provided in this section.
 The components are: brass sleeve, wear plate, valve guide, long stud,
shaft etc.
In drum type turret lathe M/C manufacturing pin cam roller, cup end,
bush washer etc.
09. DRILLING SECTION :-
In this section dials with various Types of drilling, reaming, counter
bore spot tracing and counter sinking operation done of various small
components.
The components are, F.P. support, P.R. Lighter, X head, Valve Lever,
Spring Lever, Brg, Bracket, Pin, Ecc Lever, Upper housing etc.
MACHINE PROVIDED:-
1. Radial drilling Machine,
2. Gang drilling machine of multy spindle drilling machine
3. Drilling Machine
4. Electronic drilling machine.

10. MILLING MACHINE:-

This section manufacturing various types of milling operation of the
components in types of milling machine.
MACHINE PROVIDED:-
1. Vertical milling machine
2. Horizontal milling machine
3. Universal milling machine.
CAM -SHAFT
OBJECTIVE: - The Cam shaft is made replaceable section of heat
treated precision machined alloy steel with chromium. The Cams are
formed internal with shaft and bearing and Cam Surfaces and hardened
by high frequency induction .
shaft is driven from the crank shaft through a forged steel heat treated
span type gear train of adjusted adequate diameter and face width.
The push rod lifter having contact with its cams through their rollers
over the valves air inlet and exhaust gases. The middle cross head lifted
operates the injection to inject the fuel.
In the generator end of cam shaft a gear is coupled with which gives
the motion to turbo generator which generate the electricity for the governor
of the engine.
In the other end of the cam shaft a carrier weight is linked after the
cam shaft vibration dumper which is housed in O.S. Trip assly and operates
tripping of system. Through its plunger that is opened by the centrifugal
force of cam shaft rotation.
PROCEDURE: - Four shafts having no 77, 78 79 +80for right side ware
leaned thoroughly. Passed the dowel pins in holes of 0.499”. Kept these
shafts on leveled co- boars with the pilots.
The sequence of number male and female flanges must be like 77, 78,
79&80respectivesly .applied 18 no studs of y2 N.F. and fastened items with
elastic stop nuts 36 no. applied y2” plug on generator end.
Similarly other four shaft having SL. no. 73, 74, 75, &76 for left side
were assly.
Material specification: - M.S., CR steel D.81602HR application of cam
shafts for the different engines is as fallows:-
M.G. 95, 96, + 97
B.G. 73 74 75 &76 , 77, 78, 79, & 80
L.S. R.S.
WDML: - 107, 108, &109/L.S. ,
104,105,&106/R.S.VIBRATION DAMPER ASSEMBLY.-
CRANK SHAFT (TYPE 251 B)OBJECTIVE:- The Vibration
damper is fitted with crank shaft to prevent the vibration of crank
shaft when
the engine starts the Crank shaft gets a sudden shock the Vibration
Trademark diminishes these shocks. In the same way when the engine
Stops unexpectedly the crank shaft gets a heavy shock. So the get heavy
shock. so we gets reduced of these shocks we use the vibration damper as
a safety device and to increase the life of crank shaft .
Material:--
Outer ring steel 54190
Intermediate ring steel 54190
Spider cast iron 8054

PROCEDURE: -- Debarred the holes of outer ring and screw hole of 1 by

2”. Applied lye bolt in the threaded holds cleaned.
Placed the outer ring plate on a round wooden piece of 6” height from centre
bore side of it to downward. Place the intermediate ring on the outer plate
dropped a little oil on the top of the intermediate ring.

