Underfloor Wheelset Lathe: Operating / Maintenance Manual

Operating / Maintenance Manual
(User documentation)
Underfloor Wheelset Lathe
Type: U2000-400
Machine number: 101 543
Year of manufacture: 2009
Client: Vietnam Railways
EC-Declaration of conformity: CE-K-101 543 en
Manufacturer: Hegenscheidt-MFD GmbH & Co. KG

Hegenscheidt Platz
D-41812 Erkelenz
Tel. ..49 - 24 31 86-0
Fax ..49 - 24 31 86 470
E-Mail hegenscheidt.mfd@nshgroup.com
 1 General Information
12/2009 en
List of Folders U2000-400
List of Folders
General Information 1
General Data 1.1
Machine Safety 1.2
Machine Equipment 1.3
Technology 1.4
Technical Data 1.5
Transport / Installation 1.6
Operation 2
Operating elements 2.1
Machine Operation 2.2
Corrections of malfunctions and defects 2.3
Maintenance 3
Preventative Maintenance 3.1
Maintenance / Setting - Mechanic 3.2
Maintenance / Setting - Electric 3.3
101 543 en 12/2009 I-1

List of Folders U2000-400
Plans / Drawings 4
Plans / Drawings (Part 1) 4.1
Plans / Drawings (Part 2) 4.2
Fluid – Plans 4.3
Hardware 5
Hardware – Plan / Part List 5.1
Supplier's documentation 6
Supplier's - Documentation (Part 1) 6.1
101 543 en 12/2009 I-2

General Data U2000-400
General Data 1.1 - ┐

Introduction...............................................................................3
Warning indicators and symbols...........................................4
Basic principle; use for the intended purpose.......................5
Taking out of service, disassembly and disposal .................6
How to contact Hegenscheidt-MFD..........................................7
Manufacturer’s information ................................................................... 7
Customer Service Contact .................................................................... 7
101 543 en 12/2009 1.1-1

U2000-400 General Data
1.1-2 101 543 en 12/2009

1 1 AA0 0 1 -
001-01_EN
Introduction These operating instructions form an integral part of our
product and should be at the disposal of operating,
maintenance and repair staff.
Please familiarize yourself with the machine/equipment and

note the information contained in these operating instructions.
Only in this way can perfect operation and satisfactory

production results be obtained.
The relevant accident prevention and industrial safety

regulations must also be observed.
In the case of queries, replacement parts orders etc. please

indicate the Machine number of our product
(see Technical Data/Title Sheet).
Our address and the customer service representative

responsible for this machine/installation can be found under
"Contact to Hegenscheidt-MFD“ at the end of this chapter.
We wish you every success in your work.
Hegenscheidt-MFD GMBH & Co. KG

ERKELENZ
© Copyright
All rights for this operation manual reserved by Hegenscheidt - MFD GmbH & Co. KG.
This manual is intended to be used by shop personnel, operators and supervising staff.
The reproduction, distribution and utilization of this document as well as the
communication of ist contents to others without explicid authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the
event of the grant of a patent, utility model or design.
101 543 en 12/2009 1.1-3

# 1 1 AA0 0 2 -
001-01_EN
Warning indicators and symbols
The following symbols are used in the operating instructions to

denote particularly important information:
 Note of special information regarding the economical

operation of the machine.
 Attention, special information, required and

prohibited measures to prevent damage.
 Danger, required and prohibited measures to prevent

injuries or extensive material damage.
 Indicated possible damage to the Environment.
1.1-4 101 543 en 12/2009

# 1 1 AA0 0 3 -
002-01_EN
Basic principle; use for the intended purpose
1. The machine is constructed according to the latest

standards of technology and accepted safety rules.
However, utilisation which is contrary to the intended
purpose can result in danger of injury or death to the user
or third parties and can affect the machine and other
property.
2. Only use the machine when it is in a faultless technical
condition and for its intended purpose, bearing safety and
danger in mind and under observance of the operating
instructions.
In particular, alleviate faults which influence safety
immediately.
3. The machine is intended exclusively for reprofiling steel
wheelsets or processing their brake discs*.
any other application is not in accordance with this intent.
The manufacturer can nor be held liable for any resulting
damage. This risk is carried by the user alone.
The observance of the operating instructions as well as
the inspection and maintenance provisions encompassed
by the intended use of the machine.
* if existing
The permissible processing data can be found in chapter 1.5

"Technical Data".
101 543 en 12/2009 1.1-5

Taking out of service, disassembly and disposal
When taking the machine out of service or disassembling the

same, all connections (electric, hydraulic, pneumatic, and
mechanical) must be separated. The plant, in particular oil-
stained machine parts, must be cleaned completely and all
residues (e.g. oil, greases) must be removed.
All materials, cooling lubricants, cleaning agents and oils

(e.g. hydraulic fluid) must be disposed via a suitable disposal
system in agreement with the waste disposal agent / the
competent expert for industrial safety. The relevant statutory
regulations applicable at the time of disposal must be taken
into account. All other components can then be recycled as
metal scrap.
Qualification of the personnel
The personnel for taking the machine out of service / for

disassembling the same must have the relevant qualifications
for this task. External personnel must be instructed in
accordance with the applicable health and safety and
environmental protection regulations.
A determination of any extraordinary hazards which may occur

must be carried out and documented in advance by competent
personnel. Safety measures for the protection of personnel
must be planned and implemented.
1.1-6 101 543 en 12/2009

# 1 1 AA0 0 4 -
003-01_EN
How to contact Hegenscheidt-MFD
Manufacturer’s information
In the case of questions, machine problems or for ordering spare parts, you will get in touch
with us as follows:
Postal address: Hegenscheidt-MFD GmbH & Co. KG

Hegenscheidt Platz
D 41812 Erkelenz
Telephone: . . 49 - 24 31 / 86-0  0 24 31 / 86-0
Telefax: . . 49 - 24 31 / 86-470  0 24 31 / 86-470
Internet: www.hegenscheidt-mfd.de
Customer Service Contact
Hegenscheidt-MFD: Mr. Gedden

Service Manager Railway
Core time: Monday – Friday 7.00 a.m. – 5.00 p.m
Telephone (direct): . . 49 - 24 31 / 86-302  0 24 31 / 86-302
Fax (direct): . . 49 - 24 31 / 86-476  0 24 31 / 86-476
E-MAIL: c.gedden@de.heg.nshgroup.com
101 543 en 12/2009 1.1-7

Machine Safety U2000-400
Machine Safety 1.2 - ┐

General Safety Instructions ......................................................3
Safety instructions for operating and servicing the machine 3
Organisational measures......................................................7
Selection and qualifications of personnel; general duties...................... 8
Safety information for specific phases of operation..............9
Normal operation .................................................................................. 9
Sporadic operation................................................................................ 9
Special work within the usage of the machine, maintenance work and
alleviation of faults during work; disposal ............................................ 10
Notes on specific types of danger ......................................12
Electrical energy ................................................................................. 12
Gas, dust, steam, smoke .................................................................... 13
Hydraulics ........................................................................................... 13
Noise................................................................................................... 14
Oils, greases and chemical substances.............................................. 14
Remaining risks......................................................................15
101 543 en 12/2009 1.2-1

U2000-400 Machine Safety
1.2-2 101 543 en 12/2009

# 12MS001-
003-01_EN
General Safety Instructions
Safety instructions for operating and servicing the machine
 This machine may only be operated

and serviced by persons who are
authorised to do so and have read
the operator manual !
 Maintenance only from skilled

personnel !
 Staying inside the machine while

operating is strictly prohibited !
 Before closing this door, make sure that

no one is inside the machine !
 The main power switch must be switched

off and locked for all work on the machine !
101 543 en 12/2009 1.2-3

 When maintenance and repair work is

carried out in the interior of the machine, the
chip crusher (if existing) must be covered such
that it is not possible to step into the blades
of the crusher.
 Drive a vehicle onto the machine only when

the slide rails are closed. Note signal lamps!
 Before opening the slide rails, the operator

must ensure that no wheel set is located
on the rail system.
 The maximum speed of 5 km/h is

admissible for overtravelling the rail system.
 During the clamping/unclamping process it

may be possible that the vehicle/wheel set
moves.
1.2-4 101 543 en 12/2009

 Danger of injuries in the whole machine

area caused by:
- sharp-edged parts,
- getting caught on protruding parts,
- pinching,
- shearing,
- risk by gripping and coiling,
- hazard due to moving machine parts,
- parts falling down,
- breakage of tools and
parts contacting the workpiece and
- spinning chips.
 During the operation of the machine plant,

close-fitting clothes, safety goggles and a
protective helmet must be worn!
 Attention!
Despite proper operation there may be the
following risks
in case of a power supply failure:
- abrupt stopping of the drive units,
- failure of the control or regulating loop,
- uncontrolled movements.
101 543 en 12/2009 1.2-5

