75Maintenance Procedures of U2000-150 Underfloor Wheel LatheU2000-150型不落轮镟床维修保养规程译文

AALRT
AALRT Enterprise Standard
U2000-150
Maintenance Procedures of U2000-150 Underfloor
Wheel Lathe
() ()
Approved by: Checked by (Law): Checked by (English):
() 2015.08.20
Checked by (Chinese): Reviewed by: Sun Hongyu Date: August 20, 2015

2015.05.30
Dept. Maintenance
Prepared by: Zhang Yanming Date: May 30, 2015
Center
A
Version: A Revised by: Revised on:
2015.08.30
Controlled State: Internal
Issue No. Issued On: August 30, 2015
Control
2015.11.20
Implemented on: Nov.20,2015
U2000-150 A
1 47
Maintenance Procedures of U2000-150 Type Underfloor Wheel Lathe E/AALRT-0075-2015
Page 1 of 47
(Version A)
AALRT

Table of contents
1 ..............................................................................................................................................3
1 Application scope................................................................................................................................3
2 ..............................................................................................................................................3
2 Quoted standards................................................................................................................................3
3 ..............................................................................................................................................3
3 Maintenance modes............................................................................................................................3
4 .......................................................................................................................................3
4 Safety precautions...............................................................................................................................3
5 ...........................................................................................................................................4
5 Pre-maintenance preparation..............................................................................................................4
6 ..............................................................................................................................................6
6 Maintenance process..........................................................................................................................6
7 ...................................................................................................................................6
7 Maintenance items and standards......................................................................................................6
8 .....................................................................................................................................19
8 Post-maintenance work.....................................................................................................................19
9 ....................................................................................................................................................19
9 Appendix............................................................................................................................................19
U2000-150 A
2 47
Maintenance Procedures of U2000-150 Type Underfloor Wheel Lathe E/AALRT-0075-2015
Page 2 of 47
(Version A)
AALRT
1
1 Application scope
U2000-150
These procedures apply to the maintenance of Addis Ababa U2000-150 Underfloor Wheel Lathe.
2
2 Quoted standards
() 1 U2000-150 Hegenscheidt-MFD GMBH
& Co.KG
Technical Specification for Process Equipment Integrated Pack 1 of East-West Line and North-South Line (Phase I) of Addis Ababa Light Rail in Ethiopia and
Maintenance Procedures of U2000-150 Underfloor Wheel Lathe (Hegenscheidt-MFD GMBH & Co.KG)
3
3 Maintenance modes
U2000-150
Implement periodic maintenance system for U2000-150 Underfloor Wheel Lathe; the maintenance classification includes monthly inspection and annual
inspection, which will be implemented by the equipment maintenance personnel.
4
4 Safety precautions
4.1 3 1
4.1 When the maintenance operation for the equipment is conducted, there shall be at least 3 maintenance personnel and 1 supervisor, who shall strictly
abide by the Procedures. The operation personnel must be qualified in the special training on the equipment and gain the qualification.
U2000-150 A 3 47
E/AALRT-0075-2015
Maintenance Procedures of U2000-150 Type Underfloor Wheel Lathe (Version A) Page 3 of 47
AALRT
4.2
4.2 The operation personnel shall wear the work clothes, work shoes and work caps as required, and all the clothing shall not be loose; self-control and
mutual control must be conducted during operation
4.3
4.3 Achieve good call and response when operating the lathe; the operation personnel are strictly prohibited to enter into the moving parts area.
5
5 Pre-maintenance preparation
5.1
5.1 Materials to be prepared

Number for Number for Number for Number for
SN Name monthly annual SN Name monthly annual
inspection inspection inspection inspection

Lubricating grease
1 2
1 6 MICROLUBE-GB 00 0.5kg 5kg
Solidified stains detergent 1 bottle 2 bottles
(Knife rest, MICROLUBE-GB
00)

1 2 Lubricating oil
2 7 32L
Rust-inhibiting lubricant 1 bottle 2 bottles HD220
(gear case, HD220)
2 4 46
3 8 30L
Teflon tape 2 bottles 4 bottles 46# antiwear hydraulic oil
1 2 1
4 9
Electrical insulation type 1 roll 2 rolls Oil return filter element 1 element
U2000-150 A 4 47
E/AALRT-0075-2015
AALRT

ISOFLEX-NCA 15 1
5 0.5kg 5kg 10
Lubricating grease Pressure filter element 1 element
(ISOFLEX-NCA 15)
5.2
5.2 Tools and appliances to be prepared

Number for Number for Number for Number for
SN Name monthly annual SN Name monthly annual
inspection inspection inspection inspection
500V 1 1 1
1 6
500V megameter 1 piece Socket head wrench 1 set 1 set
1 1 2 2
2 7
Multimeter 1 piece 1 piece Flashlight 2 pieces 2 pieces
1 1 1 1
3 8
Test pencil 1 piece 1 piece Do Not Operate Plate 1 piece 1 piece
1 1 1
4 9
Clamp ammeter 1 piece Control key 1 piece 1 piece

8mm10mm13mm17mm19
mm24mm27mm 1 1
5
Solid wrench (8mm, 10mm, 1 set 1 set
13mm, 17mm, 19mm, 24mm,
27mm)
5.3 DCC
5.3 Before operation, assign the person in charge and apply for approval from DCC, and then the personnel can go to the equipment site for operation.
5.4
5.4 Before operation, inspect and clear obstacles and people without fixed duties at the site, and make the appropriate safety precautions; disconnect the
U2000-150 A 5 47
E/AALRT-0075-2015
AALRT
main power switch of the storage area and the power disconnecting switch of lathe power supply control box, and hang the Do Not Operate in place.
5.5
5.5 Before operation, use test pencil to confirm whether input end of the main power supply of power supply control box has been disconnected; if it is
disconnected, start the operation.
6
6 Maintenance process
Flow chart for maintenance of underfloor wheel lathe
Pre- Pre-
maintenance Lathe top Lathe left Lathe back Lathe right Lathe front Printer cabinet Complete machine maintenance
preparation test preparation
7
7 Maintenance items and standards

Maintenance
Maintenance item
classification

SN Maintenance standards
Monthly Annual
System Component inspectio inspectio
n n
1
U2000-150 A 6 47
E/AALRT-0075-2015
AALRT
Electrical Power supply The appearance is free from damage or dirt; the cabinet door can be opened and
system control box body closed flexibly.

