Problem's in wagon tippler

 All mechnical equipments indeed any equipment need maintenance at regular intervals. By proper maintenance we can stretch the life of the equipment beyond the validity, Even when maintained properly, problems and failures occurs due to many reasons. Human error's have to be eliminated to avoid major accidents and failures, which causes death and economical loss.

Rack and pinion changing

When and how do we know to change the rack and pinion ? . Simple, observation and constant monitoring have to be done. So if the rack and pinion are wear out , there will be slippage, there are chances of free fall at the position where wear is more. 

                                                                       Pinion wear out

In order to change the rack, "as the rack is assembled in parts to tippler with bolts", a set simply be changed by removing bolts and replace with new one and properly tighten the bolts at required torque. For the pinion to change , the intermidiate shaft have to be decoupled , so the tippler needed to be locked at tippling angle of 135°,then the shaft is removed fro its fixed position and pinion is removed with no constraints. The pinion can be reomoved through  hydraulic puller . After completion of removing, a new pinion is heated in oil bath(usually transformer oil) nd shrink fitted to the shaft. So the shaft is reassembled in original position, fixed and coupled.

Changing of Bearing's

When we are dealing a rotating equipment, we come across bearings. Bearings are two types frictional and non frictional. Frictional Bearings are usually journal's and bushes. Non frictional bearings are divided in to six types depending on the construction of bearing. The construction indeed depends on the type of loads.Examples are Ball Bearings,Roller Bearings etc.

So in a tippler both frictional and non frictional bearing's are used. The intermidiate shaft is a 15 m length shaft along the tippler . It is actually three shafts of 5m length connected to each other through gear coupling. 


                                                             Shaft, pinions and bearings

A spherical roller bearing is mounted on the shaft ends next to the pinion , both are seprated by steps .So when the bearing is damaged or needed to be changed (When clearence increases). The tippler has to be raised 80 to 100 mm from its position untill a safe gap is acheived for the bearing to be removed. A hydraulic jack of 300 ton is carefully placed beneath the tippler and constantly raised to required gap. Atmost care and supervision is needed to avoid mishap. Saftey is utmost priority at this juncture. All lifting tools and tackles needed to be inspected before usage. Changing of bearing needed to be carried out only after the locking of tippler, cannot carry the work when the load is on jack.

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