 By regularly calibrating the diameter

measurement unit by means of a gauge
wheel set a high reliability is obtained
(see Chapter 3.2).
However, Hegenscheidt-MFD does not

assume final warranty for the correctness
of the diameter measurement.
In case of doubt, the measured result has
to be confirmed by a manual measurement.
 Shunting systems represent a danger

because of tensioned ropes.
Staying inside the rope area during shunting
operations is strictly prohibited!
 When lifting components which

exceed a weight of 20 kg
(e.g. hold-down claw), suitable lifting gear
must be provided by the customer.
 In some areas of the machine (e.g. chip

disposal area, rail system), low headroom
presents a hazard to the area around your
head.
 Further safety instructions regarding the

components of subcontractors can be found
in chapter 6 "Supplier's Documentation".
1.2-6 101 543 en 12/2009

Organisational measures 1. Keep the operating instructions easily accessible at the

installation site of the machine.
2. Observe and insist on the general, legal and other
regulations pertaining to accident prevention and
protection of the environment in addition to the operating
instructions.
These obligations also include the handling of dangerous
materials and the provision and use of personal protective
equipment.
3. Supplement the operating instructions with directions
which take account of plant-specific circumstances,
e.g. regarding work organisation, working procedures,
and the assigned personnel, including supervisory and
reporting duties.
4. The personnel assigned with work on the machine must
have read the operating instructions, particularly the
Chapter Safety Information before commencing work.
Reading during work is too late. This pertains particularly
to personnel which is only involved with the machine
intermittently, e.g. for setting, maintenance etc.
5. The observance of safety and regard to danger and
regard to the operating instructions by the operating
personnel during work on the machine must be checked
intermittently.
6. The operating personnel must not wear long, open hair
are jewellery - including rings. This causes danger of
injuries, e.g. by trapping or pulling into the machine.
7. Use personal protective equipment as necessary or as
required by regulations (Gloves, goggles, protective cap,
safety shoes)!
8. Make sure that only authorised personnel work on or with
the machine!
9. Observe all safety and danger notices on the machine.
10. Keep all safety and danger notices on/near the machine
in a complete and readable condition.
11. If changes to the machine or its operating behaviour occur
which are relevant to safety, switch off the machine
immediately and report the fault to the responsible
department/person.
12. Do not make changes or supplements to the machine
which can affect safety without permission from the
manufacturer/supplier.
This also applies to the fitting and adjustment of safety
devices and valves.
101 543 en 12/2009 1.2-7

13. Spare parts must conform to the technical requirements

specified by the manufacturer. This is always guaranteed
when original spare parts are used.
14. Do not make changes to the programs (software) of
programmable control systems.
15. Observe the intervals required by regulations or specified
in the operating instructions for recurring
checks/inspections (see Chapter 3 „Maintenance“).
16. Workshop facilities appropriate for the task are absolutely
necessary for the performance of maintenance work.
17. Inform staff of the location and operation of fire
extinguishers.
18. Observe fire detection and firefighting provisions.
19. Identify all escape routes, if necessary create escape
plans.
20. The area around the machine must be kept free of oil!
21. Do not operate chip conveyor without chip bucket.
The operator must ensure a proper and safe chip removal
downstream of the chip conveyor supplied by us.
Selection and qualifications 1. Work on and with the machine must only be performed by
of personnel; general duties reliable personnel. Observe the legally permissible
minimum age.
2. Only employ qualified or trained personnel. Clearly define
the responsibilities of the personnel for operation, setting,
maintenance and repair.
3. Define the responsibilities of the operator, including those
pertaining to traffic regulations, and ensure that he can
decline instructions from third parties which infringe safety
considerations.
4. Only allow personnel in training or learning to use the
machine or personnel engaged in general training
measure to work on the machine under constant
supervision.
5. Work on the electrical equipment of the machine may only
be performed by an electrician or by trained persons
under the supervision of an electrician as defined by the
rules of electrical engineering.
6. Work on hydraulic equipment may only be performed by
persons with special knowledge and experience in
hydraulics.
1.2-8 101 543 en 12/2009

Safety information for specific phases of operation
Normal operation 1. Reject all dangerous methods of work.

2. Take measures to ensure that the machine is only
operated in a safe and functional condition.
Only operate the machine when all protective devices and
safety-related facilities, e.g. removable protective devices,
emergency stop devices, acoustic insulation and
extractors are installed and functional.
3. Check the machine for externally visible damage and
deficiencies at least once per shift. Report any changes
(including operational behaviour) to the responsible
department/person. Switch off the machine if necessary.
4. Switch off and secure the machine immediately if
functional faults occur. Repair faults immediately.
5. Observe starting and stopping procedures and signal
devices according to the operating instructions.
6. Before the machine is switched on/started, check that
nobody can be endangered by the moving machine!
7. Operating mode "AUTOMATIC" is selected.
8. Do not switch of or dismantle extractor and ventilation
equipment when the machine is running.
Sporadic operation 1. Spray all unpainted surfaces with anticorrosion oil.

2. At least every 5 weeks, switch the machine on and, in
accordance with the relevant safety instructions, check
the following functions for standard operation:
 Switch on main power switch and control system
until hydraulic fluid has reached operating
temperature (min. 40 °C);
 Switch on main drive and run drive rollers for
approx. 10 min;
 Move Z and X tool block axes in manual mode;
 Move outer bearing fixing devices (right and left),
once or twice in Z and X directions;
 Raise and lower left and right roller carriers at least
twice.
101 543 en 12/2009 1.2-9

Special work within the 1. Observe the adjustment, maintenance and inspection work and
usage of the machine, intervals specified in the operating instructions, including
maintenance work and directions on the replacement of parts/assemblies. This work
may only be performed by qualified personnel.
alleviation of faults during
work; disposal 2. Inform operating personnel before special and maintenance
work begins. Delegate a job supervisor.
3. Observe the starting and stopping procedures and other
information in the operating instructions for all work which
serves operation, production fitting, setting or adjustment of the
machine and its safety facilities as well as for inspection,
maintenance and repair.
4. If necessary, secure a wide area around the maintenance site.
5. If the machine is switched off completely for maintenance and
repair work, it must be secured against unexpected activation:
- lock the main command facilities and remove the key and/or
- attach a warning sign to the main power switch.
6. Components and large assemblies must be carefully
suspended on lifting equipment during replacement to prevent
danger from occurring. Use only suitable and technically
satisfactory lifting equipment and supporting devices with
sufficient load capacities.
Do not stand or work under suspended loads.
7. During maintenance work pay attention to risks caused by
pretensioned springs (e.g. chip retaining window, chip flap,
interlock bolts of the slide rail).
8. Delegate experienced personnel only when suspending loads
and instructing crane operators. The instructor must remain
within sight of the operator or be in audible contact with him.
9. Use the provided or other sufficiently safe climbing aids or work
platforms for fitting work above body height. Use securing lines
for work at greater heights.
Keep all handles, steps, rails, pedestals, platforms, and ladders
free of dirt.
10. Clean the machine and particularly connections and screw
fittings of oil and preservatives before beginning maintenance
or repair work. Do not use aggressive cleansing agents. Use
non-linting rags.
1.2-10 101 543 en 12/2009

11. The machine may not be cleaned with water, steam jets (high-
pressure cleaner) or compressed air.
12. After cleaning, remove coverings/tape completely.
13. After cleaning, check all hydraulic lines for leaks, loose
couplings, abrasion and damage. Alleviate any deficiencies
immediately.
14. Always tighten loosened screw couplings after maintenance and
repair work.
15. If it is necessary to dismantle safety devices for setting,
maintenance or repair work, the safety devices must be replaced
and checked immediately after completion of the maintenance or
repair work.
16. Ensure safe and environmentally suitable disposal of operating
and auxiliary substances and replaced parts.
Notes on the operation can be found in chapter 2.
Notes on the maintenance can be found in chapter 3.
101 543 en 12/2009 1.2-11