2
Transformer coil The surface is free from burn mark or damage.

3 Terminal block of
The appearance is free from damage or dirt; the installation is secure; the connecting
power supply
line is free from damage or looseness.
control box

4 Electrical control The appearance is free from damage or dirt; the cabinet door can be opened and
cabinet body closed flexibly.

5 The appearance is free from damage or dirt; the installation is secure; the connecting
Disconnecting
line is free from damage or looseness, the line size is clear and intact without loss; the
switch
disconnecting switch can move flexibly, and can realize mechanical interlocking; using
multimeter for measurement can realize effective make-and-break.

Relay
line is free from damage or looseness, the line size is clear and intact; the name plate is
complete, clear and intact, and is securely pasted.

Breaker, shielding
line is free from damage or looseness, the line size is clear and intact; the name plate is
switch, air switch
clear and intact, and is securely pasted.
8
line is free from damage or looseness, the line size is clear and intact.

U2000-150 A 7 47
E/AALRT-0075-2015
AALRT
/

AC transformer, DC
transformer, voltage
distributor, power
supply filter, power
supply/ feed
module, braking
resistor

External device
line is free from damage or looseness, the line size is clear and intact; the plug is
connector
securely connected.

10 PLC The appearance is free from damage or dirt; the installation is secure; the connecting
line is free from damage or looseness, the line size is clear and intact; the address code
is clear and intact.

All parts of the lighting fixtures are securely installed without damage; the modulator
11
Floodlight and tube is without burning loss or blackening; the manual on-off action is flexible without
control travel switch clamping stagnation; manually pressing the travel switch is flexible without clamping
stagnation.

12 Emergency stop The wiring terminals are securely connected; pressing the emergency stop button is
button without clamping stagnation, and clockwise rotation can make it bounce and reset.
13
Running time
counter The appearance is free from damage or dirt; the installation is secure; the connecting
line is free from damage or looseness, the line size is clear and intact; record the
running time of lathe.
U2000-150 A 8 47
E/AALRT-0075-2015
AALRT

14
Modem, Router line is free from damage or looseness, the line size is clear and intact; the plug is
securely connected.

I/O
Distributed I/O
line is free from damage or looseness, the line size is clear and intact; the plug is
interface
securely connected.

16 Filtration blocking
The appearance is free from damage or dirt.
monitor

17 The appearance is free from damage or dirt; the cabinet door can be opened and
Printer cabinet
closed flexibly; the printer appearance is without damage, the wiring is secure; test the
printer for proper function.

18 The installation is secure, the appearance is clean; the station lighting and reduction of
Lathe floodlight
station lighting are effective.

19
The appearance is clean, and the installation is secure.

Key switch box
20 Key switch is securely wired with flexible action; using multimeter for measurement can
realize effective make-and-break.

21 The appearance is free from damage; the wiring terminals of terminal box are securely
connected, and are free from rusting or dirt.

22 500V 0.5M
Hydraulic oil pump Use 500V megameter to measure the single phase to ground insulation of the motor of
motor, driving wheel chip crushing machine: the value of resistance is greater than 0.5 M.
U2000-150 A 9 47
E/AALRT-0075-2015
AALRT
motor, cable stayed

traction motor of
chip removal
machine, horizontal
traction motor of

23 Limit switch, The appearance is free from damage or dirt; the installation is secure, the action of limit
proximity switch switch is flexible without clamping stagnation; the connecting line is free from damage
or looseness, the line size is clear and intact without loss.

Hose and cable
24 conduit leading to
Without damage.
each electrical
terminal and knife
rest

Mechanical Driving wheel
25 system The appearance is clean without grease attached; the anti-loose line of fixed bolt is
clear without malposition; the bearing end plate is free from oil leakage; the drive wheel
is free from deformation, damage or crack;
:0.1mm0.5mm
0.5mm6mm
26 Measure the profile of driving wheel. The standard values are: the ovality of single
wheel 0.1mm, the profile deviation of single wheel0.5mm, the wheel diameter
difference of two driving wheels on the same side of the machine 0.5mm, and the
decrease amount of wheel diameter 6mm.
27 ISOFLEX-NCA 153-4
U2000-150 A 10 47
E/AALRT-0075-2015
AALRT
Use grease gun to fill lubricating grease (ISOFLEX-NCA 15) at the lubricating point for
3-4 times.
6 140Nm
28 Check the moments of 6 fixed bolts on the driving wheel; the tightening torque is
140Nm.

29 Lateral supporting The appearance is clean without deformation, damage or crack. The attachment bolts
wheel are fastened, and the anti-loose line is clear without malposition.

30 The appearance is clean without deformation, damage or crack. The attachment bolts
are fastened, and the anti-loose line is clear without malposition.
Axial guide wheel ISOFLEX-NCA 153-4
31 Use grease gun to fill lubricating grease (ISOFLEX-NCA 15) at the lubricating point for
3-4 times.

32 Surface cover plate
The appearance is free from damage, and the installation is secure.
and service pedal of
lathe

33 Safety protective
door

34 Observation The appearance is free from dirt; the observation window can be opened and closed
window without clamping stagnation.

35
Each hose guider The appearance is free from damage, and the installation is secure.
and cable guider
36
U2000-150 A 11 47
E/AALRT-0075-2015
AALRT
Setting mechanism
of wheel diameter The appearance is free from damage or crack.
range
XZ ,
37 Toothed belts of X The appearance is free from damage, crack or obvious wear; the tensile force is
and Z axles moderate, otherwise it shall be adjusted.

