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ESR 0330 - Wheel defect manual

1. cccccccccecsseeeeeeeeeeeeeeeeceeeeeeeeseeeeeeeeeeaeeeeeeesaaaess 46 FART WCE S Ree ene eee ee 46 DM died ies Witness MVNA neraino aa naaa ARA aa aAa 46 rS WON AIG erensia IN a A AE N n A EE 46 7 11 4 Examination of tyred wheels IN service cccccccceeseeeeeeeeeueeeeeeeseuaeeeeeesaaeeeeeeaaaees 46 8 WBE ACS arises EE SE EN AE E asinine aide sioasets nea accu mamececesnnl 47 9 WISE Ol DONNY DODIG S airn E 48 Appendix A Quick reference tables of wheel defects and actiOns cseecsesseeeeeneeeees 50 RailCorp Page 4 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 4 1 Introduction Wheels with defective wheels may cause damage to both the track and the vehicle or lead to derailment Purpose This standard provides staff with a summary of wheel conditions under which wheels may continue in service and operating restrictions imposed for defective wheels found on vehicles operating on the RailCorp network Application This standard is intended for use by train crew vehicle maintainers and engineering staff for any vehicle operating on the RailCorp network Referenced documents RailCorp standards ESR 0331 Wheel and axle reference manual ESR 0334 Welding of skidded wheels in situ ESR 0311 Single car air test Wheel rim thickness A rail vehicle shall not remain in service if it has a wheel
2. 30 mm i 12 mm Any visible Cracks greater than 40 mm long Cracks greater crack on Flange anywhere on the wheel tread than 10 mm long Figure6 Class 4 thermal crack zone Photograph 3 class 4 thermal crack RailCorp Page 11 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 Action Required If the defect is found en route or at a location with no repair facility the vehicle may continue through to the scheduled destination and or be transferred to the nearest depot at a speed of not more than 40 km h providing the brakes are isolated passenger and freight or the use of independent brake can be kept to an absolute minimum locomotives If these restrictions unduly affect operations the vehicle must be immediately removed from service The vehicle may then be repaired bogie wheelset change at the location where the defect was found Speed Restriction 40 km h 7 1 5 Class 5 thermal crack Any crack running through the rim web or boss of the wheel must be considered as a class 5 defect Action Required The vehicle shall not be moved until the damage has been examined and assessed by the attending Qualified Worker After examination the vehicle may be allowed to clear the section at the speed nominated by the attending mechanical maintenance officer Speed Restrictions Vehicle not to be moved until inspected Photo
3. 8 Wheel gauges R 9 5 mm R 4 mm 35 mm R 2 mm 70 mm rA 4 5 mm 13 mm 24 mm Due to the introduction of the WPR 2000 wheel profile these dimensions have been reduced by 1 5 mm to effectively maintain a 19 mm minimum Tolerance on dimensions 0 2 mm flange thickness Figure 23 Flange height and thin flange gauge controlling dimensions 5 mm radius 5 mm 1 12mm 5 mm radius Figure 24 Short flange gauge controlling dimensions RailCorp Page 47 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 ari lt _ 35mm 120 mm Tolerance on dimensions marked 0 1 mm Tolerance on other dimensions 0 2 mm Figure 25 Hollow tread gauge controlling dimensions 9 Use of pony bogies When a vehicle is fitted with a pony bogie it shall be transferred to the nearest depot as follows Defective locomotives or loaded freight vehicles supported by pony bogies must be accompanied by a suitably trained mechanical maintenance officer who shall take every opportunity to examine the assembly and bearings The speed for locomotives and loaded freight vehicles when mounted on pony bogies shall not exceed 15 km h reduced to 8 km h over points and crossings Empty freight and empty passenger type vehicles supported by pony bogies are permitted to travel unaccompanied at a maximum speed not excee
4. 30 mm 12mm Figure 5 Class 3 thermal crack zone Action Required Locomotives and passenger vehicles with class 3 thermal cracks must be scheduled for wheel turning within 14 days of detection Electric multiple unit vehicles with class 3 thermal cracks may defer wheel turning provided the wheels are inspected and details recorded by the Operator every 14 days to ensure they have not progressed to a class 4 thermal crack Freight vehicles with class 3 thermal cracks must be worked out of service for repairs Speed restriction No speed restriction Photograph 2 class 3 thermal crack RailCorp Page 10 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 1 4 Class 4 thermal cracks Any thermal crack greater than 10 mm long in the shaded zone adjacent to the rim face or any visible thermal crack on the flange shaded zone as shown in Figure 5 or a thermal crack greater than 40 mm long anywhere on the wheel tread This is a serious defect which can result from extended heavy braking or periods of abnormal braking for instance in the case of overhanging brake blocks Note If there is any evidence of a crack on or extending onto the rim face then this condition will be considered a class 4 defect Under no circumstances must a wheel with this defect be allowed to enter service if found at a pre trip examination or at a depot
5. Cracks greater than 40 mm long anywhere on the wheel Y 12mm Fractured Wheel NOT TO MOVE Examine defect in the section before movement to the nearest siding at the until wheel Any crack running through the rim web or boss of speed nominated by the attending maintenance officer inspected wheel RailCorp Page 50 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 Table 2 Spalling Description of defect Action required Speed restriction Spalled regions less than 12 mm in diameter Maximum 10 No action required Normal speed wheel coverage Spalled regions less than 25 mm in diameter Maximum 20 Re examine carefully to ensure that no Class 3 Spalls exist Normal speed wheel coverage Defects must be reported Spalled regions greater than 25 mm in diameter Sharp and Locomotives amp passenger vehicles Defects must be Normal speed jagged Maximum 50 wheel coverage recorded and scheduled for turning within 14 days Wagons Green card For Repairs Extensive spalling 3 mm or more deep sharp and jagged More If found pre trip or at a depot the wheel must not enter Speed 40 km h than 50 wheel coverage service If found en route continue at reduced speed with maximum the brakes cut out RailCorp Page 51 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rol
6. On locomotives locomotive hauled passenger cars and multiple unit rolling stock the diameter variations on wheels shall be in accordance with vehicle manufacturer s requirements but they shall not exceed the limits in dot points 2 and 3 above IGHT cI FLANGE THICKNESS FLANGE H FACE ANGLE a TREAD CENTRE LINE alg Li RIM THICKNESS 70 mm RIM WIDTH BORE HUB TREAD A Figure 2 Location of limiting dimensions RailCorp Page 7 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 Wheel defects This specification details the allowable limits for the inspection of all rail vehicle wheels for various tread and flange defects The text outlines the action to be taken when defects are found Allowable speeds mentioned below are not to exceed the prevailing track speed limit The accompanying series of instructions and associated diagrams are included to indicate degrees of severity of wheel tread damage likely to be found and the appropriate action to be taken in each case 7 1 Thermal cracks Thermal cracks are the result of alternate heating and cooling of the wheel tread and rim area and originate from metallurgical changes in the wheel material Thermal cracks are the most severe form of wheel defect Heating from brake blocks when braking frequently produces a fine net