Notes on specific types of danger
Electrical energy 1. Work on electrical equipment and components may only

be performed by an electrician or by trained persons
under the supervision of an electrician according to the
rules of electrical engineering.
2. Replace face identical with the original fuses with the
specified current values, Switch off the machine
immediately if faults occur in the electrical energy supply.
3. De-energise machine and plant components on which
inspection, maintenance or repair work is to be performed
if this is specified. First check the de-energised parts for
zero voltage, then earth and bridge them. Isolate from
neighbouring, energised parts!
4. The electrical equipment of the machine must be
inspected/checked regularly. Deficiencies such as loose
contacts or burnt cables must be alleviated immediately
(see Chapter 3 „Maintenance“).
5. Any work on live parts is not permissible!
6. During work on high-voltage assemblies, earth the supply
cable after disconnection and short-circuit the
components, e.g. capacitors, with an earthed rod.
7. No measurements may be performed on the power
converters. Risk caused by arising ark!
1.2-12 101 543 en 12/2009

Gas, dust, steam, smoke 1. Perform welding, cutting or grinding work on the machine
only when this is specifically permitted to avoid the danger
of fire or explosions.
2. Clean the machine and its surroundings of dust and
inflammable materials before performing welding, cutting
or grinding work on the machine and ensure sufficient
ventilation (danger of explosions).
3. Observe any national regulations during work in narrow
spaces.
4. If smoke develops on surfaces contaminated with oil or
grease* (e.g. wheelset machining), the smoke must be
extracted as a personal protective measure if required (if
not included in the scope of supply).
The smoke extraction unit contains dust that is hazardous
to health. Emptying and maintenance processes -
including the disposal of dust collecting vessels - may
only be performed by professionals wearing the
corresponding protective equipment. Do not operate the
smoke extraction unit without the complete filtration
system.
(The composition of the smoke is unknown to us due to the use of differing
types of grease and oil).
Hydraulics 1. Work on hydraulic equipment may only be performed by

persons with specialised knowledge and experience.
2. Check all pipes, hoses and couplings for leaks and
externally visible damage regularly. Alleviate damage
immediately. Discharged oil can cause injuries and fires.
Ground contamination due to leakages/ oil changes/
rinsing/ venting must be prevented on the part of the
operator by means of suitable collection devices.
3. Depressurize sections of the system and pressure lines
which are to be opened according to the assembly
description before beginning repair work.
4. Lay and mount hydraulic lines correctly. Do not confuse
couplings. Fittings, length and quality of the hose must be
suitable for the requirements.
5. Hydraulic hose lines must be replaced at intervals of
6 years (including 2 years of shelf life) even if safety-
relevant deficiencies can not be detected.
(Safety rules for hydraulic hoses DIN 20066)
101 543 en 12/2009 1.2-13

Noise 1. Acoustic insulating equipment on the machine must be in

place during operation.
1. If necessary wear ear protection!
The values for noise emission can be found in chapter 1.5

"Technical Data".
Oils, greases and chemical 1. When handling oils, greases and other chemical
substances substances, observe the safety regulations which apply to
the product.
2. Take care when handling hot operating and auxiliary
materials (danger of injury or burning).
3. Avoid lengthy, frequent and intensive contact with the
skin. Wear protective gloves and/or apron if necessary.
4. Wash hands thoroughly after work and before breaks with
water and a mild cleaning agent or soap.
After washing, replace lost skin grease with a grease-
bearing lotion.
5. Remove oil-saturated clothing immediately. Clean areas
of skin coated in oil thoroughly with soap and water.
6. Avoid inhalation of oil vapours as far as possible.
 Collect/wipe leaking oil/grease.

Dispose of oils/greases or oily/greasy materials with some
regard for the environment.
1.2-14 101 543 en 12/2009

Remaining risks
 There is a remaining safety risk for the user of the

machine.
The following areas are affected:
 rotating drive rollers,

 vehicle axles,
 movable supports,
 the measurement unit (the measuring probe is only
extended at the measuring positions),
 Slide rails.
If existing protective devices are bypassed, there is:
 danger of being drawn in or of pinching in the area of the

drive rollers;
 danger of pinching in the area of the measurement unit
when closing the chip retaining cover;
 danger of pinching and burning through hot chips in the
area of the tool parts;
 when the slide rails are open, there is a risk of fall for
wheel sets or vehicles.
101 543 en 12/2009 1.2-15

Machine Equipment U2000-400
Machine Equipment 1.3 - ┐

Intended use.............................................................................3
Short description...................................................................5
Construction of modules...........................................................9
Rail system .........................................................................10
Machine stand ....................................................................11
Wheel set drive...................................................................12
Wheel set driving system .................................................................... 12
Motor / Gearbox.................................................................................. 13
Drive roller mount................................................................................ 14
Lateral support rollers ......................................................................... 15
Axial guide rollers................................................................................ 16
Wheel set fixing / Hold-down systems ................................17
General ............................................................................................... 17
Supporting outer bearing fixing ........................................................... 18
Outer bearing fixing device ................................................................. 20
Inner bearing fixing device .................................................................. 22
CNC turning tool post .........................................................24
Measuring and positioning unit...........................................26
Automatic positioning and wear measurement ................................... 26
Profile wear measurement .................................................................. 27
Diameter measuring unit..................................................................... 28
Electrical equipment and control system ............................29
Control cabinet.................................................................................... 29
Control panels/operating panels ......................................................... 29
Hydraulics...........................................................................30
Hydraulic unit ...................................................................................... 30
Additional modules .................................................................31

Chip disposal ......................................................................31
101 543 en 12/2009 1.3-1

U2000-400 Machine Equipment
1.3-2 101 543 en 12/2009

# 1 3 M A1 0 1 -
003-01_EN
Intended use
Your Hegenscheidt-MFD Underfloor Wheelset Lathe t is a
high performance machine.
Operative range It is suitable for the reprofiling and brake disks (if existing) of
worn wheel sets of:
 motor cars,
 bogies,
 passenger cars,
 single wheel sets,
 freight wagons.
Reprofiling of a wheel set and machining of brake disks are
effected at the vehicle or the wagon respectively.
 No other application is intended.

The manufacturer is not liable for any damage resulting
from this.
The risk is carried by the operator alone!
The permissible processing data can be found in chapter 1.5

"Technical Data".
101 543 en 12/2009 1.3-3

The machine design and the applied modern technologies

ensure perfect metal removal efficiency, high machining
accuracy and service life.
The sequence of operations is automatic. For operating the

machine one operator only is required.
Construction example:
.wmf 0tbi007
1.3-4 101 543 en 12/2009

Short description
2 6 4 7
3 1 5 2
The machine consists of the following

components:
1 Machine stand
2 Rail system
3. Hydraulic unit
4. Electrical cabinet
5. Main operating panel
6. Stairs, railings (construction example)
7. Chip disposal system (construction example)
 The illustrations and descriptions in this manual present a

machine design with variants and with options.
101 543 en 12/2009 1.3-5

Layout The machine is placed in a pit underneath the approach rails.

Prior to the machining of a wheel set part of these rails (slide
rails) is hydraulically moved out of the machine range.
Two compact machine column are supporting:
 the drive and centring systems for the wheel set,

 the crossbeams with both tool posts,
 the hold-down unit,
Feed When the slide rails are closed, the wheel set to be machined
is positioned on the machine.
Photoelectric switches enable precise positioning of the wheel
set on the machine.
The wheel set is driven by means of infinitely variable three-

Drive phase motors. The drive forces are transmitted to the wheel
tread by 4 driving rollers.
Another 2 rollers serve as axial guiding system for the wheel

set.
Centering A maximum of rotational accuracy of the wheel set tread

relative to the axis of rotation can be achieved by fixing the
axle boxes while turning. For this purpose, an axle box fixing
device is provided on the machine.
The machine can be provided with outer and inner (optional)

axle box fixing units.
1.3-6 101 543 en 12/2009

Measure Wear measurements of the wheel set profiles and the

automatic positioning of the tool blocks are controlled by the
combined positioning and wear probe installed on the
longitudinal slide.
The electronic slippage monitor recognises momentary

slipping of the drive rollers (if existing).
Tools For wheel set machining, tools with throw away carbide inserts
are used.
Processing All highly-stressed positioning guides are tempered. All roller

bearings are sufficiently lubricated for their service life.
The gear units of the drive roller drive are filled with oil.
All positioning guides in the machining range are protected

against the penetration of turnings.
Control The machine is equipped with a CNC control system.

