Branding of Wheels,Tyres and Axles Signatures removed from electronic version Submitted by G A Clayton Nominated Responsible Manager Synopsis This standard details the branding requirements for all wheels, tyres and axles used on rail vehicles operating on Railtrack controlled infrastructure. Approved by R Illingworth Chairman, Electrification & Plant Subject Committee Chairman, Traction and Rolling Stock Subject Committee.Authorised by M H Walter Controller, Safety Standards This document is the property of Railtrack PLC. It shall not be reproduced in whole or in part without the written permission of the Controller, Safety Standards Railtrack PLC. Published by Safety & Standards Directorate Railtrack PLC Floor 2, Fitzroy House 355 Euston Road London NW1 3AG Copyright 1996 Railtrack PLC
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Page 1 of 16 Contents Section Description Page Part A Issue record 2 Responsibilities 2 Implementation 2 Health and Safety Responsibilities 2 Supply 2 Part B 1 Purpose 3 2 Scope 3 3 Definitions 3 4 Safety management 3 5 Branding requirements 3 6 Records 4 7 Axle serial numbers 5 8 Manufacture branding of wheel centres 5 9 Manufacture branding of tyres 5 10 Manufacture branding of monobloc wheels 5 11 Manufacture branding of axles (as forged condition) 5 12 Manufacture branding of axles (finished machined condition) 5 13 Axles over forty years old 6 14 Assembly branding of monobloc wheels 6 15 Assembly branding of tyred wheels 6 16 Assembly branding of axles 6 17 Axle geometry codes 6 Illustrations Fig 1 Manufacture branding of wheel centres 7 Fig 2 Manufacture branding of tyres 8 Fig 3 Manufacture branding of monobloc wheels 9 Fig 4 Manufacture branding of roller bearing type axles 10 Fig 5 Manufacture branding of plain bearing type axles 11 Fig 6 Assembly branding of monobloc wheels 12 Fig 7 Assembly branding of tyred wheels 13 Fig 8 Assembly branding of roller bearing axles 14 Fig 9 Assembly branding of plain bearing axles 15 Related Documents 16 R A I L T R A C K 1
Page 2 of 16 Withdrawn Document Part A Issue record The standard will be updated when necessary by distribution of a complete replacement. Material changes to of this standard are marked by a vertical black line in the adjacent margin. No. Issue Rev Date Comments GM/TT0134 1 A May 93 Original Document (Supersedes MT240) 1 - September 95 Superseded GM/TT0134 2 October 96 Assemblers and Contractors lists deleted See GM/RM2525 INF. Responsibilities s are mandatory on all members of the Railway Group* and apply to all activities which fall within the scope of each individual s Railway Safety Case. If any of those activities are performed by a Contractor, the contractor s obligations in respect of s is determined by the terms of the contract between the respective parties. Where a contractor is a duty holder of a Railway Safety Case then s apply directly to the activities described in the Railway Safety Case. *The Railway Group comprises Railtrack, the duty holders of Railway Safety Cases accepted by Railtrack and the British Railways Board as long as it owns train operators. Implementation The requirements of this are mandatory and replace those in Issue 1 from 1 February 1997. Health and Safety Responsibilities In authorising this Standard, Railtrack PLC makes no warranties, express or implied, that compliance with all or any s is sufficient on its own to ensure safe systems of work or operation. Each user is reminded of its own responsibilities to ensure health and safety at work and its individual duties under health and safety legislation. 2 R A I L T R A C K
Page 3 of 16 Supply Controlled and uncontrolled copies of this standard must be obtained from The Catalogue Secretary, Safety & Standards Directorate, Railtrack PLC, Floor 2, Fitzroy House, 355 Euston Road, London, NW1 3AG. R A I L T R A C K 3
Page 4 of 16 Withdrawn Document Part B 1 Purpose To support traceability and maintenance of records, this standard mandates the branding of all wheels, tyres and axles of rail vehicles operating on Railtrack infrastructure. 2 Scope The requirements of this standard apply to all wheelsets for use on rail vehicles to be operated over Railtrack controlled infrastructure, except Foreign registered vehicles accepted for international running under RIV or RIC Regulations. 3 Definitions Cold Stamping Stamping performed on the component while it is at ambient temperature and in the finished condition. Competent Organisation An organisation which employs staff with the necessary skills, experience and knowledge to undertake specific tasks. Engineering Director Engineer responsible to a railway business, independent train operator or vehicle owner for the engineering management of traction and rolling stock. Hot Stamping Stamping performed on the component in the heated state during manufacture. Rail Vehicle Any vehicle described as traction and rolling stock (ie locomotive, coaching stock or wagon) or on-track machine. Re-Wheeling/Re-Tyring The terms re-wheeling/re-tyring apply to the replacement of any wheel, wheel centre or tyre, whether new or used, fitted to existing wheelsets. 4 Safety management All applicable statutory safety regulations shall be observed in applying this standard. The operations shall be performed in such a way that they do not constitute unacceptable hazards to any person at any time between wheelset manufacture and withdrawal from service. 5 Branding 5.1 All monobloc wheels, wheel centres, tyres and axles shall be requirements legibly branded in accordance with the requirements of this Railway Group Standard, (). 4 R A I L T R A C K