7. and flange after machining shall not exceed 12 5 um micrometres RA Roughness Average Undercutting grooving or waviness of the tread surface between the flange root radius and the outer edge of the tread is permitted but shall not exceed 0 25 mm in depth below the true tread profile Localised undercutting grooving or waviness of the flange profile between the wheel tread side of the flange root radius and the back face of the wheel is permitted but shall not exceed 0 25 mm in depth below the true flange profile 7 11 3 2 Witness marks Witness marks used for an indication of machining efficiency are permitted on the flange face between a point 10mm above the wheel tread baseline and the tip of the flange but shall not exceed 6 mm in width 7 11 3 3 Tolerance The tolerance of a remachined wheel tread and flange profile shall not deviate below the true profile by more than 0 25 mm That is it shall not be possible to insert a 0 25 mm feeler gauge beneath a profile gauge positioned on the wheel tread 7 11 4 Examination of tyred wheels in service Tyred wheels must be inspected prior to each trip for relative movement between the tyre and wheel centre If any relative movement is detected between the tyre and wheel centre the vehicle must be immediately removed from service RailCorp Page 46 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330
8. mechanical maintenance officer nominates Once the vehicle is in the siding it shall not be further moved until e the wheel profile has been completely restored or e awheelset bogie change or the fitting of a pony bogie e apony bogie is fitted the vehicle shall then be transferred to the nearest wheel lathe in accordance with section 9 Upon reaching the wheel lathe the defective wheel is to be reprofiled to ensure all weld metal and the heat affected zone is removed In practice this can be achieved by machining the wheel such that the radius is reduced by an amount no less than the skid length divided by eight 8 Bogies which have had wheels in this condition shall have their running gear thoroughly examined for evidence of loose or adrift components particularly in the axlebox and traction motor areas Bearings shall be rumble tested and visually inspected with the removal of the front cover or gas plug The vehicle brake system shall also be tested for correct operation and sensitivity Speed Restriction Vehicle not to be moved Photograph 19 Class 5 skidded wheel RailCorp Page 26 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 7 Scaled wheels Scaling is the build up of metallic material on the surface of the wheel tread It is usually attributed to sticking brakes which cause the wheel to slip or slide on the rail
9. occurs as the result of a heavy impact on the wheel and may show up as a chip or gouge in the wheel flange or a bruise on the wheel tread A fatigue crack can start at this defect and propagate quickly through the entire wheel Action Required A close visual examination must be made of both flange surfaces and the wheel tread in order to detect the presence of any damage Any chip or gouge in a wheel which is more than 25 mm long and or 12 mm wide shall be classified as a class 4 defect see clause 7 10 4 Speed Restrictions 40 km h RailCorp Page 42 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 10 4 7 10 5 Class 4 manufacturing defect or external wheel damage Under no circumstances shall a wheel with a class 4 defect be allowed to enter service if found at a pre trip examination or at a depot Action Required If the defect is found en route or at a location with no repair facility the vehicle may continue through to the scheduled destination and or be transferred to the nearest depot at a speed of not more than 40 km h providing the brakes are isolated passenger and freight or the use of independent brake can be kept to an absolute minimum locomotives If these restrictions unduly affect operations the vehicle must be immediately removed from service The vehicle may then be repaired bogie wheelset change at the location
10. thus heating it to the stage where the material becomes soft enough to flow on the tread surface It mixes with brake dust and other foreign material and is deposited back onto the wheel where it cools in layers giving the tread a scaly appearance Scaling may cover the entire wheel surface or any part of it The method used to determine the severity of any given scaling is to measure its height from the normal wheel surface A single car air test Refer to ESR 0311 must be carried out on vehicles with scaled wheels Important If there is the slightest doubt as to the severity of scaling always report the higher classification Note Class 1 scaled wheel and Class 2 scaled wheel classifications are not relevant 7 7 1 Class 3 scaled wheels Light surface smearing very light scale may be present Scale height too small to measure with a standard rule less than 1 mm This smearing effect is caused by the wheel sliding but not completely stopping for a very short time Photograph 20 Class 3 scaled wheel Action Required No action is required at this stage although the brake system should be examined for defects which could cause the wheels to over brake No speed restriction for any vehicle with class 1 scale However Trim Blocks may be used on multiple unit trains and cast iron brake blocks on locomotives and locomotive hauled vehicles to dress the wheel tread surface Speed Restriction No speed restriction Rai
11. where the defect was found Speed Restriction 40 km h Overheated wheels Any wheel which has become severely overheated due to excessive braking or dragging brakes is a class 4 defect An overheated wheel can be identified by a blueing discolouration and may be evident after a skidded wheel or dragging brake incident Action Required Under no circumstances shall a wheel with a class 4 defect be allowed to enter service if found at a pre trip examination or at a depot If the defect is found en route or at a location with no repair facility the vehicle may continue through to the scheduled destination and or be transferred to the nearest depot at a speed of not more than 40 km h providing the brakes are isolated passenger and freight or the use of independent brake can be kept to an absolute minimum locomotives If these restrictions unduly affect operations the vehicle must be immediately removed from service The vehicle shall then be repaired bogie wheelset change at the location where the defect was found Wheels which have been severely overheated must be thoroughly inspected for possible thermal defects and checked for changes in metallurgical structure If there is any doubt as to the structural integrity of the wheel and the heat affected area cannot be removed by machining then the wheel must be scrapped Overheated tyred wheels must be removed from service and replaced immediately Speed Restrictions 40 km
12. 013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 5 4 Class 4 spalling Extensive spalling of greater than 50 of wheel surface area coverage or large spall areas 3 mm or more deep Spalling of any size on wheel flanges is a class 4 defect Any circular cracks associated with the early stages of spalling are also a class 4 defect CLASS 4 SPALLING Photograph 15 Action Required Under no circumstances must a wheel with this defect be allowed to enter service if found at a pre trip examination or at a depot If the defect is found en route or at a location with no repair facility the vehicle may continue through to the scheduled destination and or be transferred to the nearest depot at a speed of not more than 40 km h providing the brakes are isolated passenger and freight or the use of independent brake can be kept to an absolute minimum locomotives If these restrictions unduly affect operations the vehicle must be immediately removed from service The vehicle may then be repaired bogie wheelset change at the location where the defect was found Bogies which have had wheels in this condition shall have their running gear thoroughly examined for evidence of loose or adrift components particularly in the axlebox and traction motor areas Bearings shall be rumble tested and visually inspected with the removal of the front cover or gas plug Speed
