The 1AK200 is a mobile wheel lathe designed to re-profile railway wheels without removing the wheel sets from railcars. It consists of a turning caliper, wheel rotation driver, frames, and hydraulic jacks that lift the wheel pair. The lathe allows defects to be eliminated on-site, saving time and money compared to stationary lathes. Weighing 350kg, it is lightweight and portable. Operators use carbide cutters to remove wheel defects like flanges and hollows, extending wheel life and reducing railcar downtime.

1. 1AK200
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Mobile Wheel Lathe
1AK200
Passport and User Manual
The 1AK200 wheel lathe is a multifunctional machine for turning the wheel sets of railcars, designed
to re-profile wheels and repair high wheel flanges, swells, influxes, and hollow threads if any. The
1AK200 wheel lathe costs several times less than stationary wheel lathes; another indisputable plus
and huge competitive advantage is its mobility and light weight that saves considerable amounts of
time and money.
1. 1AK200 Lathe, Basic Information and Technical Data
The 1AK200 Ltd., located in Narva, Estonia, manufactures the 1AK200 mobile lathe designed for
turning the wheels of passenger and freight cars and locomotives, in particular, without rolling the
wheel sets out of railcars.
The 1AK200 mobile wheel lathe was invented and patented in Estonia in 2002 and in the Russian
Federation in 2003.
The invention was first presented at the international exhibition in Brussels (Belgium), where the
1AK200 mobile lathe for turning wheels of railcars was awarded a gold medal. Also, the 1AK200
machine was recognized at the exhibitions in Moscow (VDNH, Archimedes) and Geneva (gold
medals); then, after a series of modifications, the 1AK200 lathe won another gold medal at the
EUREKA exhibition in Belgium.
The 1AK200 mobile wheel lathe is designed for railway vehicles, in particular, for the wheels of diesel
locomotives, passenger and freight cars, and intended to eliminate defects appeared on the wheels
during exploitation. In well-known similar stationary machines, to eliminate defects, one should roll
the wheel set out of the railcar using lifting mechanisms for repairs in the depot. A stationary wheel
lathe treats each of the wheels separately. The 1AK200 mobile wheel machine allows eliminating
wheel defects without rolling the wheel sets out of the railcars. The 1AK200 mobile wheel lathe can

2. 1AK200
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be used wherever there is an asphalt or concrete platform at the level of the rail head, and the
voltage of 380 or 220 V for the wheel rotation driver (WRD-380 or WRD-220); when turning the
wheel sets of locomotives with the 1AK200ZIP modification, an additional ditch is required.
The complete weight of the 1АК200 lathe with a wheel rotation drive WRD-220 or WRD-380 is about
350 kg. The transportation volume is 2 euro pallets, i.e. the whole set fits easily in a small minibus
such as a Gazelle. The cost of consumables (a cup-shaped cutter) is 35 euro per piece, EXW / EX
Works Narva. One cutter can be used to turn 50 or more wheels (the record is 65).
The warranty for the 1AK200 mobile lathe is five years from the date of delivery (except for the
components covered by the standard manufacturer's one-year warranty, i.e. electric drivers, jacks,
frequency converters, etc.). According to the specification, the service life of the machine is 7 years;
however many 1AK200 lathes have been successfully operating for over 15 years.
Technical Data of 1AK200 Lathe
Parameter Value for 1AK200 with WRD-380 drive
Dimensions and weight
- frame with wheel rotation driver 1450x450x100 mm
- frame with turning caliper 1450x450x100 mm
Diameter of the wheel to be turned 800-1050 mm
Maximum length of movement, at least
- longitudinal slide 200 mm
- lateral slide 100 mm
Driver power, kW 7.5 kW
Assembly weight of turning caliper 50 kg
Standard weight of delivery set 350 kg
2. Principle of Operation
The 1AK200 wheel lathe consists of the following five main elements: a turning caliper and a wheel
rotation driver, mounted on frames of special design, a frequency converter (acts as a rheostat) and
two hydraulic jacks. The turning caliper consists of two slides to move the cutter in the holder along
parallel and perpendicular paths to the axis of the wheel pair, and a double frame of special design
that allows using a hydraulic jack to lift the wheel pair and turn the wheel.
For turning and re-profiling the wheel sets of railcars, a tool holder of special design with a round-
shaped carbide plate (a cup-shaped cutter of the RAFAMET wheel lathe) is used. Optionally, the
machine can be equipped with ceramic cutters and tangential plates with appropriate tool holders.
The wheel pair rotator consists of a DC or AC electric motor that transmits the torque to one of the
wheels of the wheel pair, an adjusting mechanism that controls the adhesion force between the drive
roller and the wheel, and a double frame for turning the wheel. A frequency converter provides the
motor control via a remote control (with a cable or Wi-Fi), ensures a smooth start with adjusting the
power and the number of the engine revolutions.

