Trouble shooting booklet on wheel press covering typical problems faced by Zonal railway workshops and production units

1. WHEEL PRESS
TSB - WP1TSB - WP1
ISSUE DATE:- 17/12/17ISSUE DATE:- 17/12/17
RAIL WHEEL FACTORY KNOWLEDGE CENTER ON WHEEL SHOP MACHINESRAIL WHEEL FACTORY KNOWLEDGE CENTER ON WHEEL SHOP MACHINES
TROUBLE SHOOTING BOOKLET ONTROUBLE SHOOTING BOOKLET ON ''WHEEL PRESS''''WHEEL PRESS'' COVERING TYPICAL PROBLEMSCOVERING TYPICAL PROBLEMS
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2. WHEEL PRESS
ENCOUNTERED BY RAILWAY WORKSHOPS & PRODUCTION UNITENCOUNTERED BY RAILWAY WORKSHOPS & PRODUCTION UNIT
This Trouble Shooting Booklet (TSB) issued by RWF Knowledge Center
covers mainly those problems which are not covered in normal trouble
shooting guide given by OEM's and were hi-lighted by participants from
Zonal Railways/Production Units in the seminar / work shop / training
session organised at RWF Knowledge Center
The approach in preparing the Booklet has been:
(1) For the given ''Problem''- list all possible causes.
(2) Then give cause wise solution using pictures and bulleted text for
easy of understanding of user.
(3) The copy of TSB is also being shared with participating Zonal Railways /
Production Units staff through dedicated “Whatsapp Group” and dedicated
“Email Group” (which are getting increasingly patronised).

3. WHEEL PRESS
PROBLEM:- 1) HIGH TONNAGE AND LOW TONNAGE PRESSING
SL NO POSSIBLE
CAUSE
REMEDIES PICTURES
1 a) Bore
diameter
finish not as
per drawing
Check Finish of
wheel Bore
diameter. Positive
taper to be
ensured between
0.02 mm to 0.06
mm on finished
wheel Bore.
0.06
INSIDE
MICROMETER
WHEEL BORE

4. WHEEL PRESS
PROBLEM:- 1) HIGH TONNAGE AND LOW TONNAGE PRESSING
SL NO POSSIBLE
CAUSE
REMEDIES PICTURES
1 b)
Pressure
transducer
not working
properly
(Abnormality
in graph w.r.t
pressure vs
distance)
a) Check/Ensure
oil supply to
Pressure
transducer .
b) Check Data
cable for proper
securing of ends
and cable
continuity.
PRESSURE TRANSDUCER

5. WHEEL PRESS
PROBLEM:- 2) WHEELS NOT PRESSED PROPERLY ON BOTH SIDES OF THE WHEEL SET
SL NO POSSIBLE
CAUSE
REMEDIES PICTURES
2 a)
Lack of
Lubrication
to axle
centering and
sliding
surfaces
Check
lubrication
system and
ensure proper
speed variations
in movement
between the two
centres.
CENTRE UNIT

6. WHEEL PRESS
PROBLEM:- 2) WHEELS NOT PRESSED PROPERLY ON BOTH SIDES OF THE WHEEL SET
SL NO POSSIBLE CAUSE REMEDIES PICTURES
2 b)
Proportionate
valve
malfunctioning
Check / replace ,
adjust the
proportionate
valve flow
PROPORTIONATE VALVE

7. WHEEL PRESS
PROBLEM 3 ) IMPROPER TRACK GAUGE & OFFSET i.e DISTANCE B/W TWO WHEELS & DISTANCE FROM
AXLE FACE TO THE WHEEL RIM
SL NO POSSIBLE CAUSE REMEDIES PICTURES
3 a)
Improper
Wheel
gripping
Check / ensure
for tightness of
fasteners .
Check encoder
of wheel gripper
working &
ensure proper
feed back
WHEEL GRIPPER

8. WHEEL PRESS
PROBLEM 3 ) IMPROPER TRACK GAUGE & OFFSET i.e DISTANCE B/W TWO WHEELS & DISTANCE FROM
AXLE FACE TO THE WHEEL RIM
SL NO POSSIBLE CAUSE REMEDIES PICTURES
3 b)
Wheel gripper
encoder not
functioning
properly
Check encoder of
wheel gripper
working &
ensure proper
feed back.
Replace if
required
ENCODER FOR WHEEL GRIPPER