38 The appearance is clean without damage or crack; the attachment bolts are fastened,
and the anti-loose line is clear without malposition.
External axle box 2 HD220 7.6L
39 Replace the lubricating oil (HD220) of gear case every 2 years; the dosage of single
gear case is 7.6L.

40 The appearance is clean without damage or crack; the attachment bolts are fastened,
and the anti-loose line is clear without malposition.
Supporting arm of
idler wheel ISOFLEX-NCA 153-4
3-4 times.

42 The pressure claw is free from damage or crack, and can slide smoothly in the rail
without clamping stagnation.
ISOFLEX-NCA 153-4
43 Pressure claw Use grease gun to fill lubricating grease (ISOFLEX-NCA 15) at the lubricating point for
device 3-4 times.
ISOFLEX-NCA 1540-60g
44 Apply 40-60g of lubricating grease (ISOFLEX-NCA 15) in the pressure claw sliding
chute and on the sliding rails.
45
Movable rail and The appearance is clean without deformation, damage or crack; the attachment bolts
guide rail bridge are fastened, and the anti-loose line is clear without malposition.
U2000-150 A 12 47
E/AALRT-0075-2015
AALRT
ISOFLEX-NCA 15 50-70g
46
Apply 50-70g of lubricating grease (ISOFLEX-NCA 15) on the bottom of movable rail.
12863mm 14353mm
47 Measure the internal side spacing (standard value1,2863mm) and rail spacing
(standard value1,4353mm).

48 Hydraulic The hydraulic pipeline is securely connected, the pipe joints are free from rusting or
Hydraulic pipeline
system leakage, and the hydraulic hose is free from damage or crazing.

49
Cooling fin The appearance is free from damage or dirt.

50 The hydraulic oil is free from emulsification or dilution; the oil level is between the upper
and lower marks, add oil when it is insufficient.
Hydraulic oil
2 46 20L
51
Replace 46# antiwear hydraulic oil (20L) every 2 years, and clean the oil tank.

52
Hydraulic block The appearance is free from damage, leakage or dirt.

53
The appearance is free from damage or dirt, the installation is secure.
Filter
54
Replace the filter elements of oil return filter, pressure filter and filtration components.

55 Main hydraulic
The attachment bolts are fastened, and the anti-loose line is clear without malposition.
pump

56 Auxiliary hydraulic
The attachment bolts are fastened, and the anti-loose line is clear without malposition.
pump
57
The appearance is clean without deformation, damage or crack; the attachment bolts
U2000-150 A 13 47
E/AALRT-0075-2015
AALRT
Hydraulic cylinder are fastened, and the anti-loose line is clear without malposition.

Wheel diameter
range setting
58
mechanism, The appearance is clean without damage or crack.
hydraulic motor
components of
pressure claw
NC

59 NC The appearance is clean without damage or crack; the attachment bolts are fastened,
processing and the anti-loose line is clear without malposition; the sealing rubber on the sliding
system Knife rest connection rail end and the knife rest is free from damage.
MICROLUBE-GB 003-4
3-4 times.

Wear probe cover
61 plate, wear probe,
The appearance is clean without deformation, damage or crack.
and diameter
measurement
wheel

Lathe operation
62 panel, hand wheel The appearance is clean without damage; the connecting line is free from damage;
operation panel, pressing the emergency stop button is without clamping stagnation, and clockwise
and hand-held rotation can make it bounce and reset.
controller
63 840D NCU
U2000-150 A 14 47
E/AALRT-0075-2015
AALRT

SIMODRIVE 611 The appearance is free from damage or dirt, the installation is secure; the connecting
line is free from damage or looseness, and the line size is clear and intact; the
840D NCU module, connecting sockets of the drive bus, equipment bus and feedback line are securely
SIMODRIVE 611 connected, and can realize mechanical locking.
power module and
driver module 5 NCU
64
Replace NCU battery every 5 years.

The appearance is free from damage or dirt, the installation is secure without
65
Air conditioner looseness; the connecting line is free from damage or looseness, and the line size is
clear and intact.
Air
conditionin
66
g system Dust filtering screen Clean the dust filtering screen

67
Water outlet Unobstructed
ISOFLEX-NCA 153-4
Chip crushing 3-4 times.
Chip machine
69
crushing The cutting blade is free from damage.
and
removal 1L
system
70 Chip removal Chip removal machine is free from residual cuttings inside; the chain protective device,
mechanism conveyer belt and chain are free from rubbing or damage; lubricate the conveyer belt
and chain with a dosage of 1L.
PLCMMCNC
71
Functional Start-up inspection PLC, MMC and NC have no fault alarm.
test
72
Functional test of When opening the electrical cabinet door, the service floodlight will be on automatically;
electrical system when closing the cabinet door, the service floodlight will be off automatically.
U2000-150 A 15 47
E/AALRT-0075-2015
AALRT

73
Press the red scram button, the lathe will stop.

74 The lathe floodlight will be on automatically, and the light will directly point at the lathe
wheel area.

75 The electrical safety interlocking devices on the safety protective door and observation
window can realize interlocking.

76
The hydraulic oil pump motor and driving wheel motor operate smoothly.
(10% 8.0A)
(10% 61.5A)
77 Measure the three-phase current balance of motor: hydraulic oil pump motor (the three-
phase imbalance 10%, the rated value is 8.0A); the driving wheel motor (the three-
phase imbalance 10%, the rated value is 61.5A).

78 Functional test of The indicator light of filtration blocking monitor is on; the main hydraulic pump and
hydraulic system auxiliary hydraulic pump operate smoothly; the hydraulic cylinder acts flexibly without
clamping stagnation, and the piston rod is free from scratch or damage.
NC
79
Functional test of The hydraulic motor components operate smoothly;
NC system
80 The single function and linkage function of the actuator are consistent with the operating
instruction.
SIMODRIVE 611 NCU
81 The status indicators of SIMODRIVE 611 power module, NCU module and driver
module are on.
82 NCU
NCU has no power shortage alarm.
U2000-150 A 16 47
E/AALRT-0075-2015
AALRT
PLC
83 The program error indicator light, battery error indicator light and stop indicator light on
PLC component are off.