3. 1AK200
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Press and hold the green button on the remote control to increase
revolutions; press and hold the red button to decrease revolutions.
Set the black switch in the vertical position to put off the machine;
move the switch to the left or to the right to change the direction
of the motor shaft rotations. The remote control saves the last
preset mode, so, at the end of the cycle you should reduce the
speed to the minimum value.
You can also control the speed and direction of the rotations from
the built-in control panel on the frequency converter (multilingual);
press the Loc / Rem button to switch between the remote and built-
in controls.
All elements of the 1AK200 machine are mobile and easy to use. The
1AK200 wheel lathe facilitates parallel operations while turning the
wheel sets and maintaining the railcars, which ensures the safety of
railway traffic and significantly reduces the downtime of rolling
stock for maintenance and repair.
The goal to be achieved with application of the 1AK200 wheel lathe is to extend the service life of the
wheels and reduce the downtime of rolling stock for repair.
The technical result to be obtained is the elimination of defects in wheel sets, such as high wheel flanges,
swells, influxes, and hollow threads.
3. Operating Procedure
Prior to work on turning the wheel sets, the locomotive or the railcar
shall be secured against spontaneous movement by brake shoes. For
training and acquaintance with the machine, it is recommended to
start with turning the wheel sets of old wagon trolleys or railcars to
be disposed.
When turning a railcar wheel set with the 1АК200 machine, the
frame with the turning caliper and the first jack shall be installed
under the wheel to be turned. The frame with the wheel rotation
driver and the second jack shall be installed under the opposite
wheel of the wheel pair. The wheel pair shall be lifted with the
hydraulic jacks (preferably, simultaneously) by 15-25 mm, relative
to the rail head.

4. 1AK200
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The wheel lathe shall be connected to the power supply
network of 380 V (WRD-380 model). The rotation driver
wheel shall be put in contact with the rolling surface of
the railcar wheel. Using the frequency converter, the
rotation speed of the wheel set shall be smoothly
adjusted to the required values (the speed is determined
empirically, depending on the used cutters and actual
wheel defects, taking into account the recommended
turning speed of 80 m / min). The number of the electric
motor revolutions is displayed on the control panel;
using the remote control, you can smoothly adjust the
rotation speed of the turned wheel to achieve the best
results.
The tool holder with a cup-shaped cutter shall be brought to the surface to be turned, and the turning
process shall start. The surface to be turned shall be checked with a wheel profile template. When
turning, the wheel profile shall be monitored to remain unchanged, only swells and influxes shall be
removed.
Several Tips for a Specialist Operating the 1AK200 Wheel Lathe
Fix the railcar with brake shoes. Install the frames with the
caliper and the drive under the wheel pair; watch that the
cutter and the drive roller are brought away from the
wheels almost to the stop. After installing the frames, try if
the caliper and the drive screws are long enough for the
cutter, and the roller come in contact with the wheel
flange and rolling surface with an overlap of 1-2 cm.
Using the two jacks, preferably simultaneously, lift the
wheel pair by 15-25 mm above the rail head. Slowly
increasing the speed of the electric motor, bring the wheel
into a slow rotation. Carefully bring the cutter to the ridge
until the cutter comes in contact with the surface to be
turned. If any beating occurs, the wheel set is subject to
disposal, or try to use a holder with vibration damper (to
be ordered and delivered separately). Bring the wheel
speed to the optimum (the recommended turning speed is
80 m / min) and proceed with turning the ridge. The chip
thickness should be kept as small as possible.
The recommended number of personnel working with the 1AK200 machine is 3 people (a turner and
two assistants). When turning a wheel set, the wheel profile shall be monitored to remain
unchanged, only swells and influxes shall be removed. Only the trained and instructed workers,
preferably with skill and qualification of a turner, are allowed to operate the machine. All elements of
the machine require careful handling, impacts or freight falls are excluded. Any sharp movement of

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the cutter is forbidden. The working area shall be kept clean, dry, provided with fire-fighting
equipment.
4. Delivery Set of 1AK200 M195 Machine
Name Qty Notes
Wheel rotation driver WRD-380
Double frame 1
Movement mechanism of electric driver 1
Drive wheel with keyway, 150x50 mm 1
Electric driver ABB, 7.5 kW, 1500 rpm 1
Frequency converter ABB 1
Hydraulic jack, 30 t 1
Jack nozzle 1
Flexible cable, m 40
Trolley 1
Turning caliper for a wheel set
Double frame 1
Caliper with two-way cross slide 1
Holder with straps 1
Cup-shaped cutter 10
Trolley 1
Hydraulic jack, 30 t 1
Jack nozzle 1
Accessories in general package
Set of wrenches 1
Lubricant, 1 l 1
Magnetic level, 80 cm 1
Magnetic level, 23 cm 1
Brake shoe 2
Hard hat with shield 2
5. Service Life, Storage and Disposal
5.1 The service life of the machine is 7 years.
5.2 The service life of the 1AK200 wheel lathe and its trouble-free operation depend on proper
maintenance, timely troubleshooting, thorough preparation for work, and compliance with the
storage rules.
5.3 The storage rules: store in a dry, closed warehouse at ambient temperature of +5 to + 40° С; relative
humidity shall not exceed 80%.
5.4 The specified service life is valid if the consumer complies with the requirements of this manual.
5.5 On the full depletion of the machine resource, it must be disposed in compliance with the valid norms and
rules. To implement this, you shall call a specialized company, professionally engaged in the disposal of
equipment, in accordance with the current legislation.
Manufacturer: 1AK200 Ltd., Maslova Street 1, Narva, 20308 Estonia