The electrical components are installed in the control cabinet
on the rear side of the machine. Machining can be performed
in either semi- or fully automatic modes. The machine is
operated from the main operating panel.
It is possible to observe the cutting via monitors (if available).
101 543 en 12/2009 1.3-7

Chip disposal The chips generated during machining are fed to the crusher (if
existing) by
means of the casings mounted on the machine,
where they are crushed and transported to the outside by a
chip conveyor (if existing).
Dust collection Any dust that arises during machining is sucked out of the
(if existing) working area of the machine.
Camera monitoring Cutting is monitored by CCD color cameras. Two monitors in

(if existing) the working area of operation enable observation of the
machining process.
External control position An external control position, equipped with a second main
(if existing) operating panel, and two monitors enable the machine to be
operated from a protected area outside the pit.
1.3-8 101 543 en 12/2009

# 1 3 M A3 0 1 -
003-01_EN
Construction of modules 3
Construction example: 3
9 2 6
. w m f 1 B AU0 0 8
10
1. Rail system
4, 5
2. Wheel set driving system
8
3. Wheel set fixing
4. Tool block
5. Tools
6. Measuring and positioning device
7. Electrical cabinet
8. Hydraulic unit
9. Chip disposal
10. Dust extractor system
101 543 en 12/2009 1.3-9

# 1 3 M A3 0 2 -
002-01_EN
Rail system For moving in the rail vehicles (1), the machine (2) is provided
with a rail system (3).
This is a welded steel structure featuring hydraulically

operated sliding rails (4) for bridging the area over the
centerline of the machine. Once a vehicle has been moved
into position, the sliding rails will be retracted from the machine
centerline for clearance of the operator’s space.
The position of the slide rails is monitored.
In order to position the wheel sets more or less symmetrically
to the centre of the machine, they are moved to the area in
front of the slide rails.
1
3 2 4 2
. w m f 1 S AN0 0 3
Rail profile (by Rail profile with Sliding rails profile

customer) restricted guidance (Area C)
(Area A) (Area B)
 The maximum speed of 5 km/h is admissible for

overtravelling the rail system.
1.3-10 101 543 en 12/2009

# 1 3 M A3 0 3 -
001-01_EN
Machine stand The strongly dimensioned machine stand is fixed to foundation
and aligned using levelling shoes.
The following machine components are fixed to the

machine stand (1):
 driver roller mount (2)

 crossbeam with tool blocks (3),
inside and outside bearing fixing device (4),
 Main control panel (5),
 covering sheets (6).
The covering sheets prevent chips flying out of the machine

and guide these chips to the chip crusher (if existing) and to the
chip conveyor (7).
2 4
1
6
.wmf 1MST004T
101 543 en 12/2009 1.3-11

# 1 3 M A3 0 5 -
001-01_EN
Wheel set drive
Wheel set driving system Wheel set take up and driving are effected by means of a
vertically floating friction roller drive system.
The friction rollers used for power transmission are mounted in
pairs in two separate roller carriers each of which is supported
in a low friction three-point mounting.
Within the area of the friction rollers, the mounting is

hydraulically pressurised via cylinders on a continuous basis
so that the system can follow non-positively the eccentricities
and flat spots of the wheel treads.
Opposite each of the two rear drive rollers, an axial guide roller
is located.
In combination with the wheel set centering methods

described below, the system guarantees a maximum
conversion capability of axle load into torque, that is, maximum
chip cross sections and optimum machining precision are
reached.
 A danger of accidents exists if protective devices are

bypassed.
Never reach into the rolling area of the machine when
in operation as the danger of injury here is very high.
3
1 2 5
4
1. Drive roller
2. Three-point support 6
3. Drive roller support
4. Lateral support roller
5. Bearing box centering
6. Supporting post
7. Vertical lifting cylinder
. w m f Rol t - 2
7
1.3-12 101 543 en 12/2009

Motor / Gearbox
The wheel set is driven by two drive rollers (1) per roller
carrier.
The drive system comprises a three-phase asynchronous
motor (2) with frequency control, via V-belt (3), reduction
gear (4) and shaft.
1 2 3 4
.wmf1sup_get
1. Drive roller
2. Three-phase asynchronous motor
3. V-belts
4. Reduction gear
101 543 en 12/2009 1.3-13

Drive roller mount
By means of a hydraulic cylinder (1) the roller carrier (2) is

vertically adjusted.
Two lateral support rollers (3) hold it horizontally in position.
If the roller carrier moves upwards, the wheel set is lifted

approx. 5-10 mm off the slide rails.
3 3
. w m f Rol t s - 2
1.3-14 101 543 en 12/2009

Lateral support rollers
Each roller carrier is horizontally guided by two lateral support

rollers (1).
These serve to keep the roller carrier (2) in a central position.
1 2
.pcx Seitro_2
101 543 en 12/2009 1.3-15

# 1 3 M A3 0 6 -
001-01_EN
Axial guide rollers For centring the wheel set, one axial guide roller each (2) is
located within the area of the rear drive rollers (1).
The radial and axial application of the guide rollers is effected

by one hydraulic cylinder each.
A pressure regulating valve controls the axial contact pressure

of the guide rollers. Normally, this valve is set to 2.5 MPa. The
pressure can be reduced if necessary (e.g. for rubber-sprung
wheel sets).
 Following the turning operation and before the slide rails

are advanced, the guide rollers are set (returned) to their
initial position.
 A danger of accidents exists if protective devices are

bypassed.
Never reach into the rolling area of the machine when in
operation as the danger of injury here is very high.
2 1
. w m f 1 AF R 0 0 2
1.3-16 101 543 en 12/2009

# 1 3 M A3 0 7 -
001-01_EN
Wheel set fixing / Hold-down systems
General In order to achieve ultimate machining precision it is important

that, during reprofiling, the position of the inserted wheel set is
kept constant to the reference points of the measuring and
turning tools. Depending upon vehicle and wheel set type, this
is achieved by radial and axial fixing of the wheel sets, with
priority over their bearing casing and inner tyre surface or the
axle centre bores.
Alongside this wheel set fixing, hold-down devices can provide

increased axle loads for light vehicles, thus also enabling
these to be machined economically with large chip sections.
1 2 3
4 5 .wmf 1FIX017
1. Outer bearing fixing*

2. Inner bearing fixing*
3. Centre point centering*
4. Outer hold-down*
5. Inner hold-down*
* Customer-specific
101 543 en 12/2009 1.3-17

# 1 3 M A3 0 8 -
001-01_EN
Supporting outer bearing The axial bearing fixing device is used to support an axial-lying
fixing wheel set with a limited force (2 x ca. 25 kN) at the outer
bearing box (1), whereby the wheel set is centered in the
radial direction.
The wheel bearing is therefore at the rotational centre point

during the turning process, which guarantees optimal
precision.
The outer bearing fixing device comprises a horizontally

shiftable slide and a vertically adjustable base frame (2).
 The slide glides on two antifriction guideways that are
bolted onto the crossbeam. The movement is effected by
means of a hydraulic cylinder.
 The base plate is clamped into any vertical position by
means of a self-locking spindle. The spindle is driven by
means of a hydraulic motor.
The base frame can be provided with adapter elements (3)
which are suitably shaped to fit to the axle boxes.
The end positions of the base plate and the slide are
monitored by means of limit switches.
 When not being used or when wheel sets are being rolled
in and out, the adapter elements must be in their external
safety position.
(Construction example) .wmf 1FIX018
1.3-18 101 543 en 12/2009