13. 0334 for Welding of skidded wheels in situ After weld repair the vehicle must proceed directly to the nearest repair facility for wheelset change or reprofiling A suitable weld procedure must be developed for the repair Notwithstanding this welding shall be carried out circumferentially not transversely across the tread All surface irregularities and deposited weld metal shall be ground smooth to the contour of the wheel after the welded area has cooled to ambient temperature The surface of the weld and adjacent area shall be inspected for flaws prior to movement of the vehicle Once the vehicle has been moved to a suitable repair location for wheel turning all weld metal including the heat effected zone must be removed and the wheel surface inspected for possible flaws prior to replacing the vehicle into service RailCorp Page 45 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 11 3 Wheel tread profile remachining 7 11 3 1 Surface finish lt is important when remachining the wheel tread and flange profile that the surface finish be maintained within acceptable limits This is to ensure that surfaces which can normally contact the rail and or check rail are smooth free of machine chatter marks Surface waviness or grooving which could contribute to a wheel flange climb type derailment The surface finish of the wheel tread
14. 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 1 2 Class 2 thermal cracks Any thermal cracks between 10 mm and 30 mm long in the zone shown in Figure 3 Cracks between 10 mm and 30 mm long in this zone 2 Figure 4 Class 2 thermal crack zone Action Required Locomotives and passenger vehicles Any wheels with class 2 thermal cracks must have inspection details recorded by the Operator to ensure that the wheel condition is identified as soon as it progresses to a class 3 thermal crack Freight vehicles If any class 2 thermal cracks are found the examining officer shall re examine the wheel during vehicle examination inspection and maintenance No other action is required for class 2 thermal cracks Speed restriction no speed restriction ne a Photograph 1 Class 2 thermal crack RailCorp Page 9 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 1 3 Class 3 thermal cracks Any thermal cracks over 30 mm and up to 40 mm long in the zone shown in Figure 4 Note Any vehicle found with a class 3 thermal crack which has the wheel approaching the condemning diameter i e less than 6 mm left on the tread above the condemning dimension must be treated as if it had a class 4 defect Cracks between 30 mm and 40 mm long in this zone
15. CLASS 4 SKIDDED WHEEL Photograph 18 Action Required Under no circumstances must a wheel with this defect be allowed to enter service if found at a pre trip examination or at a depot If the defect is found en route or at a location with no repair facility the vehicle may continue through to the scheduled destination and or be transferred to the nearest depot at a speed of not more than 25 km h providing the brakes are isolated passenger and freight or the use of independent brake can be kept to an absolute minimum locomotives If these restrictions unduly affect operations the vehicle must be immediately removed from service The vehicle may then be repaired bogie wheelset change at the location where the defect was found Speed Restriction 25 km h RailCorp Page 25 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 6 5 Class 5 skidded wheels Single skid greater than 100 mm in length or multiple class 4 skids Action Required This vehicle shall not be moved until the tread surface defect is adequately rectified This can be achieved by in situ welding and build up of the tread defect area followed by grinding to restore a uniform profile Refer to ESR 0334 Welding of skidded wheels in situ After rectifying the defect in the section ensure that the vehicle movement is to the nearest siding at the speed which the attending
16. Engineering Standard Rolling Stock ESR 0330 WHEEL DEFECT MANUAL Version 1 2 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 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 u N p N Transport NSW RailCorp UNCONTROLLED WHEN PRINTED Page 1 of 57 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 Document control Version Date Summary of change Summary of change August 1997 Reissued as a Railcorp standard Scaled wheel classes RSS 0030 1 2 October 2005 amended witness marks altered qu
17. ONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 Any gap at this point indicates excessive tread hollowing 120 mm The maximum allowable tread hollowing shall be 0 5 mm measured below the highest point on the outer tread surface beyond the 120 mm dimension shown Figure 17 Application of hollow tread gauge RailCorp Page 36 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 9 4 Thin flanges A visual examination of the wheel will be necessary to determine if a thin flange is evident Note Class 1 thin flange class 2 thin flange and class 3 thin flange classifications are not relevant 7 9 4 1 Class 4 thin flange The minimum allowable flange thickness is 19 mm Less than 19 mm we Full flange profile Figure 18 Thin flange The recommended method for detecting a thin flange is using a flange height and thin flange gauge see Figure 18 A thin flange will be detected when the end of the gauge touches the tread surface of the wheel Action Required Under no circumstances must a wheel with a flange thickness of 19 mm or less be allowed to enter service if found at a pre trip examination or at a depot If a vehicle is found with a wheel flange thickness of less than 19 mm to a minimum of 18 mm en route or at a location with no repair facility th
18. RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 Table 6 Tread Flange Wear continued Description of Defect Action Required Speed restriction 5 Less than 18 Flanges with thickness less than 18mm must be removed NOT TO MOVE until Thi g from service immediately wheel is replaced n Full flange or Pony Bogie flanges g profile used 3 Locomotives amp passenger vehicles Defects must be Normal speed recorded and scheduled for turning within 14 days Short Contact flanges Wagons Green card For Repairs RailCorp Page 56 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 Table 7 Damaged Wheels Description of defect Action required Speed restriction Fatigue cracks Solitary cracks that usually have propagated from a manufacturing defect Manufacturing defects Include those that i degenerate into fatigue cracks in the wheel web and ii cause large portions of the flange to break away from the wheel External wheel damage generally results from heavy impact loads on the wheel which may show up as a chip or gouge in the flange or as a bruise on the tread Fractured wheel Any crack running through the rim web or boss of the wheel If found pre trip or at a depot the wheel must not enter Speed 40 km h service If found en route continue at reduced s
19. Restriction 40 km h RailCorp Page 22 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 6 Skidded wheels flats Skids occur when a wheel locks up while the vehicle is moving All skids eventually lead to further wheel damage such as spalling and reduce the life of bogie components such as bearings Impact forces produced by a skid are also detrimental to the track structure Important If there is the slightest doubt as to the severity of skidding always report the higher classification Skids may be ground to reduce the severity to the next lower category A single car air test Refer to ESR 0311 must be carried out on vehicles with skidded wheels 7 6 1 Class 1 skidded wheels A single skid with length less than 25 mm Action Required No action required for locomotives or freight vehicles However Trim Blocks or cast iron brake blocks may be used to dress the wheel tread surface Trim blocks must be fitted to suburban and intercity cars with class 1 skids Speed Restriction No speed restriction 7 6 2 Class 2 skidded wheels Single skid length between 25 mm and 40 mm or multiple class 1 skids Action Required Passenger vehicles Any wheels with class 2 skids must be fitted with trim blocks Locomotives Any wheels with class 2 skids must have inspection details recorded by the operator to ensure that the wheel condit