ROTOR SHOP
This shop is deals with the manufacturing of Turbocharger.
Turbocharger is known as the Heart of Diesel Locomotive. Basically in this
section manufacturing of assembly & sub assembly of Turbocharger is
made. But the outer casing of Turbocharger is made up in Heavy Machine
Shop.
 Turbocharger is use for the providing fresh air to the engine. Due to
this the efficiency & power generated by engine is increased. For the
running of Turbocharger we are not using any extra energy source like
generator, motor etc. For starting of Turbocharger generally we use exhaust
gasses.
Components of Turbocharger:--
For assembly of Turbojet following parts are manufactures in rotor
shop----
1. Impeller
2. Inducer
3. Nose piece
4. Stud Rotor
5. Nut
6. Washer
7. Thrust Washer
8. Key
9. Oil Slinger
10. Turbine Disc
11.Turbo Shaft
12. Lock plate
Assembly of Turbocharger:--
The assembly of turbocharger is done by dividing whole
turbocharger in three parts. These are as follows----
1. Rotor
2. Compressor
3. Casing

1. Rotor:--
 Rotor is the inlet part of turbocharger which is comprises with
following parts. Turbo Disc, Rotor stud, Turbo shaft, thrust collar, Nose
disc, Washer & Nut.
Rotor is rotating at speed of 18000 rpm & working at high
temperature due to that the rotor is made of steel.
2. Compressor:--
Compressor is the combination of impeller & inducer. Impeller is
made up of Al-alloy. Impeller & inducer is use for sucking of fresh air
from environment.
3. Casing:--
Casing is made of M.S. & also a special type of coating is done. Due
to that coating it can easily resist the heat.
For the proper working & life of Turbocharger balancing of impeller,
inducer & turbine disc is done by help of Dynamics Balancing Machine.
Working of Turbocharger:--
Exhaust gasses are entering form inlet strikes onto the nozzle
disc. Then after it will strike onto the turbine blade. Due to this the
turbine starts rotating at a speed from 0-18000rpm. It will be transfer the
motion to compressor which is comprises with impeller & inducer. From
that rotation sucking of fresh air from environment is occurring. That air
is now entered in intermediate casing and blow from blower casing.
That air is contains some dust particles and also temperature of
that coming air is high. For removing heat and dust particles a special
arrangement will be done in between the blower casing and cylinder.
That special arrangement comprises with continuous flow of water.
For ALCO, simple turbocharger is use. In ALCO the power required
is less up to level of 2600-1350 HP i.e. there is not any arrangement of
starting of turbine. So initially when the engine is at starting position the
rich mixture enters into the cylinder. When exhaust gasses are generate
then the turbocharger is in working conditions.
For GM Loco, we are using self starting turbocharger. In this a special
arrangement will be done for starting of turbocharger. Main shaft is
connected to the crank shaft of main engine i.e. by this arrangement
initial starting problem is removed. And after that all the working of
turbocharger is same as ALCO. Here the sun & planet gear combination
is present which is come in slip position after achieving proper speed of
turbine blade.
In turbocharger, lubrication system is also provided for increasing life
of turbocharger’s subassembly.

SALIENT FEATURE OF G.M. MOTOR TURBOCHARGER

1. No. per engine—1
2. Stages—Single stage
3. Drive—Mechanical drive as well as exhaust gas driven with
over running clutch.
4. Air Flow—6.35kg/s
(Rated O/P)
5. Efficiency (At match pt.)--
 Turbine—87.2%
 compressor—81.5%
 Mechanical—87.8%
6. Temperature for which critical components are designed—
• Compressor Stage—
--Air temperature up to 190.6°C
• Turbine stage--
--Gas temperature up to 593.3°C
--Gas temperature up to 482.2°C on outlet side.
7. Pressure Ratio of Compressor –2.8
8. Temp. (Charge air after compressor)-- 171°C
9. Speed of Turbo (At rated O/P)—18,950rpm

HEAT TREATMENT SHOP

 In this shop hardening, stress leaving, tempering, normalizing,
carburizing, quenching, is done by help of conventional &
unconventional process. Here we are doing hardening of cam-shaft,
connecting rod, piston pin, different small components of cylinder head.
This shop is divided in two parts which are as follows—
1. Induction Section—Use for Induction hardening
2. Furnace Section—Use for Overall process

