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Wheel and Axles Reference Manual

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Wheel and Axles Reference Manual Engineering Standard Rolling Stock ESR 0331 WHEEL AND AXLES REFERENCE MANUAL Version 1.1 Issued May 2013 Owner: Technical Specialist Rolling Stock Performance Standards Approved Stephen White, Authorised Michael Uhlig, by: A/Manager, by: A/Chief Engineer Rolling Stock Rolling Stock Access Integrity Disclaimer This document was prepared for use on the RailCorp Network only. Engineering Standard RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by RailCorp. RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes any liability which arises in any manner by the use of this document. Copyright The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of RailCorp. UNCONTROLLED WHEN PRINTED Page 1 of 63 RailCorp Engineering Standard — Rolling Stock Wheel and axles reference manual ESR 0331 Document control Version Date Summary of change (RSS 0031) 1.0 January 2004 Based on a number of TRS standards (RSS 0031) 2.0 May 2007 Reissued as a RailCorp standard. Some amendments (RSS 0331) 1.0 May 2008 Renumbered RSS 0331 (ESR 0331) 1.0 June 2010 Reformatted and renumbered ESR 0331 1.1 May 2013 Summary of changes from previous version Summary of change Section Version 1.1 Minor reformatting Missing figures added various Paragraph on fitting on pressure not being less than 60% of min fitting on pressure 8.2.5 deleted Axle run out was H, Radial run out was G, Measurement location added. Radial runout 8.3.2.1 was 0.5 mm. Axle run out was H, Radial run out was G. Radial runout was 0.5 mm. 8.3.3.2 Profile drawing number “ESR 0038” amended to read “ESR 0332” 10.5 Profile drawing number “ESR 0038” amended to read “ESR 0332” 10.12 Details of wheel diameter measuring gauge add from 13.6.3.1 13.2.1 Profile drawing number “ESR 0038” amended to read “ESR 0332” 13.6.3.3 Drawing number for back to back gauge was 306-579 4.2, 13.8 © RailCorp Page 2 of 63 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1.1 RailCorp Engineering Standard — Rolling Stock Wheel and axles reference manual ESR 0331 Contents 1 Introduction .............................................................................................................................7 2 Scope........................................................................................................................................7 3 Application...............................................................................................................................7 4 Reference documents.............................................................................................................7 4.1 RailCorp standards ...................................................................................................................7 4.2 Drawings ...................................................................................................................................7 4.3 Other standards ........................................................................................................................8 4.4 Australian standards for railway rolling stock:...........................................................................8 5 Wheels......................................................................................................................................8 5.1 Wheel identification...................................................................................................................8 5.2 Freight vehicle wheel data table .............................................................................................10 5.3 Locomotive wheel data table ..................................................................................................10 5.3.1 Maximum tread thickness variation between wheelsets in turning .........................11 5.4 Passenger car wheel data table..............................................................................................11 5.5 Measurement of wheels..........................................................................................................12 5.5.1 Scope.......................................................................................................................12 5.5.2 Wheel profile measurement gauges........................................................................12 5.5.3 Wheel measurement requirements .........................................................................12 5.5.3.1 Freight vehicles ........................................................................................12 5.5.3.2 Locomotives .............................................................................................13 5.5.3.3 Passenger ................................................................................................14 5.5.3.4 Actions – (Refer to ESR 0330).................................................................14 6 Axles.......................................................................................................................................16 6.1 Axle identification ....................................................................................................................16 6.2 Inspection criteria for the exposed surfaces of axles..............................................................16 6.2.1 Description:..............................................................................................................16 6.2.2 Procedure for the inspection of surface imperfections on the barrels of freight axles .............................................................................................................17 6.2.2.1 Introduction...............................................................................................17 6.2.2.2 Procedure.................................................................................................17 6.2.2.3 Grinding....................................................................................................17 6.2.2.4 Qualification of defects.............................................................................17 6.2.3 Examples - full depth grinding: ..............................................................................18 6.2.3.1 Full depth grinding - Isolated Imperfections from localised damage ....................................................................................................18 6.2.3.2 Full depth grinding - narrow imperfections...............................................18 6.2.4 Examples - touch-up grinding..................................................................................19 6.2.4.1 General.....................................................................................................19 6.2.4.2 Touch - up grinding of lips & roll-overs.....................................................19 6.2.5 Touch - up grinding of isolated pitting......................................................................19 6.2.6 Circumferential grooves from rotating and/or rubbing damage...............................20 7 Wheelsets ..............................................................................................................................21 7.1 Maximum wheel diameter variation between wheels .............................................................21 © RailCorp Page 3 of 63 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1.1 RailCorp Engineering Standard — Rolling Stock Wheel and axles reference manual ESR 0331 7.2 Wheelset back to back measurement.....................................................................................21 7.2.1 Limits........................................................................................................................21 7.2.2 Action.......................................................................................................................21 7.3 Freight wheelset inspection and attention when reprofiling....................................................21 7.3.1 Axles ........................................................................................................................21 7.3.2 Wheels.....................................................................................................................22 7.3.3 Bearings...................................................................................................................22 8 Assembly of wheelsets.........................................................................................................23 8.1 Correct wheelset components ................................................................................................23 8.1.1 Axles ........................................................................................................................23 8.1.2 Wheels.....................................................................................................................23 8.1.2.1 Wheel boring requirements ......................................................................23 8.1.2.2 Machine requirements..............................................................................25 8.1.3 Bearings...................................................................................................................25
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