20. a steep running face See Section 4 7 on Steep Flanges _ 5 o ee Figure 13 Class 4 arris Note A class 2 arris in conjunction with a steep flange is a class 4 defect Action Required Under no circumstances must a wheel with this defect be allowed to enter service if found at a pre trip examination or at a depot If the defect is found en route or at a location with no repair facility the vehicle may continue through to the scheduled destination and or be transferred to the nearest depot at a speed of not more than 40 km h over normal track and at not more than 25 km h over points turnouts or crossings If these restrictions unduly affect operations the vehicle must be immediately removed from service The vehicle must then be repaired bogie wheelset change at the location where the defect was found As a temporary measure the arris may be hammered down at the location to allow vehicle movement as per a lower classification of defect The arris may be ground off for a permanent measure Speed Restriction 40 km h RailCorp Page 32 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 9 Tread flange wear 7 9 1 Steep flanges A visual examination of the wheel will be necessary to determine if it has a steep flange Note Class 2 steep flange class 3 steep flange class 4 steep flange and class 5 s
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22. and extreme spalling can increase this rate to approximately 20mm per 1000 km Pitting is the presence of very small marks on the tread It can be the initial stages of spalling but is not in itself a concern Important If there is the slightest doubt as to the severity of spalling always report the higher classification RailCorp Page 18 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 5 1 Class 1 spalling The wheel tread is mostly smooth with minor visible flaws or a blotchy appearance Pitting may also be noticed Areas of spalling up to 12 mm diameter may be scattered on up to 10 of the total tread area ac ES A a T j ae aw m E f gi H CLASS 1 SPALLING Photograph 12 Action Required No action required However Trim Blocks or cast iron brake blocks may be used to dress the wheel tread surface Speed Restriction No speed restriction RailCorp Page 19 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 5 2 Class 2 spalling The spalling has progressed such that the spalled areas are up to 25 mm diameter The total coverage may be up to 20 of the total tread area and the edges of the spalls may be sharp and jagged CLASS 2 SPALLING Photograph 13 Action Required Locomotives and p
23. assenger vehicles Any wheels with class 2 spalling must have inspection details recorded by the operator to ensure that the wheel condition is identified as soon as it progresses to class 3 spalling Freight vehicles If any class 2 spalls are found the examining officer shall re examine the wheel during vehicle examination inspection or maintenance No other action is required for class 2 spalling No speed restriction for any vehicle with class 2 spalling However Trim Blocks or cast iron brake blocks may be used to dress the wheel tread surface Speed Restriction No speed restriction RailCorp Page 20 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 5 3 Class 3 spalling The spalling has progressed such that the spalled areas are larger than 25 mm diameter These spalls may cover up to 50 of the total tread area and will be sharp edged and jagged CLASS 3 SPALLING Photograph 14 Action Required Locomotives and passenger vehicles must have inspection details recorded by the operator and be scheduled for wheel turning within 14 days of detection Note The minimum 10 mm depth of cut at required when turning wheels Freight vehicles must be worked out of service for repairs No speed restriction for any vehicle with class 3 spalling Speed Restriction No speed restriction RailCorp Page 21 of 57 Issued May 2
24. ding 20 km h reduced to 10 km h over points and crossings RailCorp Page 48 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 Photograph 30 Pony bogie assembled and in position Note A pony bogie is used to move a Class 5 defect RailCorp Page 49 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 Appendix A Quick reference tables of wheel defects and actions Table 1 Thermal cracks Description of defect Action required Speed restriction Cracks between 10 mm and 8 30 mm in shaded area No action required Normal speed _ Cracks between 10 mm and z 30 mm in shaded area Re examine carefully to ensure that no class 3 thermal cracks exist Defects Normal speed must be reported Pa tar If wheel is approaching condemning diameter treat as class 4 defect ii lalate Locomotives amp passenger vehicles Defects must be recorded and Normal speed FI scheduled for turning within 14 days For EMU s turning may be deferred provided inspections monitor cracks before reaching class 4 Wagons Green card For Repairs Cracks greater than 10 mm long TL eaer anada arm If found pre trip or at a depot the wheel must not enter service If found en Speed 40 km h route continue at reduced speed with the brakes cut out Maximum
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26. e from a defect in the wheel These defects can be caused by either external damage or a manufacturing defect Fatigue cracks usually appear as a solitary crack and must not be confused with thermal cracks Photograph 11 Class 5 Fatigue Crack propagated from a thermal crack Action Required Any fatigue crack found in a wheel must be classified as a class 4 defect see clause 7 10 4 or a class 5 defect see clause 7 1 5 Speed Restrictions 40 km h for Class 4 vehicle not to be moved for Class 5 7 5 Spalling or shelled tread Spalling or shelled tread occurs when pieces of metal break out of the tread surface in several places more or less continuously around the tread circumference This defect can result from thermal damage skidding or over stressing at the wheel rail contact point It is usually attributed to a combination of two or more of the following factors poor track and excessive speed resulting in high impact stresses excessive vertical loads excessive braking thermal damage and or skidding or the use of wheels of insufficient hardness Spalls can range in size depending on the age and depth of the defect Their frequency can be such that the entire tread circumference is covered with craters to the extent that they become joined Wheel tread condition particularly spalling has a pronounced effect on wheel and brake block life For example brake block wear is approximately 1 5mm per 1000km travelled with new wheels
27. e vehicle may continue through to the scheduled destination and or transferred to the nearest depot at a speed of not more than 40 km h Note In this case any arris present on the flange must be removed completely Speed Restrictions 40 km h RailCorp Page 37 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 9 4 2 Class 5 thin flange If this portion of the gauge touches the wheel tread the flange is too thin EOR Te o e EOR e e e e e e e a Figure 19 Application of thin flange gauge Refer to Figure 18 for flange height and thin flange gauge Action Required If a vehicle is found with a wheel flange thickness of less than 18 mm the vehicle must be immediately removed from service Speed Restrictions Vehicle not to be moved RailCorp Page 38 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 9 5 Short flange A visual examination of the wheel will be necessary to determine if a short flange is evident Note Class 1 short flange class 2 short flange class 4 short flange and class 5 short flange classifications are not relevant 7 9 5 1 Class 3 short flange In some cases where rapid flange wear takes place without significant tread wear a worn wheel profile is produced having a ramp at the root of the flan
