S.C.R. WAGON WORK SHOP, GUNTUPALLI

                        MOUNTING AND DE-MOUNTING MACHINE FOR CTRB

Trouble shooting of CTRB Mounting/Demounting Machine 100 / 70 Ton:

MECHANICAL

SNSYMPTOMSProbable Cause of FailureRemedial Action
01Excessive pump noise1. Low oil in the tank1. Maintain the oil in between minimum and maximum levels.
2. Clogged filter2. Ensure the filter is free from foreign particles and clean the filter if required.
3. Air locking in the hydraulic system3. Vent the air by removing cap.
4. Coupling misalignment.4. Align the coupling properly and replace if required
5. Pump elements are slack5. Align the pump elements properly and replace the damaged pump elements.
6. Motor rotating in wrong direction.6. Reverse the direction by changing phase sequence.
02Excessive heat generated in Power pack1. Pressure set to high value.1. Set required pressure for operation (50 ± 5 ton).
2. Excessive system leakage through cylinders, valves and hydraulic hoses. 2. Check the leakages in cylinders, valves and hydraulic hoses. Replace the damaged seals and 'O' Rings if required.
3. High ambient temperature.3. Relocate the power pack
4. Malfunctioning of solenoid valve.4. Repair / Replace the defective solenoid valve.
03Bearing failure1. Coupling misalignment1. Align the coupling between pump and motor shafts properly and replace if required.
2. Electric motor end play.2. Eliminate all electric motor play.
3. Pump running too fast.3. Ensure the speed the of the motor to 1440 RPM (at rated speed).
4. Foreign material in bearing.4. Clean the bearing and lubricate it.
04Pump not delivering pressure1. Air locking in the hydraulic system1. Vent the air from hydraulic system.
2. Insufficient supply of oil in pump.2. Maintain sufficient oil in the power pack
3. Key sheared at coupling.3. Check the condition of the Key and key way. Replace the key.
4. filter is clogged4. Clean and replace the filter.
5. Relief valve set too low or not functioning.5. Set the relief valve at required position.
6. oil leakage through valves/ cylinder6. Arrest the oil leakage in cylinder and valves.
05Erratic movement of cylinder1. Malfunctioning of Direction Control (DC) valve.1. Replace the DC valves.
2. Cylinder sticking/ Binding due to deterioration of seals.2. Replace the seals and oil if required.
3. Flow is set at low value.3. Adjust the flow control valve.
06Oil leakage from cylinder1. seals , 'O' rings and chevron packing are damaged
2. end cover bolts are sheared
3. piston is worn out
1. Detect the location of the leakage and replace the damaged seals, ‘O’ rings and chevron packing.
2. Replace and tighten the cover bolts.
3. Replace the piston