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Railway Group Standard

Uncontrolled When Printed
GM/RT2026
Issue One
Date May 1994

Wheelsets: In
Service Safety and
Maintenance
Attention

Signatures removed from electronic version Synopsis

This document defines the
requirements for the in service
maintenance examinations for all
wheelsets fitted under vehicles
Submitted by operating on Railtrack lines
(except those on foreign
........................................................................................................... registered RIC/RIV vehicles
G. A. Clayton working in International Traffic).
Nominated Responsible Manager
This document is the property of
Railtrack. It shall not be
Approved by reproduced in whole or in part
without the written permission of
........................................................................................................... the Controller, Safety Standards.
J. R. Mitchell
Chairman, Traction and Rolling Stock Subject Committee Published by
Safety & Standards Directorate
Authorised by Railtrack
Railway Technical Centre
........................................................................................................... London Road
Ken Burrage Derby
Controller, Safety Standards
Copyright 1994 Railtrack
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Railway Group Standard
GM/RT2026
Wheelsets: In Service Safety and Issue One
Date May 1994
Maintenance Attention
Page 1 of 10

Contents

Section Description Page

Part A Issue record 2

Responsibilities and distribution 2
Implementation 2
Disclaimer 2
Supply 2

Part B
1 Purpose 3
2 Scope 3
3 Definitions 3
4 Safety Management 3
5 Policy for Examinationof Wheelsets Fitted Under Vehicles 3
6 Policy for Approval of Inspection and Maintenance Facilities 3
7 Wheelset Examinations 4
8 Dimensional Limited 6
9 Recording 6

APPENDICES

A References 7
B Mandatory Wheelset Limits 8

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Part A

Issue record This standard will be updated when necessary by distribution of a

complete replacement.

Amended or additional parts of revised pages will be marked by a

vertical black line in the adjacent margin.

Issue Date Comments

1 May 94 Previously GM/TT0115 which is amended here to
reflect the restructuring of BR.

Responsibilities and Train Operators shall ensure that the provisions of the standard are
distribution communicated to all persons and organisations with responsibilities
for the inspection and maintenance of wheelsets for vehicles which
will operate over Railtrack lines. This standard shall therefore be
distributed to:

- Train Operators
- Organisations responsible for inspection
and maintenance of wheelsets.

Implementation The provisions of this Railway Group Standard are mandatory and
apply and shall be implemented from 1 May 1994

Disclaimer The Safety & Standards Directorate (S&SD) shall use its best
endeavours to ensure that the content, layout and text of its
standards are accurate, complete and in line with current best
practice insofar as is reasonably practicable. It makes no
warranties, express or implied, that compliance with all or any of its
standards shall be sufficient to ensure safe systems of work or
operation. The S&SD will not be liable to pay compensation in
respect to the content or subsequent use of its standards, except
where it can be shown to have acted in bad faith or there has been
wilful default.

Supply Controlled and uncontrolled copies of this standard must be obtained

from the TDCC Manager, Document Services, Railway Technical
Centre, London Road, Derby, DE24 8UP.

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Date May 1994
Maintenance Attention
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Part B

1 Purpose Wheelset wear and damage can affect the safe operation of vehicles
and it is the purpose of this document to specify the policy for
examination of wheelsets that must be incorporated into a vehicle
maintenance policy and to state the minimum safety limits of wear
and damage.

2 Scope This standard is applicable to all wheelsets, as defined in

GM/RT2020, which are fitted under railway vehicles operating over
Railtrack lines, (except those on foreign registered RIC/RIV vehicles
used in International Traffic).

3 Definitions Definitions of terms used in this document are in accordance with

GM/RT2020.

4 Safety Management All applicable statutory safety regulations shall be observed when
performing work necessary to comply with the requirements of this
standard. All equipment shall be designed and used such that it
does not constitute any hazard to any person.

5 Policy for 5.1

Examination of Train Operators must include in the Wheelset Policy the wheelset
Wheelsets Fitted Under examinations detailed in Section 7 which must be undertaken at
Vehicles predetermined periods of examination, maintenance, repair or when
reports of suspected damage or poor vehicle riding performance are
received. The examinations are to be performed at a periodicity to
ensure safe operation by competent staff using approved gauges,
where applicable, and in accordance with defined procedures.