28. es 15 7 2 4 Class 4 rolling contact fatigue cracks cccccccccccseeeeeeeecaeeeeeeessueeeeeeeseaeeeeeessaaeeeees 15 7 3 SUD SUT ACS TAU each cec2cee deco s gt aetsceasachencses onsieescodcueauaetwseatont ara e Ra ei aTa 17 7 4 Fr AMS CN AG OS e E E E aise aman neta ndlecbsaiee te 18 es Spalling or Shelled redd ereraa EEE EA Ea EAEE 18 7 5 1 ASS TSG ee escenaccins secs ccecewescie e A E E NE 19 7 9 2 6 F220 oF 9s eee ere a E E EES 20 7 5 3 ASS St ANN e A E E E N A E E aes eee 21 7 5 4 Seca Ee o ae E E E E E ee TO A T E TT 22 7 6 okidded Wheels HAIS assais E ce ee 23 7 6 1 Class 1 skidded WHEELS aactaiictscctiebacancvatosiancintetameietasattetuciuelatecenselalssansiatoaiiatabemuaveless 23 7 6 2 Class 2 skidded WNEEIS ccccceecccececeeeeeeeeceueeceueeeeeeeeceueeueeeeeeceuseueueeuceeeeneeeaneenenes 23 7 6 3 Class 3 skidded wheels eseisesnnernesresrnerrenrnerrrnnrrnrnnrrennrenrrnnrnnrenrinnrenrinnrennnenrenne 24 7 6 4 Class 4 skidded wheels vecniuiavivanosaniainiasaiitcainsahideamtatemtaiiabrstoutiabplanastiddnavnwensnainituenainaleanieat 25 7 6 5 Class 5 skidded wheels sc rasvessseeiusasuniabsianboiscantiebuedsentiaiasuininaisepeotnsinenstuhwauiniedaivoiueant 26 7 7 R672 216 a1 2 came ew E a E E EE 27 7 7 1 Class 3 scaled wheels sininscrasiinveidccvaecnstndnensdouddeensivesnenrndciuentdanvnedundsienntiaevadnnrdiciaanends 27 7 7 2 Class 4 Scaled WNEE ccc cceccceccccececeeeecenceceueeueeeeeueeeceeseneeeeueeu
29. eueeseesegeeeaeeeaneanenes 28 Tl Class 5 scaled wheels ssseesssrnesrnerrennesrnerrenrrenrrnnrrnrinnrinnrenrinnrnaniunrennnnrnenrenrnen nenni 29 7 8 i E E E E E E E E E A E E EEE AA E E EET 30 7 8 1 Class T a sensns A E AERO 30 7 8 2 ASS 2 GIS asetuntasencsaelasace tices E 30 7 8 3 ASS U E E N E E A EAE E T A A A 31 7 8 4 Glass 4 AS oe caeoca ara rea iataeaee ot taney acarentapre a atin sentenataneenae 32 7 9 T IC WAC NCA cea E E E E oademestenoeee 33 RailCorp Page 3 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 9 1 EEPE cates cere E sesennece an E EE A 33 7 9 14 1 Class 1 st ep fange sccscicissscisneiciisk ai 33 19 2 FUNCT TAVIS e E E sah E E E T E T 34 7 9 2 1 Class 3 high flANGE ccccesecccccceeeeeeeccceeueeceescueuececeseaaseeeessaueeeesssaaseeees 34 1 9 3 FOON TOI ciieaninsieatonsnaanediswiencobeuannenswidivansadaedhaatiacieotancmesetnncheasubtewnen cabtananepearniceosaaan 35 7 9 31 Class 3 hollow WAG agence ccennsdoasacnasd lt dseudacoscmonacedetacoentencnecGssnienckanauedosssobesie 35 7 9 4 Thin flanges siti svessveessvecsuwasmersuieline csmcnscesasdusetsvusasneasviezedsnsdeiaecsnunsaccests lnesenenicerauiaieicas 37 TOA SASS A WAT OS cn a E 37 7 9 4 2 Class 5 thin TAN GC wrcsicnas scence destnacenestnnas ahaksunnaduskocseadsinnnd adaiesansadedenatdeateeceeds 38 7 9 5 5 Fete IN LUN aos ict case aco signpost casein S
30. evant No action required Normal speed Light surface smearing too small to measure with a Examine brake gear for defects Normal speed standard rule Scale height from 1mm to 5 mm Speed 25 km h maximum If found pre trip or at a depot the wheel must not enter Scale height greater than 5 mm up to 10 mm service If found en route clear the section at reduced Speed 15 km h speed with brakes cut out Maximum Scale height greater than 10 mm up to 15 mm Speed 5 km h maximum Scale height greater than 15 mm Rectify defect in the section before movement to the NOT TO MOVE nearest siding at a speed nominated by the attending until wheel is maintenance officer rectified RailCorp Page 53 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 Table 5 Arrisses Description of defect Action required Speed restriction o Classification not relevant No action required Normal speed o Arris less than 1 5 mm No action required Normal speed _ Arris greater i E Aai areata Locomotives amp passenger vehicles Defects must be Normal speed than 1 5 mm than 1 5 mm recorded and scheduled for turning within 14 days l Wagons Green card For Repairs E Arris greater than 1 5 mm Speed 4 km h Near vertical flange face l Maximum n 2 If found pre trio or at a depot the wheel must not enter APAS ana E a Full flange profile
31. evant section of this standard Where non metallic and or segmented brake blocks are used particular attention shall be paid to the presence of thermal cracks and skids If a shoulder has worn on the edge of the brake block face then action shall be as per clause 7 11 1 2 Important Non metallic blocks will not exhibit a pronounced shoulder as the overhanging area tends to break away before achieving any noticeable size unless the overhang is excessive Speed Restrictions No speed restriction Figure 21 Example of temporary overhanging brake block RailCorp Page 44 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 11 1 2 Permanent brake block overhang An overhanging brake block is determined to be a permanent fault by evidence of a shoulder on the wheel tread a shoulder on the brake block face and or class 4 thermal cracking at the edge of the wheel tread Action Required The vehicle shall not be permitted to enter service until the matter is rectified Speed Restrictions Vehicle not to enter service Figure 16 Example of permanent brake block overhang Pronounced tread ridge Figure 22 False flange due to brake block overhang 7 11 2 Weld repairs of wheel skids The repair of wheel skids by welding is a temporary measure to allow recovery of a vehicle with class 5 wheel skids as outlined in section 7 6 5 Refer to ESR
32. ge This ramp effectively shortens the flange thereby allowing the gauge corner of the rail to work closer to the flange tip This arrangement reduces the safety margin for wheel climb derailments The short flange gauge is designed to arrest this phenomenon before it becomes critical For a correct indication the short flange gauge must be in contact with the wheel tread and flange at these two points The flange is too short if clearance exists here between the gauge and the tip of the flange after removal of any arris Figure 20 Application of short flange gauge Action Required Locomotives and passenger vehicles must have inspection details recorded by the operator and be scheduled for wheel turning within 14 days of detection Freight vehicles must be worked out of service for repairs Speed Restrictions No speed restriction for any vehicle with a short flange Refer to Figure 20 for short flange gauge RailCorp Page 39 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 10 Damaged wheels 7 10 1 Manufacturing defects This type of defect generally occurs on the wheel web and can result in a fatigue crack which propagates circumferentially around the web In other cases defects have led to large pieces of the flange falling off in service W37 type freight wheels originating in New South Wales these are fi
33. graph 4 Once the vehicle is in a siding it shall not be further moved until the fitting of a pony bogie or a wheelset bogie change Once the vehicle has had a wheelset bogie change it may be returned to service RailCorp Page 12 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 1 6 Fractured wheel A fractured wheel is a Class 5 defect A fractured wheel may be the result of either a thermal crack or a fatigue crack which has propagated or grown Photograph 5 Fractured wheel caused by thermal crack Action Required This vehicle shall not be moved until e awheelset bogie change or the fitting of a pony bogie or e apony bogie is fitted Speed Restrictions Vehicle not to be moved RailCorp Page 13 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 2 7 2 1 7 2 2 Rolling contact fatigue Rolling contact fatigue cracks is caused by repeated contact stress during the rolling motion Rolling contact fatigue cracks usually develop on rhe tread surface and are generally not oriented perpendicular to the running direction This type of defect can lead to spalling Class 1 rolling contact fatigue cracks Any rolling contact fatigue cracks up to 10 mm long on the tread surface within the zone shown in Figure 2 but no