84
When electrifying the lathe, all button indicator lights on the operation panel will flicker.

85 When operating the buttons on the lathe operation panel, the operation actions are
consistent with the button functions.

86 When operating the buttons on the hand wheel operation panel, the operation actions
are consistent with the button functions.

87 When pressing the red scram button on the lathe operation panel, hand wheel operation
panel, and hand-held controller, the lathe will stop.
Functional test of
88 chip crushing and
When pressing the reset button on the lathe operation panel, the lathe processing
removal system
procedure can automatically interrupt and reset.

89
The knife rest moves flexibly.

90
Start the lathe processing procedure, the chip removal system will start automatically.

91 The rotation of cutter teeth of chip crushing machine is free from clamping stagnation,
and the motor has no overload.

92
The chip removal machine is free from blocking and operates smoothly.
93
Standard wheel set
The chip crushing machine motor, horizontal traction motor of chip removal machine,
U2000-150 A 17 47
E/AALRT-0075-2015
AALRT
cable stayed traction motor of chip removal machine, reduction gearbox of chip crushing
machine, and reduction gearbox of chip removal motor operate smoothly.

94 Press the red scram button on the distribution box of the chip removal system, the lathe
will stop.
10% 5.3A
10% 1.5A
10% 1.5A
95 test Measure the three-phase current balance of motor: chip crushing machine (the three-
phase imbalance 10%, the rated value is 5.3A); horizontal traction motor of chip
removal machine (the three-phase imbalance 10%, the rated value is 1.5A); cable
stayed traction motor of chip removal machine (the three-phase imbalance 10%, the
rated value is 1.5A)
HMI
0.10mm
96 Select and enter HMI mode interface, operate according to the operating steps of
standard wheel set, and then the system can automatically execute the measurement.
The absolute value of five measurements of standard wheel set 0.10mm.
8
8 Post-maintenance work
8.1 HMI

8.1 After the HMI fault alarm message collection and the functional test, disconnect the main power switch of storage area, power disconnecting switch of
lathe power supply control box and the disconnecting switch of the lathe main power; lock the disconnecting switch of the lathe main power, and assign
special person to keep the key.
8.2 DCC
8.2 Restore the equipments, clear the site, check the tools and appliances, and cancel the point on DCC.
8.3 U2000-150 AU2000-150 B
U2000-150 A 18 47
E/AALRT-0075-2015
AALRT

8.3 The maintenance personnel shall timely fill in the Monthly Inspection Log Sheet of U2000-150 Underfloor Wheel Lathe (Appendix A) or the Annual
Inspection Log Sheet of U2000-150 Underfloor Wheel Lathe (Appendix B); the shift leader and technical personnel shall sign and confirm the results.
9
9 Appendix
AU2000-150
Appendix A: Monthly Inspection Log Sheet of U2000-150 Underfloor Wheel Lathe
BU2000-150
Appendix B: Annual Inspection Log Sheet of U2000-150 Underfloor Wheel Lathe
U2000-150 A 19 47
E/AALRT-0075-2015
AALRT
A
Appendix A
U2000-150
Monthly Inspection Log Sheet of U2000-150 Underfloor Wheel Lathe

Maintenance date:

Maintenance item
SN Maintenance standard Results
System Component

1 Electrical Power supply The appearance is free from damage or dirt; the cabinet door can be opened
system control box body and closed flexibly.

2

3 Terminal block of
The appearance is free from damage or dirt; the installation is secure; the
power supply
connecting line is free from damage or looseness.
control box

4 Electrical control The appearance is free from damage or dirt; the cabinet door can be opened
cabinet body and closed flexibly.
5
Disconnecting
switch The appearance is free from damage or dirt; the installation is secure; the
connecting line is free from damage or looseness, the line size is clear and
intact without loss; the disconnecting switch can move flexibly, and can realize
mechanical interlocking; using multimeter for measurement can realize
U2000-150 A 20 47
E/AALRT-0075-2015
AALRT
effective make-and-break.

6 The appearance is free from damage or dirt; the installation is secure; the
Relay
intact; the name plate is complete, clear and intact, and is securely pasted.

Breaker, shielding
switch, air switch
intact; the name plate is clear and intact, and is securely pasted.

/

8 AC transformer, The appearance is free from damage or dirt; the installation is secure; the
DC transformer, connecting line is free from damage or looseness, the line size is clear and
voltage distributor, intact.
power supply filter,
power supply/
feed module,
braking resistor

9 External device The appearance is free from damage or dirt; the installation is secure; the
connector connecting line is free from damage or looseness, the line size is clear and
intact; the plug is securely connected.
10 PLC

intact; the address code is clear and intact.
U2000-150 A 21 47
E/AALRT-0075-2015
AALRT

11 All parts of the lighting fixtures are securely installed without damage; the
Floodlight and
modulator tube is without burning loss or blackening; the manual on-off action
control travel
is flexible without clamping stagnation; manually pressing the travel switch is
switch
flexible without clamping stagnation.

12 The wiring terminals are securely connected; pressing the emergency stop
Emergency stop
button is without clamping stagnation, and clockwise rotation can make it
button
bounce and reset.

13 Running time The appearance is free from damage or dirt; the installation is secure; the
counter connecting line is free from damage or looseness, the line size is clear and
intact; record the running time of lathe.