Load The roller contact pressure „P“ is determined from half the
axle load „P1“ minus the reduction in axle load „P3“.
P1
P = P1 - P3
P3
P = roller contact pressure
P1 = ½ axle load
P3 = increase in axle load = ca.25 kN
P
.wmf 1FIX019
 This operating mode requires a sufficient axle

load  150 kN!
101 543 en 12/2009 1.3-19

# 1 3 M A3 0 9 -
001-01_EN
Outer bearing fixing device The Outer bearing fixing device enables the drive rollers to be
pressed against the wheel set at a higher force in the case
of wheel sets with reduced axle load.
At the same time, this equipment serves to hold the wheel set
by the axle boxes (1) and in this way to radially position it.
The additional load exerted by the lifting cylinder pressing

against the hold-down equipment through roller mount and
wheel set, may not exceed 70 kN per wheel.
In the same way, the additional load is dependent upon the

design of the hold-down claws.
 Care must be taken for the wheel set and its bearings
not to be damaged due to too high a press-on force.
The base frame (2) enables the insertion of hold-down claws

(3), which must be adapted to the bearing housing and the
additional load to be applied.
 When not being used or when wheel sets are being rolled
in and out, the hold-down claws must be in their external
safety position.
(Construction example) .wmf 1FIX020
1.3-20 101 543 en 12/2009

Load The roller contact pressure „P“ is determined from half the
axle load „P1“ plus the increase in axle load „P2“.
P2
P1
P = P1 + P2

P1 = ½ axle load
P2 = increase in axle load
(additional load)
P
.wmf 1FIX021
 The maximum permissible hold-down force that may be

utilised by Outer bearing fixing device is 70 kN per side.
Please observe the maximum permissible bearing load!
101 543 en 12/2009 1.3-21

# 1 3 M A3 1 1 -
002-01_EN
Inner bearing fixing device In the case of wheel sets with smaller axle loads, the inner
bearing fixing device enables the drive rollers to be pressed
against the wheel set with greater force.
The wheel set is simultaneously held against the axle bearing

box (1) by this device and is thereby radially fixed.
The additional load exerted by the lifting cylinder pressing

against the hold-down equipment through roller mount and
wheel set, may not exceed 40 kN per wheel.
In the same way, the additional load is dependent upon the

design of the hold-down claws.
 Care must be taken for the wheel set and its bearings
not to be damaged due to too high a press-on force.
The inner bearing fixing device consists of a horizontally

adjustable skiving head support (3) for the hold-down clamp
(2), hook or bolt.
The contact point on the axle bearing box is dependent upon

the axle bearing box design and the vehicle type.
After manual assembly of the inner bearing fixing device the

additional load is exerted by increasing the hydraulic pressure
in the lifting cylinder of the drive roller mount (4).
 When rolling the wheel set in or out the hold-down clamp,

hook or bolt must be dismantled in order to prevent
damage to the machine and/or track carriage.
Construction example
.wmf 1Fix_innen_413
1.3-22 101 543 en 12/2009

Load The roller contact pressure "P“ is determined from half the
axle load "P1“ plus the increase in axle load "P2“.
P = P1 + P2

P1 = ½ axle load
P2 = increase in axle load
(additional load)
.wmf 1Fix_innen2
 The maximum permissible hold-down force that may be

utilised by inner bearing fixing device for inner-lying axle
bearings is 40 kN per side.
Please observe the maximum permissible bearing load!
101 543 en 12/2009 1.3-23

# 1 3 M A3 1 2 -
001-01_EN
CNC turning tool post The turning tool post carries out the longitudinal movement
(Z axis) and the plane movement (X axis) required for
machining.
It supports the machining tool (2) and the measuring device.
The longitudinal slide (1) moves along two guideways (10)

that are bolted to the crossbeam (11). They are driven by a
3-phase servomotor (6). The helical ball spindle (4) is driven
by a gear belt. A prestressed nut is used to connect the
longitudinal slide to the helical ball spindle without any
clearance.
The plane movement is performed by a piston support (3),

which is mounted into the longitudinal slide.
They are drive by a 3-phase servomotor (7). This drives the

helical ball spindle via a gear belt (8). The piston with the tool
holder is connected to the helical ball spindle via a prestressed
nut (9).
2
1 3
4
10
11
5
10
6
7
9 .wmf 1SUP003
8
1.3-24 101 543 en 12/2009

Direction designation on tool block:
-X -X
+Z -Z -Z +Z
+X +X
%% c[m m ] %% c[ mm ]
1400 14 00
110 0 11 00
92 0 9 20
78 0 7 80
66 0 6 60
58 0 5 80
520 5 20
470 47 0
430 43 0
Get rie be May fan Varia nt e 2
Best el l Nr.
Mayfran Brec her TA4
.wmf 1SUP004
101 543 en 12/2009 1.3-25

# 1 3 M A3 1 3 -
002-01_EN
Measuring and positioning unit
Automatic positioning and wear measurement
A hydraulically extendable measuring device (3) is attached to

each longitudinal slide in order to determine the axial and
radial position and the profile wear values of wheel tyre
profiles. This device, consisting of two different measuring
wheels (2), is used to automatically position the turning tool to
the wheel set (1).
The measuring device also serves for measurement of the

wheel inner distance (Ar), the axial and radial eccentricity.
The wear measuring device integrated into the measuring

device is set up in such a way that it measures the wear at
defined points on the profile of the wheel set to be machined.
This wear profile is compared with a reference profile in the
control system and the optimum required cutting depth is
display on the CNC monitor. This takes place within the
framework of the premeasuring program.
3
.wmf 1MES006
1.3-26 101 543 en 12/2009

# 1 3 M A3 1 5 -
001-01_EN
Profile wear measurement Measurements are taken by the two measuring wheels on the
measuring support (1). The number and position of the
measuring points on the wear profile is selectable. The
collected values are compared with the respective permissible
profiles for reprofiling contained in the CNC control system in
order to determine the new diameter to be turned. Radial and
axial eccentricity deviations, flat points, axial position of the
profile and gauges to be kept to are taken into account (see
chapter 2.1 "Operation", Menu screen "Premeasurement“).
This produces the values for an automatic cut segmentation

and tool lining in dependence on the selected machining
principles. The calculation can be performed with regard to
either the gauge or wheel flange.
The profile wear measurement is taken in working steps:

 When the wheel set is rotating, the measuring wheel (2)
determines the measured values from the top of flange till
the outer end of the running surface.
 In special cases and when the wheel set is stationary the
flange rear face is measured by the measuring wheel (3)
(suburban vehicles).
The measuring tool block is integrated into the longitudinal

slide and is hydraulically extended and retracted in the
X direction. When retracted the measuring tool block is
protected from chips by a flexible flap.
2
3
1
.wmf 1MES007
101 543 en 12/2009 1.3-27

# 1 3 M A3 1 4 -
001-01_EN
Diameter measuring unit
The determination of the wheel diameter is performed
separately for each wheel by circumference measurements
with a measuring wheel (1) made from tempered steel.
The swivelling of the measuring wheel is transferred directly
to a hollow shaft rotary transducer.
The measuring tool block (2) is inserted in the longitudinal

slide and is hydraulically adjusted to the wheel set.
Before measurement commences, a reflector (3) is placed at

the height of the photoelectric switch (4) on the front side of
the wheel.
Reflectors should be placed on both sides of individual wheels.
The wheel set diameter is measured within a defined number

of wheel revolutions that are counted by the photoelectric
switch.
The measured diameter results of the left and right wheel are
displayed on the CNC monitor.
The measure "Z“ between the measuring circle level (MKE)

and inner wheel tyre end surface must be the same on the
right and left wheel.
MKE Z
.wmf 1MES005
2
1.3-28 101 543 en 12/2009

# 1 3 M A4 0 1 -
003-03_EN
Electrical equipment and control system
Control cabinet The electrical control elements including the main switch (2)
are installed in the air-conditioned control cabinet (1).
The control cabinet is solidly fixed to the machine stand.

1 1
2
.wmf 1ELE006
Control panels/operating The machine has the following control/operating elements:

panels  Main operating panel (1)
 Hand-held operating device (2)
 Extended control panel left / right (3)
1 2 3
.wmf 1BED005
Notes on the operation can be found in chapter 2.
101 543 en 12/2009 1.3-29

# 1 3 M A5 0 1 -
Hydraulics 003-01_EN
Hydraulic unit The hydraulic system consists of the hydraulic unit to supply
pressurised hydraulic oil and the control valves for function
control.
The hydraulic unit is arranged next to the machine in the pit.
Oil level and oil pressure are monitored automatically.