34. h RailCorp Page 43 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 11 Miscellaneous 7 11 1 Misaligned brake gear Inspection for overhanging brake blocks or misaligned brake gear must be carried out with the brakes applied 7 11 1 1 Temporary brake block overhang In the case where an overhanging brake block is found and there is no evidence of shouldering on the brake block or wheel tread and no evidence of class 4 thermal cracks then the overhanging brake block may be a temporary condition Consideration must be given to the lateral float of the wheelset together with brake rigging clearances to determine if the brake block is overhanging temporarily If evidence suggests that the brake block overhang is temporary then the vehicle is suitable for service subject to regular inspections of the brake block s in question Action Required Locomotive and passenger vehicles with brake gear in this condition are to have the defect recorded and be inspected at the next routine inspection On vehicles where brake rigging is tied together laterally there should be no excuse for overhanging brake blocks and if found corrective action must be taken to adjust the rigging or replace worn components such as brake heads pins and or bushes If there is evidence of any other wheel tread surface defect the vehicle shall be attended to as per the rel
35. h RailCorp Page 16 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 3 Sub surface fatigue Sub surface fatigue cracks initiate from metallurgical defects in the wheel The cracks generally develop 3 to 25 mm below the tread surface in the region of maximum shear stress in the wheel rail contact area Sub surface defects are normally identified by ultrasonic testing however there are three visual ways to identify a sub surface fatigue defect Cracks appear on the tread or flange during wheel turning Cracks appear on the rim or back of the wheel and these cracks will be circumferential A portion of the tread may be displaced and protrude past the wheel rim Any sub surface crack running through the rim web boss or back of wheel that can be visually identified is to be treated as a Class 4 or 5 defect depending on severity 7 Photograph 7 Sub surface fatigue crack Photograph 8 Sub surface fatigue crack identified during wheel turning extending to back of wheel Photograph 9 Sub surface fatigue crack Photograph 10 Sub surface fatigue crack Note protrusion on chamfer rim of wheel propagated to surface RailCorp Page 17 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 4 Fatigue cracks Fatigue cracks generally originat
36. ick reference tables added Standard moved to General Maintenance Standards and RSS 0330 1 0 May 2008 renumbered RSS 0330 Classes of Scaled wheels amended ESR 0330 1 1 July 2010 Document revision history corrected May 2012 ee Summary of changes from previous version Summary of change Version 1 2 Minor reformatting New section on rolling contact fatigue added New section on sub surface fatigue added Note added re minimum cut 10 mm for removing spalling 5 61 Requirement for trim blocks on suburban and intercity cars with class 1 skidded wheels 5 6 1 Requirement for trim blocks on suburban and intercity cars with class 2 skidded wheels Increase in speed for diesel and electric passenger trains to 115 km h Actions required for Class 3 short flanges added 5 9 5 1 New section on machining defects added New section on out of round wheels added 5 10 2 RailCorp Page 2 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 Contents 1 BREN OCU LO acca cioticctc ec cecicticicuipaipatinate E NEEE E 5 2 PU DOS ieoi E a 5 3 PRD DN CaO a E E 5 4 Referenced documents nssnnnnnnnnnnnnnnrnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nennu nenun nnmnnn ennnen eae 5 4 1 mate G10 4 Sanda S eenen e E e a ee eer ee eee eee eee 5 5 Wheel rim CNG INOS S cates ce sceece icc edeetececduesecccdeesece ie aeieesseegeecseseeusecedesu
37. ing within 14 days of detection Freight vehicles must be worked out of service for repairs Speed Restrictions No speed restriction for any vehicle with high flanges When the hook gauge touches the flange tip the flange is too high 35 mm maximum flange height aoe em A me ie 70 mm Figure 16 Application of flange height gauge Refer to Figure 18 for flange height and thin flange gauge RailCorp Page 34 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 9 3 Hollow tread A visual examination of the wheel will be necessary to determine if a hollow tread is evident Note Class 1 hollow tread class 2 hollow tread class 4 hollow tread and class 5 hollow tread classifications are not relevant Photograph 25 Tread wear showing hollow tread 7 9 3 1 Class 3 hollow tread The maximum permissible tread hollowing is 3 mm nominal as determined using the wheel gauge as shown in Figure 11 Refer to Figure 20 for wheel hollow tread gauge Action Required Locomotives and passenger vehicles must have inspection details recorded by the operator and be scheduled for wheel turning within 14 days of detection Freight vehicles must be worked out of service for repairs Speed Restrictions No speed restriction for any vehicle with a hollow tread RailCorp Page 35 of 57 Issued May 2013 UNC
38. ion is identified as soon as it progresses to a class 3 skid Freight vehicles If any class 2 skids are found the examining officer shall re examine the wheel during vehicle examination inspection or maintenance No other action is required for class 2 skids However Trim Blocks or cast iron brake blocks may be used to dress the wheel tread surface Speed Restriction Diesel and electric passenger trains 115 km h all other vehicles 80 km h RailCorp Page 23 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 6 3 Class 3 skidded wheels Single skid length between 40 mm and 60 mm or multiple class 2 skids A speed restriction of 40 km h must be placed on any vehicle with class 3 skids Action Required Locomotives and passenger vehicles must have inspection details recorded by the operator and be scheduled for wheel turning Freight vehicles must be worked out of service for repairs Speed Restriction 40 km h CLASS 3 SKIDDED WHEEL MULTIPLE CLASS 2 SINGLE SKIDS Photograph 16 Photograph 17 Class 3 skidded wheel Class 3 skidded wheel note build up of scale RailCorp Page 24 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 6 4 Class 4 skidded wheels Single skid length between 60 mm and 100 mm or multiple class 3 skids
39. k on or extending onto the rim face then this condition will be considered a class 4 defect Under no circumstances must a wheel with this defect be allowed to enter service if found at a pre trip examination or at a depot RailCorp Page 15 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 Photograph 6 Class 4 Rolling contact fatigue Note Cracks are angled across the wheel tread and may vary up to 45 degrees 30 mm 12 mm a Any visible Cracks greater than 40 mm long Cracks greater crack on Flange anywhere on the wheel tread than 10 mm long Figure 10 Class 4 rolling contact fatigue crack zone Action Required Under no circumstances shall a wheel with a class 4 defect be allowed to enter service if found at a pre trip examination or at a depot If the defect is found en route or at a location with no repair facility the vehicle may continue through to the scheduled destination and or be transferred to the nearest depot at a speed of not more than 40 km h providing the brakes are isolated passenger and freight or the use of independent brake can be kept to an absolute minimum locomotives If these restrictions unduly affect operations the vehicle must be immediately removed from service The vehicle may then be repaired bogie wheelset change at the location where the defect was found Speed Restriction 40 km