I/O
14 Distributed I/O The appearance is free from damage or dirt; the installation is secure; the
interface connecting line is free from damage or looseness, the line size is clear and

monitor

16 The appearance is free from damage or dirt; the cabinet door can be opened
Printer cabinet
and closed flexibly; the printer appearance is without damage, the wiring is
secure; test the printer for proper function.
17
Lathe floodlight The installation is secure, the appearance is clean; the station lighting and
reduction of station lighting are effective.
U2000-150 A 22 47
E/AALRT-0075-2015
AALRT

18
Key switch box The appearance is clean, and the installation is secure.

Hydraulic oil pump
motor, driving
19 wheel motor, cable
The appearance is free from damage; the wiring terminals of terminal box are
stayed traction
securely connected, and are free from rusting or dirt.
motor of chip
removal machine,
horizontal traction
motor of chip
removal machine,
and motor of chip
crushing machine

20 The appearance is free from damage or dirt; the installation is secure, the
Limit switch,
action of limit switch is flexible without clamping stagnation; the connecting line
proximity switch
is free from damage or looseness, the line size is clear and intact without loss.

Hose and cable
21
conduit leading to Without damage.
each electrical
terminal and knife
rest
22

U2000-150 A 23 47
E/AALRT-0075-2015
AALRT
Mechanical The appearance is clean without grease attached; the anti-loose line of fixed
system bolt is clear without malposition; the bearing end plate is free from oil leakage;
the drive wheel is free from deformation, damage or crack;
:0.1mm
0.5mm0.5mm6mm
23 Measure the profile of driving wheel. The standard values are: the ovality of
Driving wheel
single wheel 0.1mm, the profile deviation of single wheel0.5mm, the wheel
diameter difference of two driving wheels on the same side of the machine
0.5mm, and the decrease amount of wheel diameter 6mm.
ISOFLEX-NCA 153-4
24 Use grease gun to fill lubricating grease (ISOFLEX-NCA 15) at the lubricating
point for 3-4 times.

25 The appearance is clean without deformation, damage or crack. The
Lateral supporting
attachment bolts are fastened, and the anti-loose line is clear without
wheel
malposition.

malposition.
Axial guide wheel
ISOFLEX-NCA 153-4

28 Surface cover
plate and service
pedal of lathe
29
Safety protective The appearance is free from damage, and the installation is secure.
door
U2000-150 A 24 47
E/AALRT-0075-2015
AALRT

30 Observation The appearance is free from dirt; the observation window can be opened and
window closed without clamping stagnation.

31
and cable guider

Setting
32 mechanism of
The appearance is free from damage or crack.
wheel diameter
range

33 The appearance is clean without damage or crack; the attachment bolts are
External axle box
fastened, and the anti-loose line is clear without malposition.

Supporting arm of

36 The pressure claw is free from damage or crack, and can slide smoothly in the
rail without clamping stagnation.
Pressure claw
device ISOFLEX-NCA 153-4

38 The appearance is clean without deformation, damage or crack; the
Movable rail and
guide rail bridge
malposition.
U2000-150 A 25 47
E/AALRT-0075-2015
AALRT

39 Hydraulic The hydraulic pipeline is securely connected, the pipe joints are free from
Hydraulic pipeline
system rusting or leakage, and the hydraulic hose is free from damage or crazing.

40

41 The hydraulic oil is free from emulsification or dilution; the oil level is between
the upper and lower marks, add oil when it is insufficient.
Hydraulic oil
2 46 20L
42

43

44
Filter The appearance is free from damage or dirt, the installation is secure.

45 Main hydraulic The attachment bolts are fastened, and the anti-loose line is clear without
pump malposition.

46 Auxiliary hydraulic The attachment bolts are fastened, and the anti-loose line is clear without
pump malposition.

The appearance is clean without deformation, damage or crack; the
47
Hydraulic cylinder attachment bolts are fastened, and the anti-loose line is clear without
malposition.
48
The appearance is clean without damage or crack.

Wheel diameter
range setting
mechanism,
U2000-150 A 26 47
E/AALRT-0075-2015
AALRT
hydraulic motor
components of
pressure claw
NC

49 NC The appearance is clean without damage or crack; the attachment bolts are
processing fastened, and the anti-loose line is clear without malposition; the sealing
system rubber on the sliding connection rail end and the knife rest is free from
Knife rest damage.
MICROLUBE-GB 003-4

Wear probe cover
51
plate, wear probe, The appearance is clean without deformation, damage or crack.
and diameter
measurement
wheel

52 Lathe operation
The appearance is clean without damage; the connecting line is free from
panel, hand wheel
damage; pressing the emergency stop button is without clamping stagnation,
operation panel,
and clockwise rotation can make it bounce and reset.
and hand-held
controller
53 840D NCU
SIMODRIVE 611
The appearance is free from damage or dirt, the installation is secure; the
connecting line is free from damage or looseness, and the line size is clear
and intact; the connecting sockets of the drive bus, equipment bus and
U2000-150 A 27 47
E/AALRT-0075-2015
AALRT
840D NCU
module,
SIMODRIVE 611 feedback line are securely connected, and can realize mechanical locking.
power module and
driver module

54
Air conditioner looseness; the connecting line is free from damage or looseness, and the line
size is clear and intact.
Air
conditioning
55 Dust filtering
system Clean the dust filtering screen
screen

56

Chip ISOFLEX-NCA 153-4
57 crushing Chip crushing Use grease gun to fill lubricating grease (ISOFLEX-NCA 15) at the lubricating
and removal machine point for 3-4 times.
system
PLCMMCNC
58
Functional Start-up inspection PLC, MMC and NC have no fault alarm.
test

59 Functional test of When opening the electrical cabinet door, the service floodlight will be on
electrical system automatically; when closing the cabinet door, the service floodlight will be off
automatically.

60
61
The lathe floodlight will be on automatically, and the light will directly point at
the lathe wheel area.
U2000-150 A 28 47
E/AALRT-0075-2015
AALRT

62 The electrical safety interlocking devices of safety protective door and
observation window can realize interlocking.

63

64 The indicator light of filtration blocking monitor is on; the main hydraulic pump
Functional test of
and auxiliary hydraulic pump operate smoothly; the hydraulic cylinder acts
hydraulic system
flexibly without clamping stagnation, and the piston rod is free from scratch or
damage.