If there is no oil or the pressure is inadequate, the hydraulic
system will be switched off and a fault message will appear on
the system monitor.
The control valves assembled into valve blocks are located

inside the hydraulic cabinets on the rear side of the machine.
The scope and structure of the hydraulic system as well as

important information, such as nominal pressure settings, can
be found in the hydraulic system diagram (in chapter 4.3
“Construction and function drawings”) as well as in the
maintenance instructions (in chapter 3 “Maintenance”).
4
6
5
4
7
2
.wmf 1HYD007
Assembly overview: 1. Oil container

2. Oil level monitoring (optical)
3. Oil level monitoring (electric)
4. Pressure monitoring
5. Hydraulic pumps
6. Filter
7. Heating (if available)
1.3-30 101 543 en 12/2009

# 1 3 M A6 0 1 -
003-01_EN
Additional modules
Chip disposal
Chip disposal plays an important role in the machine's
productivity and the daily labour consumption.
Accordingly, different versions of the chip disposal system (1)
are available depending upon the local conditions.
In addition to automatic transport of the chips from the

machine, it is possible to shorten longer chips with a chip
crusher* (2).
The description of the chip disposal belonging to the machine

can be found in chapter 6 "Supplier Documentation".
* if existing
. w m f 1 S P A0 0 5
1 2
 If the swarf disposal system is provided by the owner,

the control system activation of the chip conveyor/crusher
must be integrated in the safety concept of the machine
for reasons of safety.
101 543 en 12/2009 1.3-31

Technology U2000-400
Technology 1.4 - ┐
Tools.....................................................................................3
Profile turning tool ................................................................................. 3
Shaft brake disk machining tool ............................................................ 4
101 543 en 12/2009 1.4-1

U2000-400 Technology
1.4-2 101 543 en 12/2009

Technology U2000-400
# 14TE001-
Tools 001-01_EN
Profile turning tool The tool blocks are each equipped with a profile turning tool
for profile machining. The profile, tire front and rear surface are
machined with the profile turning tools.
Double tool holders (1) with cassette acceptance for

standardised carbide metal reversible cutting plates (2 and 3)
are used. Depending upon the machining area the wheel
profile is divided into running surface steel (3) and flange rear
face steel (2). Cutting stages worked into the reversible cutting
plate generally ensure a good chip crushing.
The tool cutting system enables a quick exchanging of tools.
.wmf 1DST001
 When using or exchanging carbide metal reversible

cutting plates always ensure that they are clean, this
includes both the cutting insert and the cutting plate
acceptance.
The corresponding tools are available for further machining

tasks* (brake disk machining, inner and outer planes etc.).
* optional
101 543 en 12/2009 1.4-3

U2000-400 Technology
#14TE003-
Shaft brake disk machining tool 001-01_EN
(Option)
The shaft brake disk machining tool is equipped with a short
clamp holder (2) for clamped reversible cutting plates (1).
Standardised carbide metal reversible cutting plates are used.
The basic frame (3) is inserted in the tool holder of the piston
tool block (4).
 Depending on the position of the shaft brake disks, the

tools for wheel brake disk machining can possibly also
be used for this machining operation.
Construction example 1 2
3
4
.wmf 1WBS001
.wmf 1WBS002
1.4-4 101 543 en 12/2009

Technical Data U2000-400
Technical Data 1.5 - ┐

Technical Data .........................................................................3
Manufacturer's data .............................................................................. 3
Machine data ........................................................................................ 3
Noise emissions.................................................................................... 3
Connections/Consumption.................................................................... 4
Speeds.................................................................................................. 4
Machine data ........................................................................................ 4
Electrics ................................................................................................ 5
101 543 en 12/2009 1.5-1

101 543 en 12/2009 1.5-2

#15TD101-
443-01_EN
Technical Data
Manufacturer's data
Machine designation: Underfloor Wheelset Lathe
Type: U2000-400
Machine No.: 101 543
Year of manufacture: 2009
Manufacturer: Hegenscheidt-MFD GmbH & Co. KG, Erkelenz
Client: Vietnam Railways
Machine data
Weight: Total weight of the machine ................................ 20,000 kg
Dimensions / required space: Machine arrangement plan

Hegenscheidt Dwg. No 1032200-0...
Floor anchoring ...............................................................

Number of levelling shoes machine ...................4 pieces
Noise emissions
Sound power level LWA: .........................................xx dB(A)
Sound excess pressure level LPA: .........................xx dB(A)
Max. value of sound pressure level LPC peak: ..........xx dB(C)
The above mentioned values were measured in accordance

with DIN 45635 during official acceptance at the manufacturing
plant.
The values measured at the place of installation might be
divergent.
101 543 en 12/2009 1.5-3

Connections/Consumption
Hydraulic unit: Filling volume ................................................. 160 Litres
Operating pressure...................................... 7 / 15 MPa
Oil type .................................... PG 46, ISO VG 46
Gears: Filling volume .............................................4 x 7.6 Litres

Oil type ................................................... CLP 460
Speeds
Motors: Drive motor (rev.max)...................................... 6500 min -1
Feed motor ................................................... 3000 min -1
Hydraulic motor ............................................ 1500 min -1
Machine data
Track gauge .............................................. 1000 mm
Distance between inside surfaces of tyres

(Ar)................................................ 925 ±2 mm
Axle lengths including

bearing box .................................... 1558 - 1756 mm
Maximum tread diameter

to be machined ......................................... 1400 mm
Minimum tread diameter

to be machined ........................................... 350 mm
Tyre width ......................................... 125 – 145 mm
Maximum axle load (machine)..................... 250 kN
Cutting speed
(profile machining) ................................. 40 - 80 m/min
Cutting speed at measuring circle level

(brake disk machining) ........................max: 305 m/min
Cutting speed at measuring circle level

(brake disk machining) .............................. 0-2.5 mm/U
101 543 en 12/2009 1.5-4

Electrics
Mains connection: Rated power ..................................................... 96 kVA

Rated voltage ................................................. 400 V
Mains voltage tolerance ............................. -6/+10 %
Mains frequency ............................................... 50 Hz
Distribution systems ..................................... TN/S
Miscellaneous voltages and Control voltage ............................................... 230 V / 50 Hz

frequencies: Voltage solenoid valves.................................... 24 V/=
Voltage inputs/outputs...................................... 24 V/=
Motor power ratings: Main Drive ...................................................2 x 30 kW

Hydraulic pump ............................................... 7,5 kW
Machine control system: SIEMENS Sinumerik 840 DE
101 543 en 12/2009 1.5-5

Transport / Installation U2000-400
Transport / Installation 1.6 - ┐

Transport ..................................................................................3
Working site..........................................................................3
General information .............................................................................. 3
Transport instructions ...........................................................4
Transport damage ................................................................................ 4
Transport of the machine parts ............................................................. 5
Transport „Machine“.............................................................................. 6
Transport „Hydraulic unit“ ..................................................................... 8
Storage/Intermediate storage ...............................................9
Checks upon arrival .............................................................................. 9
Intermediate storage prior to installation and assembly ........................ 9
Installation ..............................................................................10
Preparations for installation ................................................10
Chip conveyor ..................................................................................... 11
Entry rails............................................................................................ 12
Foundation preparations.....................................................13
First installation................................................................................... 13
Determine centre of the track and machine ........................................ 14
Assembly „fixers“ ................................................................................ 15
Installation „Machine“.......................................................................... 17
Aligning the machine ..........................................................18
101 543 en 12/2009 1.6-1

U2000-400 Transport / Installation
1.6-2 101 543 en 12/2009

#16TI101-
001-01_EN
Transport
Working site The following prerequisites are necessary to choose the

working site of the machine:
 dry place;
 no exposure to rain and dripping water;
 no extreme temperature and/or humidity fluctuations as
occurring outdoors between day and night
(Moisture class "F" according to DIN 40 040);
 admissible ambient temperature between 0°C and +40°C
(+32°F - +104°F);
 no aggressive and/or corrosive ambient conditions;
 no exposure to fine dust.
Before placing the machine upon its foundation, please wait

until concrete has fully hardened.
 The plugs sealing hydraulic and pneumatic equipment

and prefabricated pipe and hose connections may not be
removed until the parts are assembled.
General information When suspending the machine/equipment from a crane,

please observe the following:
 use only cables in perfect condition and of adequate load-
bearing capacity;
 no damage may be caused by the transport cables;
 correctly adjusted settings may not be changed;
 the cables may not be guided over sharp edges.
The surface onto which the machine/equipment is lowered

must
 be clean,
 level,
 and possess the required load-bearing capacity.
101 543 en 12/2009 1.6-3