9. WHEEL PRESS
PROBLEM 3 ) IMPROPER TRACK GAUGE & OFFSET i.e DISTANCE B/W TWO WHEELS & DISTANCE FROM
AXLE FACE TO THE WHEEL RIM
SL NO POSSIBLE CAUSE REMEDIES PICTURES
3 c)
Track gauge
encoder not
working
properly
Check track
gauge encoder for
proper working
and ensure
proper feed back
TRACK GAUGE ENCODER

10. WHEEL PRESS
PROBLEM 4) HYDRAULIC POWER PACK OIL TOO HOT
SL NO POSSIBLE CAUSE REMEDIES PICTURES
4 a)
High Inlet
water
temperature
Check / ensure
for proper inlet
water
temperature as
specification
HEAT EXCHANGER

11. WHEEL PRESS
PROBLEM 4) HYDRAULIC POWER PACK OIL TOO HOT
SL NO POSSIBLE CAUSE REMEDIES PICTURES
4 b)
Clogged Heat
exchanger
Heat exchanger
to be checked for
clogging .Clean it
if found clogged
END COVER
HEAT EXCHANGER

12. WHEEL PRESS
PROBLEM 4) HYDRAULIC POWER PACK OIL TOO HOT
SL NO POSSIBLE CAUSE REMEDIES PICTURES
4 c)
Malfunctioning
of Relief valve
Check for relief
valve problems of
hydraulic power
pack.If required
replace the relief
valve .
RELIEF VALVE

13. WHEEL PRESS
PROBLEM 4) HYDRAULIC POWER PACK OIL TOO HOT
SL NO POSSIBLE CAUSE REMEDIES PICTURES
4 d)
Hydraulic
power pack Oil
too hot signal
Check oil
temperature by
using
Thermohunter
(Digital)
regularly
THERMO HUNTER

14. WHEEL PRESS
PROBLEM 5) CHUCK & UNCHUCK PROBLEM OF WHEEL BORING
SL NO POSSIBLE CAUSE REMEDIES PICTURES
5 a)
Pneumatic
brake not
working
properly
Check brake
condition, tighten
if necessary
BRAKE DRUM
BRAKE LINER

15. WHEEL PRESS
PROBLEM 5) CHUCK & UNCHUCK PROBLEM OF WHEEL BORING
SL NO POSSIBLE CAUSE REMEDIES PICTURES
5 b)
Recommended
air pressure
not coming
from main air
line.
Check
pneumatic air
pressure 3 to 5
KG. Adjust if
required
PNEUMATIC PRESSURE GAUGE

16. WHEEL PRESS
PROBLEM 5) CHUCK & UNCHUCK PROBLEM OF WHEEL BORING
SL NO POSSIBLE CAUSE REMEDIES PICTURES
5 c)
FRL unit not
functioning
properly
Check FRL unit
for lubricating oil
level, top up
lubricating oil if
necessary. If FRL
unit found
defective than,
replace the FRL
unit
FRL UNIT

17. WHEEL PRESS
PROBLEM 5) CHUCK & UNCHUCK PROBLEM OF WHEEL BORING
SL NO POSSIBLE CAUSE REMEDIES PICTURES
5 d)
Malfunctioning
of Pneumatic
DC valve.
Check pneumatic
DC valve replace
if necessary
PNEUMATIC VALVES

18. WHEEL PRESS
PROBLEM 5) CHUCK & UNCHUCK PROBLEM OF WHEEL BORING
SL NO POSSIBLE CAUSE REMEDIES PICTURES
5 e)
Pneumatic
brake cylinder
not working
properly
Check pneumatic
brake cylinder
replace if
necessary
PNEUMATIC CYLINDER

19. WHEEL PRESS
PROBLEM 5) CHUCK & UNCHUCK PROBLEM OF WHEEL BORING
SL NO POSSIBLE CAUSE REMEDIES PICTURES
5 f)
Brake liners
worn out
Check the
condition of
brake liners
replace brake
liners if worn out
BRAKE LINER

20. WHEEL PRESS
PROBLEMS 6) ELECTRONIC BORING BAR TOOL MOVEMENT PROBLEM
SL NO POSSIBLE CAUSE REMEDIES PICTURES
6 a)
Electronic
boring bar
cartridge
movement
strucking due
to
accumulation
of dust
Check current
for over load in
servo motor,if the
servo motor is
over loaded,
Remove
cartridges,tool
sliding blocks
clean all the
sliding ways (5
No's)
ELECTRONIC
BORING BAR
CARTRIDGES