40. lCorp Page 27 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 7 2 Class 4 scaled wheel Measurable scale height not exceeding 15 mm Photograph 21 Class 4 scaled wheel Action Required Under no circumstances must a wheel with this defect be allowed to enter service if found at a pre trip examination or at a depot If the defect is found en route or at a location with no repair facility the vehicle must clear the section subject to the following speed restrictions scale height 1 mm up to 5 mm 25 km h maximum scale height greater than 5mm up to 10 mm 15 km h maximum scale height greater than 10 mm up to 15 mm 5 km h maximum providing the brakes are isolated passenger and freight or the use of independent brake can be kept to an absolute minimum locomotives Once the section has been cleared the vehicle shall not be further moved until e the scale build up has been completely removed by grinding chiselling etc or e awheelset bogie change or e the fitting of a pony bogie If a pony bogie is fitted the vehicle shall then be transferred to the nearest depot in accordance with section 9 Upon reaching the depot workshop an abrasive brake block may be used to clean the tread and restore it to unrestricted operation as per ESR 0315 Bogies which have had wheels with class 4 scale must have their running gear thoro
41. ling Stock Wheel Defect Manual ESR 0330 Table 3 Skidded wheels flats Description of defect Action required Speed restriction Single skid length less than 25 mm No action required Single skid length between 25 mm and 40 mm OR Re examine carefully to ensure that no Class 3 Skids exist multiple class 1 skids Defects must be reported Single skid length between 40 mm and 60 mm OR Locomotives amp passenger vehicles Defects must be multiple class 2 skids recorded and scheduled for turning within 14 days Wagons Green card For Repairs Single skid length between 60 mm and 100 mm OR If found pre trip or at a depot the wheel must not enter multiple class 3 skids service If found en route continue at reduced speed with the brakes cut out Single skid length greater than 100 mm or multiple Class Rectify defect in the section before movement to the 4 Skids nearest siding at a speed nominated by the attending maintenance officer Normal speed Diesel and electric passenger trains 115 km h operation Other trains 80 km h operation Speed 40 km h maximum Speed 25 km h maximum NOT TO MOVE until wheel rectified RailCorp Issued May 2013 UNCONTROLLED WHEN PRINTED Page 52 of 57 Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 Table 4 Scaled wheels Description of defect Action required Speed restriction Classification not rel
42. ote Any vehicle found with a class 3 rolling contact fatigue crack which has the wheel approaching the condemning diameter i e less than 6 mm left on the tread above the condemning dimension must be treated as if it had a class 4 defect Cracks between 30 mm and 40 mm long in this zone 30 mm 12mm Figure9 Class 3 rolling contact fatigue crack zone Action Required Locomotives and passenger vehicles with class 3 rolling contact fatigue cracks must be scheduled for wheel turning within 14 days of detection Electric multiple unit vehicles with class 3 rolling contact fatigue cracks may defer wheel turning provided the wheels are inspected and details recorded by the Operator every 14 days to ensure they have not progressed to a class 4 rolling contact fatigue crack Freight vehicles with class 3 rolling contact fatigue cracks must be worked out of service for repairs Speed restriction No speed restriction Class 4 rolling contact fatigue cracks Any rolling contact fatigue crack greater than 10 mm long in the shaded zone adjacent to the rim face or any visible rolling contact fatigue crack on the flange shaded zone as shown in Figure 5 or a rolling contact fatigue crack greater than 40 mm long anywhere on the wheel tread This is a serious defect which can result from extended heavy braking or periods of abnormal braking for instance in the case of overhanging brake blocks Note If there is any evidence of a crac
43. peed with maximum the brakes cut out Examine defect in the section before movement to the NOT TO MOVE nearest siding at a speed nominated by the attending until wheel has maintenance officer been inspected RailCorp Issued May 2013 UNCONTROLLED WHEN PRINTED Page 57 of 57 Version 1 2
44. rim thickness less than the limits specified below with reference to Figure 1 e Freight vehicles up to 25 tonne axleload 20 mm e Freight vehicles over 25 tonne axleload 22mm e Passenger vehicles 25 mm e Locomotives 22 mm See below Locomotive wheel rim thickness may be dictated by bogie component clearances such as gearboxes above the rolling stock outline RailCorp Page 5 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 Chamfer Rim Back Rim Edge Condemn Groove Web Rim Face Tread Line Rim Edge ff Tread ie LL Flange Figure 1 Standard wheel terminology 6 Permissible variation in wheel diameter On freight vehicles the wheel diameter variation on wheelsets bogies and between bogies fitted to vehicles shall be as per the limits specified in the ROA Manual of Engineering Standards and Practices section 24 2 1 3 e f g as stated below e Maximum permissible variation in wheel tread diameter 0 5mm per axle new or re turned e Maximum permissible variation in wheel tread diameter 1mm per axle in service e Maximum permissible variation in wheel tread diameter per bogie 25mm e Maximum permissible variation in wheel tread diameter per vehicle 60mm RailCorp Page 6 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330
45. rumble tested and visually inspected with the removal of the front cover or gas plug The vehicle brake system shall also be checked for correct operation and sensitivity Wheel treads shall be examined for any evidence of thermal cracking Speed Restriction Vehicle not to be moved RailCorp Page 29 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 8 Arrises An aris is formed when flange metal has rolled towards the tip of the flange causing a step with a sharp point at the flange tip Photograph 24 Photograph 24 View of arris from outside of wheel Wheel with arris note flange wear 7 8 1 Class 1 arris This classification is not relevant 7 8 2 Class 2 arris A class 2 arris is less than or equal to 1 5 mm high Action Required No action required for a wheel with a class 2 arris Note A class 2 arris in conjunction with a steep flange is a class 4 defect Up to 1 mm high above the tip of the flange and where the arris is rolled Up to 1 5 mm high above the tip of the flange and Figure 11 Class 2 arris Speed Restriction No speed restriction RailCorp Page 30 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 8 3 Class 3 arris A class 3 arris is greater than 1 5 mm high Wheel flange tips such as these
46. service If found en route continue at reduced speed with the brakes cut out km h over points cross overs amp turnouts RailCorp Page 54 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 Table 6 Tread flange wear Description of defect Action required Speed restriction 1 Steep flanges Flange face less than 5 degrees from vertical wi Full flange High profile flanges 3 Hollow tread 4 Thin Full flange flanges profile w Hollow Tread Gauge Greater than 35 mm Examine bogie and check wheel diameters for possible Normal speed cause of steep flanges NOTE A Steep Flange in conjunction with a Class 2 Arris is a Class 4 defect treated as per Class 4 Arris Locomotives amp passenger vehicles Defects must be Normal speed recorded and scheduled for turning within 14 days Wagons Green card For Repairs Locomotives amp passenger vehicles Defects must be Normal speed recorded and scheduled for turning within 14 days Wagons Green card For Repairs If found pre trip or at a depot the wheel must not enter Speed 40 km h service If found en route flanges up to a minimum of Maximum 18mm may continue at reduced speed with the brakes cut out and any arris removed RailCorp Issued May 2013 Page 55 of 57 UNCONTROLLED WHEN PRINTED Version 1 2