#16TI102-
001-01_EN
Transport instructions For transport and lifting of the machine /equipment, only the
intended suspension rings, transport bolts and load supporting
equipment (e.g. ropes) may be used. These must be in a
perfect condition.
The load supporting equipment is delivered with the machine.
Lifting and transport of the machine may only be performed by

persons who
 have read these installation/operating instructions,
 have understood the enclosed safety instructions,
accident prevention instructions and notes on the
transport of the machine,
 are familiar with the lifting equipment, load supporting
equipment and suspending equipment.
 Observe the safety information for lifting and transport of
the machine!
 Use lifting equipment, load supporting equipment and
suspending with sufficient loading capacity.
 Do not tie knots in steel cables or round steel chains.
 Do not connect fibre ropes with knots.
 Do not twist ropes.
 Do not kink ropes at pressure clamps.
 Collars, rope eyes, suspending rings and other
suspending links must be freely movable on the crane
hook.
 Do not lift loads above persons.
 Observe the accident prevention regulations!
Transport damage Inspect the machine and accessories carefully after unpacking
for transport damage. Report damage immediately to the
haulage contractor and the transport insurer for damage
claims.
Please inform Hegenscheidt-MFD immediately.
1.6-4 101 543 en 12/2009

#16TI201-
002-01_EN
Transport of the machine The machine with tool posts and installed equipment is
parts delivered as a complete unit.
Further transportable components in the scope of delivery are:

 Rail system
 Hydraulic unit
 Dust extractor system*
 Chip conveyor*
 Chip crusher*
The way in which the machine and the hydraulic unit is to be

suspended with transport ropes from a crane or similar
equipment is indicated below.
The suspension and transportation of the other units which

form part of the machine do not represent any problem. For
this reason, further illustrations are unnecessary.
* if installed / see also subsupplier's documentation
101 543 en 12/2009 1.6-5

#16TI202-
002-01_EN
Transport „Machine“ For transportation, the machine (1) is equipped with four bolt-
on attachment swivel eyes (2).
The machine can be suspended from ropes (3) as indicated
below.
 The ropes (3) and the applied suspending equipment

must be in perfect condition and must be correctly
attached.
3 2
2
approx. 4000 % % c[m m ]

14 0 0
%% c [mm ]
1 40 0
11 00 1 10 0
92 0 9 20
78 0 7 80
66 0 6 60
58 0 5 80
52 0 5 20
470 47 0
430 43 0
1
2280
G e
t ri e b e M a y fa n Va r a
i nt e2
Be st e l Nr.
Mayfr an Brec he r TA4
.wmf2tra16
2 2
2400
5470
.wmf2tra17m
Weight:
see Chapter 1 „Technical Data“
1.6-6 101 543 en 12/2009

 The components of the control are extremely sensitive to

shock.
During transport, observe that all doors are closed and
that the measuring and display instruments and the
control elements are not damaged by the supporting
equipment.
Do not remove the protective covers of the control elements

before commissioning. During intermediate storage, protect all
components against moisture and dust.
101 543 en 12/2009 1.6-7

#16TI204-
001-01_EN
Transport „Hydraulic unit“ Before transportation of the hydraulic unit drain the fluid
(hydraulic oil).
Seal all connections on the unit, and on the piping and hosing
with PVC plugs or PVC caps.
Plugs and caps are removed during assembly. Piping, fittings
and valve unit must not be crushed or damaged in any way.
Change any damaged parts before operating the equipment.
. w m f 2 T R A0 1 8
Weight: 400 kg
1.6-8 101 543 en 12/2009

#16TI205-
001-01_EN
Storage/Intermediate storage
Checks upon arrival Please check the delivery immediately upon arrival with regard
to completeness and any transport damage.
If the crates are part of our shipment, please check their

contents as well, if possible in the presence of our service
engineer.
Report damage immediately to the haulage contractor and the

transport insurer for damage claims.
Please inform Hegenscheidt-MFD immediately.
Intermediate storage prior If our machine/equipment must be stored temporarily prior to

to installation and assembly installation and assembly, the following prerequisites to
choose the place of storage must be fulfilled:
 dry place;
 no exposure to rain and dripping water;
 no extreme temperature and/or humidity fluctuations as
occurring outdoors between day and night;
 admissible storage temperature between -20°C and
+60°C (-4°F - +140°F);
 no aggressive and/or corrosive ambient conditions;
 no exposure to fine dust.
When placing the machine on the floor, be sure the floor is

level, solid and strong enough.
 The plugs sealing hydraulic equipment and prefabricated

pipe and hose connections may not be removed until the
parts are assembled.
101 543 en 12/2009 1.6-9

#16TI301-
003-01_EN
Installation
Preparations for To ensure that your machine/equipment will work reliably and
installation without interruptions, the installation site should fulfil the
following minimum requirements:
 closed halls, protected from atmospheric influences,

 hall temperature between 10°C and 40°C
(+50°F - +104°F),
 illumination strength of approx. 300 Lux,
 free access to foundations,
 the foundation must be cleaned thoroughly,
 the forming material, loose dirt and standing water must
be removed from the anchor holes,
 all stairs that lead into the foundation pit must be installed,
 the foundation must be secured and blocked off on all
sides,
 power supply for fitting tools,
 main connection lines must be available,
 storage and locker facilities for tools and replacement
parts.
Foundation design:
 according to our recommendations/foundation plans,

 according to specifications by an architect or structural
engineer,
 no connection of the machine/equipment foundations with
other machine/crane supports etc.,
 no direct thermal influences on the machine/foundation,
 no extreme temperature/air humidity fluctuations,
 protection of the machine against damp,
 protection of the machine/equipment against excessive
dirt.
 The execution of the foundation must be examined for

compliance with the foundation plan. Deviations must
be corrected by the customer or the responsible builder
of the foundation.
1.6-10 101 543 en 12/2009

Chip conveyor Before the machine is placed in the prepared foundation pit,
the components of the chip disposal unit (chip conveyor) must
be assembled.

Because of the limited space in the foundation pit, it is
impossible or difficult to insert the chip conveyor under the
machines.
. w m f 1 S P A0 0 5
 Whether the chip conveyor is inserted in the machine as a

complete unit or in a disassembled condition depends on
the local conditions and the size of the chip conveyor.
101 543 en 12/2009 1.6-11

Entry rails The rails are to be examined 10 m before and after the
underfloor foundation pit for compliance with the tolerances
specified below and corrected by the customer
(rail construction contractor) if necessary.
The centre of the track is to be fixed with a tensioned wire

10 m before and after the foundation pit.
.wmf GLEISE1
1.6-12 101 543 en 12/2009

#16TI302-
002-01_EN
Foundation preparations If the machine/equipment requires installation on a special
foundation, you will have received the required documents
in the order processing phase.
Please check:  whether the execution of the foundation complies with our
foundation plans*.
 whether the recesses in the foundations are free
from dirt etc.
 whether the installation site is easily accessible from
all sides.
First installation Normally, your Hegenscheidt-MFD machine/equipment will

be mounted, installed and commissioned by our trained and
experienced fitters. If you intend to install the
machine/equipment yourself or wish to make certain
preparations before the arrival of our fitters, please observe
the following:
 Remove the anticorrosives from the bright machine

parts with paraffin/oil spray only.
Use only non-linting cloths for cleaning.
 Never use petrol or nitro thinners.

Use no wire brushes or scrapers.
 Then protect the bright machine parts immediately

against corrosion with acid-free oil.
 Observe safety datasheets for petroleum/detergent

oil/anti-corrosion oil.
*see also Chap.4
101 543 en 12/2009 1.6-13

Determine centre of the In order to be able to carry out erection work smoothly, the
track and machine centre of the tracks and machine are required as reference
points in the foundation pit.
For this, attach sheet plates to the 4 walls of the pit,

approx.800 mm from the upper edge of the pit.
Size of metal plates approx. 200 x 200 x 5 mm.
The vertical lines indicate the centre of the track, as well as the
future centre of the machine.
In the vicinity of the track, an additional horizontal line marks
the vertical distance to the upper edge of the track
(upper edge rail = Zero).
The height distance should be marked on the sheet plates
(XXXX).
Permissible tolerance  0.5 mm.
(Picture shows construction example) 3 .wmf Grube
1. Centre of track
2. Centre of machine
3. Wheelset lathe (future position)
1.6-14 101 543 en 12/2009

Assembly „fixers“ The fixers delivered for the installation of the machine are to
be attached according to the foundation plan to the installation
frame *, which is also supplied.
 Clean and water foundation recesses.