65
The hydraulic motor components operate smoothly;

66 The single function and linkage function of the actuator are consistent with the
operating instruction.
NC SIMODRIVE 611 NCU
67 Functional test of The status indicators of SIMODRIVE 611 power module, NCU module and
NC system driver module are on.
NCU
68
PLC
69 The program error indicator light, battery error indicator light and stop indicator
light on PLC component are off.

70 When electrifying the lathe, all button indicator lights on the operation panel
Functional test of will flicker.
71 chip crushing and
removal system
When pressing the red scram button on the lathe operation panel, hand wheel
operation panel, and hand-held controller, the lathe will stop.
U2000-150 A 29 47
E/AALRT-0075-2015
AALRT

72 When pressing the reset button on the lathe operation panel, the lathe
processing procedure can automatically interrupt and reset.

73

74 Start the lathe processing procedure, the chip removal system will start
automatically.

75 The rotation of cutter teeth of chip crushing machine is free from clamping
stagnation, and the motor has no overload.

76

77 The chip crushing machine motor, horizontal traction motor of chip removal
machine, cable stayed traction motor of chip removal machine, reduction
Standard wheel gearbox of chip crushing machine, and reduction gearbox of chip removal
set test motor operate smoothly.

78 Press the red scram button on the distribution box of the chip removal system,
the lathe will stop.

Failure description Maintenance situation

Failure record

Failure service personnel:

U2000-150 A 30 47
E/AALRT-0075-2015
AALRT
Measurement item Measurement data
1#: mm2#: mm3#: mm4#: mm
Driving wheel ovality 1#: mm, 2#: mm, 3#: mm, 4#: mm.
Measurement
record 1#: mm2#: mm3#: mm4#: mm
Driving wheel diameter 1#: mm, 2#: mm, 3#: mm, 4#: mm.

Measurement personnel:

For normal inspection result, shall be marked in the corresponding result column; for abnormal inspection result,
Filling description
shall be marked in the corresponding result column, and the detailed description shall be made in the Failure record column;
the measured data shall be filled in the Measurement record column.

Shift Technical
Maintenance personnel
leader personnel
U2000-150 A 31 47
E/AALRT-0075-2015
AALRT
B
Appendix B
U2000-150
Annual Inspection Log Sheet of U2000-150 Underfloor Wheel Lathe

Maintenance date: (YY/MM/DD)

Maintenance item
SN Maintenance standard Results
System Component

1 Electrical Power supply The appearance is free from damage or dirt; the cabinet door can be opened
system control box body and closed flexibly.

2

3 Terminal block of
power supply
connecting line is free from damage or looseness.
control box

4 Electrical control The appearance is free from damage or dirt; the cabinet door can be opened
cabinet body and closed flexibly.
5
Disconnecting
switch The appearance is free from damage or dirt; the installation is secure; the
U2000-150 A 32 47
E/AALRT-0075-2015
AALRT
intact without loss; the disconnecting switch can move flexibly, and can realize
mechanical interlocking; using multimeter for measurement can realize
effective make-and-break.

Relay
intact; the name plate is complete, clear and intact, and is securely pasted.

Breaker, shielding
switch, air switch
intact; the name plate is clear and intact, and is securely pasted.

/

AC transformer,
DC transformer,
voltage
intact.
distributor, power
supply filter,
power supply/
feed module,
braking resistor

9 External device The appearance is free from damage or dirt; the installation is secure; the
connector connecting line is free from damage or looseness, the line size is clear and
10 PLC

U2000-150 A 33 47
E/AALRT-0075-2015
AALRT
intact; the address code is clear and intact.

11 All parts of the lighting fixtures are securely installed without damage; the
Floodlight and
modulator tube is without burning loss or blackening; the manual on-off action
control travel
is flexible without clamping stagnation; manually pressing the travel switch is
switch
flexible without clamping stagnation.

12 The wiring terminals are securely connected; pressing the emergency stop
Emergency stop
button is without clamping stagnation, and clockwise rotation can make it
button
bounce and reset.

13 Running time The appearance is free from damage or dirt; the installation is secure; the
counter connecting line is free from damage or looseness, the line size is clear and
intact; record the running time of lathe.

Modem, Router connecting line is free from damage or looseness, the line size is clear and

I/O
15 Distributed I/O The appearance is free from damage or dirt; the installation is secure; the
interface connecting line is free from damage or looseness, the line size is clear and

monitor
17
U2000-150 A 34 47
E/AALRT-0075-2015
AALRT

Printer cabinet The appearance is free from damage or dirt; the cabinet door can be opened
and closed flexibly; the printer appearance is without damage, the wiring is
secure; test the printer for proper function.

18 The installation is secure, the appearance is clean; the station lighting and
Lathe floodlight
reduction of station lighting are effective.

19
The appearance is clean, and the installation is secure.

Key switch box
20 Key switch is securely wired with flexible action; using multimeter for
measurement can realize effective make-and-break.

21 The appearance is free from damage; the wiring terminals of terminal box are
securely connected, and are free from rusting or dirt.

Hydraulic oil
pump motor,
driving wheel
motor, cable 500V 0.5M
stayed traction Use 500V megameter to measure the single phase to ground insulation of the
22 motor of chip
motor of chip crushing machine: the value of resistance is greater than 0.5
removal machine, M.
horizontal traction
motor of chip
removal machine,
and motor of chip
crushing machine
23

Limit switch, The appearance is free from damage or dirt; the installation is secure, the
proximity switch action of limit switch is flexible without clamping stagnation; the connecting
U2000-150 A 35 47
E/AALRT-0075-2015
AALRT
line is free from damage or looseness, the line size is clear and intact without
loss.