47. should be removed either by wheel turning the use of an abrasive block or by some suitable grinding operation From 1 mm up to 1 5 mm high A distinct corner produced by above the tip of the flange and a flat on the flange tip in extending from the flange combination with a steep running face See Section 4 8 flange running face See on Steep Flanges Section 4 8 on Steep Flanges Over 1 5 mm high above the tip of the flange and where the arris is rolled back towards the flange tip Figure 12 Class 3 arris Note A class 2 or greater arris in conjunction with a steep flange is a class 4 defect Action Required Locomotives and passenger vehicles must have inspection details recorded by the operator and be scheduled for wheel turning within 14 days of detection Freight vehicles must be worked out of service for repairs As a temporary measure the arris may be hammered down at the location to allow vehicle movement as per a lower classification of defect Speed Restriction No speed restriction RailCorp Page 31 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 8 4 Class 4 arris The combination of a near vertical flange running face and an arris greater than 1 5 mm high can split incorrectly housed points and result in a derailment Greater than 1 5 mm high above the tip of the flange and extending from i
48. t on or extending onto the rim face of the wheel see clause 7 1 8 Action Required No action required for class 1 rolling contact fatigue cracking gt l kg Rim Face 30 mm l 12mm Figure 7 Class 1 rolling contact fatigue crack zone Speed Restriction No speed restriction Class 2 rolling contact fatigue cracks Any rolling contact fatigue cracks between 10 mm and 30 mm long in the zone shown in Cracks between 10 mm and 30 mm long in this zone Na l 30 mm 12mm _ Figure 8 Class 2 rolling contact fatigue crack zone Action Required Locomotives and passenger vehicles Any wheels with class 2 rolling contact fatigue cracks must have inspection details recorded by the Operator to ensure that the wheel condition is identified as soon as it progresses to a class 3 rolling contact fatigue crack Freight vehicles If any class 2 rolling contact fatigue cracks are found the examining officer shall re examine the wheel during vehicle examination inspection and maintenance No other action is required for class 2 rolling contact fatigue cracks Speed restriction no speed restriction RailCorp Page 14 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 2 3 7 2 4 Class 3 rolling contact fatigue cracks Any rolling contact fatigue cracks over 30 mm and up to 40 mm long in the zone shown in Figure 4 N
49. teep flange classifications are not relevant A steep flange in conjunction with a class 2 arris is a class 4 defect as per section 7 8 4 7 9 1 1 Class 1 steep flange Action Required No action required Speed Restriction No speed restriction for any vehicle with steep flanges where not associated with an arris A flange is considered to be steep when the flange face angle in this area is 5 degrees or less to the vertical 16 mm above the tread line ie oe oe ee ee y Figure 14 Steep flange RailCorp Issued May 2013 Page 33 of 57 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 9 2 7 9 2 1 High flanges A visual examination of the wheel will be necessary to determine if it has a high flange Note Class 1 high flange class 2 high flange class 4 high flange and class 5 high flange classifications are not relevant Class 3 high flange High flanges exceed a height of 35 mm Full flange profile Greater than 35 mm ae Tread line Figure 15 Class 3 high flange Action Required Vehicles found with a high flange at a depot or pre trip shall not be permitted to enter service Where the flange height exceeds 35 mm the following action applies Locomotives and passenger vehicles must have inspection details recorded by the operator and be scheduled for wheel turn
50. tted with 18R or 9R axleboxes are particularly prone to manufacturing defects and should be specifically examined for cracks Although this type of wheel has essentially been phased out of service some wheels may still be in service Action Required Any crack originating from a manufacturing defect shall be classified as a class 4 or greater defect see clause 7 10 4 Speed Restrictions 40 km h Photograph 26 badly turned wheel resulting incorrect turning process RailCorp Page 40 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 Photograph 28 badly turned wheel resulting from impact from foreign object RailCorp Page 41 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 Photograph 29 badly turned wheel resulting from impact from foreign object 7 10 2 Out of round wheels One type of machining defect is wheels that have been turned out of round for example if the mill cutter has not been fed in correctly or the wheel tread has not been turned concentric to the axle centre Out of round wheels 2 0 3 mm have been detected on the WILD wheel impact load detector sites Action Required These wheels must be returned to the wheel lathe and returned Speed Restrictions 40 km h 7 10 3 External wheel damage This type of damage generally
51. ughly examined for evidence of loose or adrift components particularly in the axlebox and traction motor areas The vehicle brake system shall also be checked for correct operation and sensitivity Speed Restriction 25 km h 15 km h or 5 km h see above RailCorp Page 28 of 57 Issued May 2013 UNCONTROLLED WHEN PRINTED Version 1 2 RailCorp Engineering Standard Rolling Stock Wheel Defect Manual ESR 0330 7 7 3 Class 5 scaled wheels Scale height greater than 15 mm Photograph 22 Photograph 23 Class 5 scaled wheel Class 5 scaled wheel extreme Note scale over the flange Action Required The vehicle is not to be moved until the tread surface defect is adequately rectified This can be achieved by in situ grinding or chiselling After rectifying the defect in the section ensure that the vehicle is moved to the nearest siding at a speed which is applicable for class 4 scaled wheels Once the vehicle is in the siding it shall not be further moved until e the scale build up has been completely removed by grinding chiselling etc or e awheelset bogie change or e the fitting of a pony bogie If a pony bogie is fitted the vehicle shall then be transferred to the nearest depot in accordance with clause 9 Bogies which have had wheels with class 5 scale must have their running gear thoroughly examined for evidence of loose or adrift components particularly in the axlebox and traction motor areas Bearings shall be
52. work of fine shallow superficial lines or checks running in many different directions on the wheel tread surface Because of its similarity to the type of fine cracks found in pottery glazes it is sometimes referred to as surface crazing This should not be confused with true thermal cracking and if found on its own causes no problems Thermal cracks are usually transverse across the wheel tread and if allowed to grow without corrective action can develop to the point where the wheel will fracture Many shallow thermal cracks can be removed by machining but extra care must be used to ensure that the crack has been completely eliminated in the operation If thermal cracks are found on a wheel then the vehicle s brake system should be checked for evidence of dragging brakes sticking brakes Important If there is the slightest doubt as to the severity of the thermal crack always report the higher classification For example if the defect description falls between a class 2 and 3 thermal crack then a class 3 thermal crack would be reported 7 1 1 Class 1 thermal cracks Any thermal cracks up to 10 mm long on the tread surface within the zone shown in Figure 2 but not on or extending onto the rim face of the wheel Action Required No action required for class 1 thermal cracking gt i _ Rim Face 30 mm l 12mm Figure 3 Class 1 thermal crack zone Speed Restriction No speed restriction RailCorp Page 8 of 57 Issued May

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