5.2
The Train Operator shall indicate how the requirements of this
standard are incorporated in the maintenance plan required by
GM/TT0188, for each type or fleet of rail vehicles to be operated.

6 Policy for Approval 6.1

of Inspection and Inspection and maintenance of wheelsets for use on Railtrack lines
shall
Maintenance Facilities only be undertaken at facilities of organisations qualified in
accordance with GM/TT0182.

6.2
Inspection and maintenance organisations shall provide and
implement auditable procedures and work instructions that ensure
compliance with the requirements of this standard.

6.3

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All inspection and maintenance organisations should be operating a
quality system which conforms to the requirements of ISO9002.

7 Wheelset Examinations 7.1 Safety Examination - Visual

This examination is a visual examination to be undertaken whenever
a vehicle is presented for safety of line examination, rough riding
examination, general vehicle condition examination, planned
maintenance or vehicle repair.

The examination covers the condition of the visible portions of the

wheelset as detailed below.

The details of a specific examination undertaken will be dependant

upon vehicle design but must be such that the condition of the
wheelset is confirmed as safe to run.

Where an axle incorporates a suspension tube or a final drive

gearbox the examination shall include the integrity of these parts as
they interface with the wheelset.

7.1.1 Integrity
The wheelsets shall be visually examined to check for any signs of
movement at any of the component interference interfaces. If any
movement is indicated the wheelset shall be further investigated.

If there is evidence of wheels overheating or derailment the back to

back dimension of the wheelset shall be checked aginst the limits set
in GM/TT0089.

7.1.2 Cracks, Damage and Corrosion

The wheelset shall be visually examined for cracks, damage and
corrosion as appropriate on the wheel tread, wheel, axlebody, brake
discs and other critical wheelset components. All such damage
must be assessed and where necessary remedial action taken.

7.1.3 Tread Wear

The tread of the wheelset shall be visually examined for signs of
excess wear. If the tread wear profile is suspected of infringing
permissible limits it shall be gauged to establish if this is the case,
see Section 7.2.

7.1.4 Axleboxes or Bearing

Axleboxes and wheelset bearings shall be examined for signs of
damage, missing components, grease/oil loss and other symptoms
of having run hot. Any suspect bearings shall be investigated
further.

7.1.5 Brake Discs

Brake discs should be visually examined to ensure they are securely
attached, complete and that thermal cracking, distortion and wear
are within specified limits.

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7.2 GO/NO GO Gauge Examination

GO/NO GO gauges shall be used to examine wheel tread profile,
tread wear, wheelset flange toe radius build up (see Appendix B, Fig
2) and any other wearing components for which gauges are
available, when the wheelset is reported for damage or rough riding
and during planned vehicle maintenance or repair. In addition any
component visually suspected of approaching or infringing wear
limits shall be gauged.

7.3 Accurate Measurement Examination

Accurate measurements shall be taken of any defects found and of
any wearing component for which a GO/NO GO gauge is not
available, when the wheelset is reported for damage, derailment or
rough riding and during planned vehicle maintenance or repair.

7.3.1 Cracks, Damage and Corrosion

If the extent of any cracks, damage or corrosion on the wheel tread,
wheel, axlebody, brake discs or other wheelset components exceed
the specified maximum limits then the wheelset must be repaired,
overhauled or scrapped.

Tread damage shall not exceed the limits specified in GM/TT0089.

7.3.2 Wear
The vehicle maintenance plan shall set wear limits in accordance
with Section 8. Wheelsets exceeding these limits must be repaired,
overhauled or scrapped.

7.3.3 Wheel Diameter

When a wheelset requires replacement the wheel diameters of the
other wheelsets on the vehicle/bogie shall be measured to ensure
compliance with the specified diameter matching requirements when
ordering and fitting the replacement wheelset.

7.4 Special Examinations

The Maintenance Policy (see also GM/TT0188) shall make provision
for the introduction of special examinations where service history
indicates the need to do so.