Hose and cable
24
conduit leading to Without damage.
each electrical
terminal and knife
rest

Mechanical
25 system The appearance is clean without grease attached; the anti-loose line of fixed
bolt is clear without malposition; the bearing end plate is free from oil leakage;
the drive wheel is free from deformation, damage or crack;
:0.1mm
0.5mm0.5mm6mm
26 Measure the profile of driving wheel. The standard values are: the ovality of
single wheel 0.1mm, the profile deviation of single wheel 0.5mm, the
Driving wheel wheel diameter difference of two driving wheels on the same side of the
machine 0.5mm, and the decrease amount of wheel diameter 6mm.
ISOFLEX-NCA 153-4
6 140Nm
28 Check the moments of 6 fixed bolts on the driving wheel; the tightening torque
is 140Nm.
29
Lateral supporting The appearance is clean without deformation, damage or crack. The
wheel attachment bolts are fastened, and the anti-loose line is clear without
malposition.
U2000-150 A 36 47
E/AALRT-0075-2015
AALRT

malposition.
Axial guide wheel
ISOFLEX-NCA 153-4

32 Surface cover
plate and service
pedal of lathe

33 Safety protective
door

34 Observation The appearance is free from dirt; the observation window can be opened and
window closed without clamping stagnation.

35
and cable guider

Setting
36 mechanism of
The appearance is free from damage or crack.
wheel diameter
range
XZ ,
37 Toothed belts of X The appearance is free from damage, crack or obvious wear; the tensile force
and Z axles is moderate, otherwise adjust it.
38
U2000-150 A 37 47
E/AALRT-0075-2015
AALRT
The appearance is clean without damage or crack; the attachment bolts are
External axle box 2 HD220 7.6L
39 Replace the lubricating oil (HD220) of gear case every 2 years; the dosage of
single gear case is 7.6L.

Supporting arm of

42 The pressure claw is free from damage or crack, and can slide smoothly in
the rail without clamping stagnation.
ISOFLEX-NCA 153-4
43 Pressure claw Use grease gun to fill lubricating grease (ISOFLEX-NCA 15) at the lubricating
device point for 3-4 times.
ISOFLEX-NCA 1540-60g
44 Apply 40-60g of lubricating grease (ISOFLEX-NCA 15) in the pressure claw
sliding chute and on the sliding rails.

45 The appearance is clean without deformation, damage or crack; the
malposition.

ISOFLEX-NCA 15 50-70g
46 Movable rail and
Apply 50-70g of lubricating grease (ISOFLEX-NCA 15) on the bottom of
guide rail bridge
movable rail.
12863mm 14353mm
47 Measure the internal side spacing (standard value12863mm) and rail
spacing (standard value14353mm).
U2000-150 A 38 47
E/AALRT-0075-2015
AALRT

48 Hydraulic The hydraulic pipeline is securely connected, the pipe joints are free from
Hydraulic pipeline
system rusting or leakage, and the hydraulic hose is free from damage or crazing.

49

50 The hydraulic oil is free from emulsification or dilution; the oil level is between
the upper and lower marks, add oil when it is insufficient.
Hydraulic oil
2 46 20L
51

52

53
The appearance is free from damage or dirt, the installation is secure.

Filter
54 Replace the filter elements of oil return filter, pressure filter and filtration
components.

55 Main hydraulic The attachment bolts are fastened, and the anti-loose line is clear without
pump malposition.

56 Auxiliary hydraulic The attachment bolts are fastened, and the anti-loose line is clear without
pump malposition.

The appearance is clean without deformation, damage or crack; the
57
Hydraulic cylinder attachment bolts are fastened, and the anti-loose line is clear without
malposition.
58
The appearance is clean without damage or crack.
U2000-150 A 39 47
E/AALRT-0075-2015
AALRT

Wheel diameter
range setting
mechanism,
hydraulic motor
components of
pressure claw
NC

59 NC The appearance is clean without damage or crack; the attachment bolts are
processing fastened, and the anti-loose line is clear without malposition; the sealing
system rubber on the sliding connection rail end and the knife rest is free from
Knife rest damage.
MICROLUBE-GB 003-4

Wear probe cover
61
plate, wear probe, The appearance is clean without deformation, damage or crack.
and diameter
measurement
wheel
62

The appearance is clean without damage; the connecting line is free from
Lathe operation damage; pressing the emergency stop button is without clamping stagnation,
panel, hand and clockwise rotation can make it bounce and reset.
wheel operation
panel, and hand-
held controller
63 840D NCU
U2000-150 A 40 47
E/AALRT-0075-2015
AALRT
SIMODRIVE 611
The appearance is free from damage or dirt, the installation is secure; the
connecting line is free from damage or looseness, and the line size is clear
840D NCU and intact; the connecting sockets of the drive bus, equipment bus and
module, feedback line are securely connected, and can realize mechanical locking.
SIMODRIVE 611
power module 5 NCU
64
and driver module Replace NCU battery every 5 years.

65
Air conditioner looseness; the connecting line is free from damage or looseness, and the line
size is clear and intact.
Air
conditioning
66 Dust filtering
system Clean the dust filtering screen
screen

67
ISOFLEX-NCA 153-4
Chip crushing point for 3-4 times.
machine
69 Chip
The cutting blade is free from damage.
crushing and
removal
system 1L
70 Chip removal Chip removal machine is free from residual cuttings inside; the chain
mechanism protective device, conveyer belt and chain are free from rubbing or damage;
lubricate the conveyer belt and chain with a dosage of 1L.

PLCMMCNC
71 Functional Start-up
PLC, MMC and NC have no fault alarm.
test inspection
72
U2000-150 A 41 47
E/AALRT-0075-2015
AALRT
When opening the electrical cabinet door, the service floodlight will be on
automatically; when closing the cabinet door, the service floodlight will be off
automatically.

73

74 The lathe floodlight will be on automatically, and the light will directly point at
the lathe wheel area.
Functional test of
75 electrical system The electrical safety interlocking devices of safety protective door and
observation window can realize interlocking.