Induction Section:-
In induction section, stress leaving & hardening of cam shaft, its
bearing & cam lobes is done at different temperatures. In induction type
hardening we are using copper coil for hardening.
Stress leaving is done below critical temperature. Cam shat is made
up of alloy steel i.e. we are doing stress leaving process at a temp 723°C.
After that hardening is done by induction coil. The major drawback of this
process is to decide what the exact temp is for stress leaving or hardening.
In induction method copper coils are heated due to this induction
current will generate. This induction current produces an electromagnetic
force. Which attracts the carbon particles to the surfaces due to this the bond
breaking energy is developed & that energy is causes heating of material. At
that we can’t does any arrangement for measuring the temp of work piece.
• Hardening—At temp 800°C
• Quenching—Water+8 to 10 %polymer quench
• Tempering—below critical temp

Furnace Section:-
In this section we are using different type of furnaces for all the heat
treatment process will be done. For hardening carbon must be present up to
0.5%.Hardening is done in furnace at 920°C here thermocouple are attach
for measure exact temp of hardened material.
Quenching:-
Quenching is done after hardening of material. In this air
cooling is done. When our job is come at 100°C then other heat treatment
process is done.
Carburizing:-
Carburizing is process for those materials which has low
percentage of carbon. Carburizing is done in a special machine. Carburizing
is done by two methods first one is Wet & second is Gas. For wet, liquid
calcium carbonate is use.
Tempering:-
Tempering is done below critical temp to release stress
between hardened & unhardened zone to increase the life of job.
After that we are checking the hardness of job on Brinell Hardness
Machine. This is done on gauge room.

SUB ASSEMBLY SHOP

This shop deals with following section:--

○ Turbo machining section

 ○ Cylinder head & shot blast section
○ Fuel pump, Support, Cam shaft ate section

○ Cylinder head
○ Turbo
○ Governor, Water Pump, Fan drive, Lube oil Pump, After cooler
assembly section.
Point 3-6 is sub assembly section.

Cylinder Head Section:-

The lay out of this section is product type. There are different
machines had do set up per sequence of operation of cylinder head.
A milling machine provides profile cutting and taper profile
according of the template. The tracer runs and cutter forms shaper radial
drilling machine. This machine provides for drilling tapping. Core boring
operation as per drawing
HEARALD BOROING MACHINE
This machine having four spindles for boring of guide hole, air &
exhaust it dimensions are—
Valve inner sheet dia 4 hole-3.1805”-3.1815”
Guide hole dia-1.0625”-1.0635”
Valve sheet depth (E1, E2, A1)-0.740” to 0.745” & A2-0.950”
Depth of sheet (A1 E1, E2)—0.205”-0.215”
Spring sheet depth (E1, E2, E1)-1.865”-1.885
Control Shaft Assembly:-
It is a link between Governor & Fuel injector pumps by which the
mechanical power from the governor transmitted to the fuel injection pump
Racks. It means to control the amount of fuel according to the requirement
of load & speed.
Explosion Door Cover Assembly:-
It is special type of main base door cover which when the crank
case exhauster failed to work.
Cam Shaft Vibration Damper Assembly:-
When vibration developed on the cam shaft will be damped by
this assembly.
O.S.T. Housing Assembly:-
This assembly controls the R.P.M. of crank shaft and keeps it a
specified limit (1000 to 11500 r.p.m.). When OST is operated in the case
16 cylinder engine the engine RPM will come in ideal but in case of 16
cylinder engines will be stopped.
Fuel Pump Support Assembly:-
It is a support of the fuel pump on which the fuel injection pump
is mounted and the power of cam shaft is transmitted to operate fuel
injection pump through the cross head lighter & to operate push rod by
PRD. Lifter by which the inlet & exhaust valve open & closed through the
valve lever & yokes.
Crank Shaft Vibration Damper:-
Damped the vibration of the crank shaft which is developed
during the power stroke of Engines as act of fly wheel of the crank shaft.

Cylinder Head Assembly:-

By this assembly cylinder of the engine covered and for the
fitment of the inlet valve, exhaust valve and atomizer assembly and
connection of air inlet & exhaust outlet.
 It is a hollow casting in which the water jacket of made for the
circulation of the cooling water to control the temperature of heat.
Acceleration Control Device:-
By this device by monopoly of the driver is controlled the air &
fuel supply is controlled by according to the fuel ratio.
“It is controlled the proper fuel and air ratio”
Schematic diagram of ALCO Engine