7.5 Examination Following Derailment

The policy shall specify the examinations to be undertaken following
a derailment.

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7.6 Examination at Ground Wheel Lathes

When a wheelset is reprofiled at a ground lathe the limits for
reprofiling shall be specified, but shall not exceed the limits stated in
Appendix B of this standard.

The maximum variation between finished wheel diameters on an

axle shall not exceed the following:

a) for locomotives and passenger stock - 0.25mm

b) for all other vehicles - 0.5mm

7.7 Periodic Testing

The policy shall define what non-destructive tests shall be carried out
on wheelsets and at what frequency, see also GM/TT0120.

8 Dimensional Limits The Train Operator shall establish dimensional limits to ensure that
the Railtrack's mandatory wheelset safety limits of wear, shown in
Appendix B, are not exceeded between examinations during normal
service operation. The maintenance policy shall incorporate the
dimensional limits appropriate to the examinations to be undertaken.
The dimensional limits may be set at different values for different
examinations, dependant upon the period before the next similar
exam.

Wheelsets with components outside the appropriate dimensional

limits shall be withdrawn from service for repair, overhaul or scrap.

9 Recording Records of examinations undertaken shall be retained in accordance

with GM/TT0083. Measurements taken and defects noted shall be
recorded and retained.

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APPENDIX A

REFERENCES

ISO9002
Quality Standards

BS 5892
Wheelset Materials

GM/TT0083
Wheelset Records

GM/TT0089
Geometric Interfaces Between Railway Vehicles and Track

GM/TT0093
Wheelset Manufacture

GM/TT0120
Wheelset Testing

GM/RT2020
Wheelset Engineering Policy

GM/TT0134
Branding of Wheels, Tyres and Axles

GM/TT0182
Qualification of Rail Vehicle Suppliers

GM/TT0188
Rail Vehicle Maintenance and Overhaul Policy

MT 276
Examination Schedule for Preserved Steam Locomotives Running
on BR Lines

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APPENDIX B

MANDATORY WHEELSET LIMITS

The dimensions shown below are the limits of wheel tread wear for acceptance for service on Railtrack
lines.

Note: The Train Operator shall establish dimensional limits to ensure that these criteria are
not exceeded between examinations during normal service operation.

TABLE 1 - FLANGE HEIGHT & THICKNESS BY TREAD PROFILE

Tread Drawing Flange Thickness Flange Height Details (mm) Flange Height
Profile Number Details (mm) Exceptions

As New Minimum As New (Y) Maximum

(W) (Worn) (X) (Worn) (Z)

P1 S8-C2-8006234 28 24 30 36.5 33mm applies to

'Flyash' wagons
CARKND CSA

P5 S8-C2-8003908 31.5 27 28.5 33

P6 S8-C2-8006238 29 24 30 36.5

P8 S8-C2-8006239 29 24 30 36.5

P9 S8-C2-8006240 25.7 (22.6) 21 (17.9) 30 36.5

P10 F-C-00234 31 27 28 33

P11 C1-C1-9016365 28 24 30 34

RD9 A1-C1-8700150 26 24 30 36.5

F01-112(SNCF) 32.5 22 28 36

Notes: (1) For datum points at which flange thickness and height are measured, see Figure 1

(2) The dimensions in brackets will apply if the Datum Face V of the tread profile is used for
measurements (see Figure 1)

(3) For steam locomotive profile requirements see MT 276

(4) For vehicles fitted with the BR P10 or the equivalent, UIC Profile 510-2 operating in
international
traffic, this dimension may be reduced to 24mm.

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APPENDIX B

FIGURE 1: DATUM POINTS FOR FLANGE HEIGHT AND

THICKNESS MEASUREMENTS

(Adapted from MT 288, Issue 1, Revision A)

*Note:-For the profile F01 112 (SNCF) this dimension is 10mm

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APPENDIX B

FIGURE 2: LIMITS OF TOE RADIUS BUILD-UP AND SHARP

FLANGES

Flange Toe-Radius
Gauge F-A4-7325

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