76
(10% 8.0A)
(10% 61.5A)
77 Measure the three-phase current balance of motor: hydraulic oil pump motor
(the three-phase imbalance 10%, the rated value is 8.0A), the driving wheel
motor (the three-phase imbalance 10%, the rated value is 61.5A)

78 The indicator light of filtration blocking monitor is on; the main hydraulic pump
Functional test of
and auxiliary hydraulic pump operate smoothly; the hydraulic cylinder acts
hydraulic system
flexibly without clamping stagnation, and the piston rod is free from scratch or
damage.
NC
79
Functional test of The hydraulic motor components operate smoothly;
NC system
80 The single function and linkage function of the actuator are consistent with the
operating instruction.
81 SIMODRIVE 611 NCU
U2000-150 A 42 47
E/AALRT-0075-2015
AALRT
The status indicators of SIMODRIVE 611 power module, NCU module and
driver module are on.
NCU
82
PLC
83 The program error indicator light, battery error indicator light and stop
indicator light on PLC component are off.

84 When electrifying the lathe, all button indicator lights on the operation panel
Functional test of will flicker.
chip crushing and
removal system
85 When operating the buttons on the lathe operation panel, the operation
actions are consistent with the button functions.

86 When operating the buttons on the hand wheel operation panel, the operation
actions are consistent with the button functions.

87 When pressing the red scram button on the lathe operation panel, hand wheel
operation panel, and hand-held controller, the lathe will stop.

88 When pressing the reset button on the lathe operation panel, the lathe
processing procedure can automatically interrupt and reset.

89

90 Start the lathe processing procedure, the chip removal system will start
automatically.
91
The rotation of cutter teeth of chip crushing machine is free from clamping
U2000-150 A 43 47
E/AALRT-0075-2015
AALRT
stagnation, and the motor has no overload.

92

93 The chip crushing machine motor, horizontal traction motor of chip removal
machine, cable stayed traction motor of chip removal machine, reduction
gearbox of chip crushing machine, and reduction gearbox of chip removal
motor operate smoothly.

94 Press the red scram button on the distribution box of the chip removal system,
the lathe will stop.
10% 5.3A
10% 1.5A
Standard wheel 10% 1.5A
set test Measure the three-phase current balance of motor: chip crushing machine
95
(the three-phase imbalance 10%, the rated value is 5.3A); horizontal
traction motor of chip removal machine (the three-phase imbalance 10%,
the rated value is 1.5A); cable stayed traction motor of chip removal machine
(the three-phase imbalance 10%, the rated value is 1.5A)
HMI
0.10mm
96 Select and enter HMI mode interface, operate according to the operating
steps of standard wheel set, and then the system can automatically execute
the measurement. The absolute value of five measurements of standard
wheel set 0.10mm.

Failure record Failure description Maintenance situation

U2000-150 A 44 47
E/AALRT-0075-2015
AALRT
Failure service personnel:

Measurement item Measurement data
IA: AIB: AIC: AR:
Hydraulic pump motor IA: A; IB: A; IC: A; R: .

IA: AIB: AIC: AR:
Chip crushing machine
IA: A; IB: A; IC: A; R: .
motor

Horizontal traction IA: AIB: AIC: AR:
motor of chip removal IA: A; IB: A; IC: A; R: .
machine

Cable stayed traction IA: AIB: AIC: AR:
motor of chip removal IA: A; IB: A; IC: A; R: .
Measurement record machine

IA: AIB: AIC: AR:
Left driving wheel
motor

IA: AIB: AIC: AR:
Right driving wheel
motor
1#: mm2#: mm3#: mm4#: mm
Driving wheel ovality 1#: mm, 2#: mm, 3#: mm, 4#: mm.
1#: mm2#: mm3#: mm4#: mm
Driving wheel diameter 1#: mm, 2#: mm, 3#: mm, 4#: mm.

Measurement personnel:
U2000-150 A 45 47
E/AALRT-0075-2015
AALRT
1.
1. For normal inspection result, shall be marked in the corresponding result column; for abnormal inspection result, shall

be marked in the corresponding result column, and the detailed description shall be made in the Failure record column.
Filling description
2.
2. The measured data shall be filled in the Measurement record column.

Shift Technical
Maintenance personnel
leader personnel
U2000-150 A 46 47
E/AALRT-0075-2015
AALRT
_____________________
U2000-150 2015.08.30

1 Maintenance Procedures of U2000-150 Underfloor A Date: August 30,
Prepared by Zhang Yanming
Wheel Lathe 2015
/ /

Preparation/Revi Prepared/Revised
S/N Standard name Revision Issued on
sion by

Standard history tracking
U2000-150 A 47 47
E/AALRT-0075-2015

75Maintenance Procedures of U2000-150 Underfloor Wheel LatheU2000-150型不落轮镟床维修保养规程译文

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

75Maintenance Procedures of U2000-150 Underfloor Wheel LatheU2000-150型不落轮镟床维修保养规程译文

Uploaded by

Copyright:

Available Formats

AALRT

AALRT Enterprise Standard

Flow chart for maintenance of underfloor wheel lathe

motor, cable stayed

Failure service personnel:

You might also like

75Maintenance Procedures of U2000-150 Underfloor Wheel LatheU2000-150型不落轮镟床维修保养规程 译文

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

75Maintenance Procedures of U2000-150 Underfloor Wheel LatheU2000-150型不落轮镟床维修保养规程 译文

Uploaded by

Copyright:

Available Formats

AALRT

AALRT Enterprise Standard

Flow chart for maintenance of underfloor wheel lathe

motor, cable stayed

Failure service personnel:

You might also like

75Maintenance Procedures of U2000-150 Underfloor Wheel LatheU2000-150型不落轮镟床维修保养规程译文

75Maintenance Procedures of U2000-150 Underfloor Wheel LatheU2000-150型不落轮镟床维修保养规程译文