 Bolt both halves of the frame (1) together.
 Centrally set the vertical adjustment (7) of the fixers.
 Attach fixers to the holes (5) of the frame according to
Table 1. The frame height corresponds to the height of
the machine foot.
 Align the fixers according to the foundation plan.
 Place the installation frame with fixers on the foundation.
 Horizontally align the mounting frame using the vertical
setting screws (2). Make sure that height from the upper
edge of the hall tack to the lower edge of the machine foot
7 is conformed to (see foundation plan). The upper side of
the height plates (3) is to be used as an auxiliary surface
for the missing machine foot (upper side of height plate =
bottom side of machine foot).
* Shipment only for installation of the fixers by the customer
A B C D E F
3
1. Mounting frame
2. Vertical setting screws
3. Height plate 2
4. Bores for alignment
measurement
5. Bores for fixer acceptance
6. Operator position M2
7. Vertical adjustment fixers
M1 center line of track centre
M2 center line of machine centre
M1 4 5
.wmf fira_dra4
101 543 en 12/2009 1.6-15

 Align mounting frame centrally to the track. Use the center

line given in the table. Alignment is facilitated by small
holes (4) in the frame, through which the steel wire
stressed for alignment can be observed.
 Also align mounting frame centrally to the machine.
In this, use the center line M2.
 Permissible tolerance for center of track and
machine 0.5mm.
 Grout the anchor bolts of the fixers with a non-shrinking

grouting compound.
 In this, observe the product description / application

instructions of the manufacturer.
When the grouting compound has hardened, the installation

frame can be removed.
 The installation frame is then returned to Hegenscheidt-
MFD (only within Europe).
 Further installation/commissioning should be performed

by our trained personnel under all circumstances.
Table 1
* see foundation plan
Allocation of fixer acceptance

bore
Track gauge Distance* A B C D E F Center line
1000 802,5 X X M1
1067 836 X X M1
1435/1445 1020 X X M1
1520 1062,5 X X M1
1600 1102,5 X X M1
1676 1140,5 X X M1
1.6-16 101 543 en 12/2009

#16TI303-
001-01_EN
Installation „Machine“
The machine (1) is suspended from the crane, or a similar

device, via ropes (2) and attachment swivel eyes (3).
 When lifting the machine, observe that it is as level as

possible when suspended from the hook.
2
3
% % c [m m] % %c [m m ]
1400 1 4 00
1100 1 1 00
92 0 920
78 0 780
66 0 660
58 0 580
52 0 520
470 47 0
430 43 0
Get ri ebe Mayf anVar a

i n
te 2
t ell N r.
Bes
Mayf ran Brec her TA4

1
. w m f 2 T R A0 1 4
101 543 en 12/2009 1.6-17

#16TI304-
001-01_EN
Aligning the machine
³ The recommendations and dimensions from the valid

foundation diagram are to be observed for all work!
Deviations from the standard execution are to be taken
into account correspondingly.
The machine must always be installed so that it is

• centrally aligned with the entry rails,
• level in the direction and perpendicular to the direction of
vehicle entry and
• its vertical position corresponds with the position of the
entry rails.
1. The points A2 and A1 are to be determined from the center
of the foundation at an interval of 10 m and the points B2
and B1 at an interval of 5 m. They must lie precisely on the
centre of the track.
2. A steel wire C must be drawn from point A2 to A1. The steel
wire must intersect points B2 and B1. If this is the case, it is
ensured that the rails are exactly opposed before and after
the machine. If the steel wire lies beside points B2 or B1,
the tracks must be corrected.
Upper surface
of the rail
10.000mm 10.000mm
5.000mm 5.000mm
Z [ m]
%%c m
140
100
0
92
0
78
0
66
0
58
%%c
[ mm]
140
100
90
2
78
0
60
6
50
8
Y
0
52 52
0
0
47 70
4
0
43 30
4
r .
lN ste e
B
e rie
G b
t e
M a
y
May fr anBr e
n
a
f r
a
V
cher T A4
n
ia 2
e
t
A1 || B1 D1 D2 B2 || A2
|| ||
. w m f 2 T R A0 1 9 / 2 T R A0 2 0
3. The machine must be deposited on the foundations with a

crane on the fixers.
4. Align the machine so that it is precisely horizontally and
vertically level on the cross-beam. Use a spirit level
(precision 0.04 mm/m) for aligning.
1.6-18 101 543 en 12/2009

5. Attach aligning aids (1) to both sides of the machine.

6. Mark arcs of an equal radius (approx. 4 m) around the
columns of the aligning aids with a third steel wire. The
1 intersection points D1 and D2 of the arcs must lie on the line
from A1 to A2.
The admissible tolerance of the intersections to the centre of
the track (steel wire) is ± 0.5 mm.
7. Place the rail bridges between the edge of the pit and the
machine and align them with the steel wire at the centre of
the track.
8. The machine stand with the rail bridges must be aligned with
the upper surface of the rail with the fixers on the machine
stand.
9. Then precisely align the machine stand. For this, apply a
spirit level to measuring points 2, 3, and 4.
Max. admissible deviation  0.02 mm.
.wmf ausri3
1
101 543 en 12/2009 1.6-19

Underfloor Wheelset Lathe: Operating / Maintenance Manual

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Underfloor Wheelset Lathe: Operating / Maintenance Manual

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Operating / Maintenance Manual

Underfloor Wheelset Lathe

Machine number: 101 543

Year of manufacture: 2009

Client: Vietnam Railways

EC-Declaration of conformity: CE-K-101 543 en

Manufacturer: Hegenscheidt-MFD GmbH & Co. KG

General Data 1.1

Machine Safety 1.2

Machine Equipment 1.3

Technical Data 1.5

Transport / Installation 1.6

Operating elements 2.1

Machine Operation 2.2

Corrections of malfunctions and defects 2.3

Preventative Maintenance 3.1

Maintenance / Setting - Mechanic 3.2

Maintenance / Setting - Electric 3.3

101 543 en 12/2009 I-1

Plans / Drawings (Part 1) 4.1

Plans / Drawings (Part 2) 4.2

Fluid – Plans 4.3

Hardware – Plan / Part List 5.1

Supplier's - Documentation (Part 1) 6.1

Supplier's - Documentation (Part 2) 6.2

Supplier's - Documentation (Part 3) 6.3

Supplier's - Documentation (Part 4) 6.4

101 543 en 12/2009 I-2

General Data 1.1 - ┐

101 543 en 12/2009 1.1-1

1.1-2 101 543 en 12/2009

Please familiarize yourself with the machine/equipment and

Only in this way can perfect operation and satisfactory

The relevant accident prevention and industrial safety

In the case of queries, replacement parts orders etc. please

Our address and the customer service representative

We wish you every success in your work.

Hegenscheidt-MFD GMBH & Co. KG

101 543 en 12/2009 1.1-3

The following symbols are used in the operating instructions to

 Note of special information regarding the economical

 Attention, special information, required and

 Danger, required and prohibited measures to prevent

 Indicated possible damage to the Environment.

1.1-4 101 543 en 12/2009

1. The machine is constructed according to the latest

The permissible processing data can be found in chapter 1.5

101 543 en 12/2009 1.1-5

Taking out of service, disassembly and disposal

When taking the machine out of service or disassembling the

All materials, cooling lubricants, cleaning agents and oils

Qualification of the personnel

The personnel for taking the machine out of service / for

A determination of any extraordinary hazards which may occur

1.1-6 101 543 en 12/2009

Postal address: Hegenscheidt-MFD GmbH & Co. KG

Telephone: . . 49 - 24 31 / 86-0  0 24 31 / 86-0

Telefax: . . 49 - 24 31 / 86-470  0 24 31 / 86-470

Customer Service Contact

Hegenscheidt-MFD: Mr. Gedden

Core time: Monday – Friday 7.00 a.m. – 5.00 p.m

Telephone (direct): . . 49 - 24 31 / 86-302  0 24 31 / 86-302

Fax (direct): . . 49 - 24 31 / 86-476  0 24 31 / 86-476