21. WHEEL PRESS
PROBLEMS 6) ELECTRONIC BORING BAR TOOL MOVEMENT PROBLEM
SL NO POSSIBLE CAUSE REMEDIES PICTURES
6 b)
Electeronic
boring bar,
encoder ,
servomotor not
functioning
properly or
coupling found
defective
Electrical
wiring , encoder
signal, coupling
to be checked. If
required replace
it
Data cable to be
checked.
ENCODER
COUPLING
TACHO GENERATOR
SERVO
MOTOR

22. WHEEL PRESS
PROBLEMS 6) ELECTRONIC BORING BAR TOOL MOVEMENT PROBLEM
SL NO POSSIBLE CAUSE REMEDIES PICTURES
6 c)
Miniature tool
movement
gearbox
components
damaged
Remove
miniature tool
movement gear
box dismantle &
check for any
damages in the
components &
replace necessary
components
lubricate &
assemble GEARS

23. WHEEL PRESS
PROBLEM 7) AXLE WHEEL SEAT MEASURING -CALLIPER NOT WORKING
SL NO POSSIBLE CAUSE REMEDIES PICTURES
7 a)
Electrical
problem
Electrical
problem , check
Junction box for
fuse / burnt
sockets
CONTROL PANEL

24. WHEEL PRESS
PROBLEM 7) AXLE WHEEL SEAT MEASURING -CALLIPER NOT WORKING
SL NO POSSIBLE CAUSE REMEDIES PICTURES
7 b)
Linear scale
not working
properly
Linear scale
cable checks .
Replace if
required
LINEAR SCALE

25. WHEEL PRESS
PROBLEM 7) AXLE WHEEL SEAT MEASURING -CALLIPER NOT WORKING
SL NO POSSIBLE CAUSE REMEDIES PICTURES
7 c)
Hydraulic
cylinder not
working
properly
Cylinder
movement, seals
leakage , external
or internal etc. /
replace if
required
HYDRAULIC CYLINDER

26. WHEEL PRESS
PROBLEM 8) HYDRAULIC PUMP NOT WORKING/OVER HEATING OF PUMP
SL NO POSSIBLE CAUSE REMEDIES PICTURES
8 a)
Hydraulic
power pack oil
level low
Check oil level of
the power pack
top up if
necessary
OIL LEVEL GAUGE

27. WHEEL PRESS
PROBLEM 8) HYDRAULIC PUMP NOT WORKING/OVER HEATING OF PUMP
SL NO POSSIBLE CAUSE REMEDIES PICTURES
8 b)
Malfunctioning
of Relief valve
Check pump
pressure and
relief valve
pressure as per
recommendation.
Always keep the
relief valve
pressure higher
than pump
pressure RELIEF VALVE

28. WHEEL PRESS
PROBLEM 8) HYDRAULIC PUMP NOT WORKING/OVER HEATING OF PUMP
SL NO POSSIBLE CAUSE REMEDIES PICTURES
8 c)
Breather hole
not closed
properly
Ensure breather
hole closed
properly
LEAKAGE LINE

29. WHEEL PRESS
PROBLEM 8) HYDRAULIC PUMP NOT WORKING/OVER HEATING OF PUMP
SL NO POSSIBLE CAUSE REMEDIES PICTURES
8 d)
Oil filters
clogged
Replace oil filter
periodically,
Replace hydraulic
oil periodically.
FILTERS

30. WHEEL PRESS
PROBLEM 9) SLUGGISH MOVEMENT OF PNEUMATIC ACTUATORS
SL NO POSSIBLE CAUSE REMIDIES PICTURES
9 a)
FRL unit not
working
properly
a) Check FRL unit
for required air
pressure adjust air
pressure necessary
b) Oil level of
lubricator bowl
top up oil if
necessary
c) Check for air
filter replace FRL
unit if necessary
FRL UNIT

31. WHEEL PRESS
PROBLEM 9) SLUGGISH MOVEMENT OF PNEUMATIC ACTUATORS
SL NO POSSIBLE CAUSE REMEDIES PICTURES
9 b)
Moisture with
pneumatic air
Check for
moisture of
pneumatic air
release water
collected in the
water vent
periodically
RELEASING WATER