Page 5 of 16 5.2 The stamps used for branding shall be scroll or block stamps of 6mm minimum height with rounded edges and corners approved by a Competent Organisation, see Section 3. 5.3 Each new axle shall be provided with a unique serial number, allocated from the assembling contractor s own series of numbers. Particular attention must be paid to the provision of the appropriate assembling contractor s code, see Table 1 of GM/RM2525 INF for list of recognised contractors and their codes. 5.4 Manufacturers/assemblers who have been prequalified by the BR Board or who have been accredited by a Competent Organisation in accordance with GM/RT2450 as suppliers of wheelsets, shall obtain from Railtrack, Safety and Standards Directorate, Head of Train & Train Systems Unit specific wheelset manufacturer/assembler codes. 5.5 Any original branding that is either removed or obscured by any subsequent machining or other remedial processes carried out shall be reinstated to the requirements of this (). For wheels, wheel centres or tyres, this shall be by COLD stamping in the locations specified. 5.6 All branding specified in this shall remain clearly legible after the application of any surface finish coating. This applies to both initial assembly and any subsequent overhaul. 5.7 When any details are changed or new components fitted (e.g. tyre profile etc.) the previous branding on the wheel hub shall be peened out and erased by filing. The new data shall be stamped in the relevant location as required by this standard. The erasing process shall be agreed by a Competent Organisation, see Section 3. 5.8 At overhaul and reassembly of wheelsets it shall be checked that the axle serial number is not duplicated and that the branding conforms with the requirements of this standard (). Note: There is a national scheme for registering axle numbers on RAVERS. 6 Records This document shall be used in conjunction with the standard GM/TT0083, which covers the mandatory requirements for wheelset records. R A I L T R A C K 5
Page 6 of 16 Withdrawn Document 7 Axle serial numbers 7.1 Axle serial numbers shall not be duplicated under any circumstances. To ensure that the serial number is unique the Assembling Contractor s Code must always be quoted as part of the axle serial number. (See also the requirements of sub-section 7.3.) 7.2 Under no circumstances shall a replacement axle be given the serial number of an original axle. 7.3 Where the axle serial number stamped on an existing axle (as formed by the assembling contractor s code and following number) is not unique or that an Assembling Contractor s Code is not present, the latest assembling Contractor shall allocate an axle serial number from its own number series. The previous axle serial number shall be recorded for reference purposes. Note: Axle serial number prefixes and suffixes different from those shown in this standard may be found. Such serial numbers relate to earlier Manufacturing and Assembling Contractors; however, the important requirement is that the stamping is alpha-numeric and unique to that axle. Known obsolete axle number prefixes and suffixes are shown in GM/RM2525 INF for reference purposes only. 8 Manufacture The branding of wheel centres shall be in accordance with Fig 1. branding of wheel centres 9 Manufacture The branding of tyres shall be in accordance with Fig 2. branding of tyres 10 Manufacture The branding of monobloc wheels shall be in accordance with Fig 3. branding of monobloc wheels 11 Manufacture 11.1 Roller bearing axles shall be branded in accordance with items 2, 3, branding of axles 4 and 5 of Fig 4. (as forged condition) 11.2 The branding of plain bearing axles shall be in accordance with items 2,3,4 and 5 of Fig 5. 12 Manufacture In order to maintain clarity of identity the branding for the finished branding of axles machined axle shall be carried out as soon as the areas to be (finished machined condition) stamped have been machined. 12.1 Roller bearing axles shall be branded in accordance with items 6, 7 and 8 of Fig 4. 6 R A I L T R A C K
Page 7 of 16 12.2 Plain bearing axles shall be branded in accordance with items 7 and 8 of Fig 5. 13 Axles over Axles over forty years old from the date of manufacture shall be forty years old identified by stamping an X in front of the Manufacturing/Assembling Contractor s code when the next wheelset repair or overhaul in accordance with GM/RT2027 takes place. 14 Assembly branding 14.1 Both wheels shall be branded on the inside face of the wheel in of monobloc wheels accordance with Fig 6. 14.2 Where stamping is not practicable on the inside of a wheel due to the close proximity of the gearwheel to wheel, or for other reasons agreed by the responsible Engineering Director, then it is acceptable to stamp at the outside location only. 15 Assembly branding 15.1 Both tyres shall be branded on the inside face of the wheel in of tyred wheels accordance with Fig 7. 15.2 Where stamping is not practicable on the inside of a wheel due to the close proximity of the gearwheel to wheel, or for other reasons agreed by the responsible Engineering Director, then it is acceptable to stamp at the outside location only. 15.3 Branding on the tyre outside face shall be located adjacent to the manufacture branding. 16 Assembly branding Assembled wheelsets shall have the axle end branded as follows:- of axles i) Roller bearing axles shall be branded in accordance with Fig 8. ii) Plain bearing axles shall be branded in accordance with Fig 9. 17 Axle geometry The axle geometry codes specified in Table 3 of GM/RM2525 INF codes shall only be added after the serial number for the following axles:- i) Axles reclaimed by modifying their geometry. ii) Replacement axles where the geometry of the new axle differs from the original due to the inclusion of transition radii, stress relief grooves, etc. R A I L T R A C K 7
Page 8 of 16 Withdrawn Document BRANDING Oil Injection Plug 1 2 3 4 5 U TB 95 A2225 1 Grade of material (Table 4 of GM/RM2525 INF). 2 Manufacturing Contractor s code (Table 2 of GM/RM2525 INF). 3 Year of manufacture. 4 * Cast identity. 5 Inspector s stamp. Notes: * - Indicates stamping to be done HOT. If not practical, then it is acceptable to COLD stamp in the location shown. Where possible branding should be located diametrically opposite the oil injection plug. Fig 1: MANUFACTURE BRANDING OF WHEEL CENTRES 8 R A I L T R A C K
Page 9 of 16 10 mm BRANDING 1 2 3 4 5 SE TB 95 B3222 1 Grade of material. (Table 4 of GM/RM2525 INF). 2 *Manufacturing Contractor s code (Table 2 of GM/RM2525 INF). 3 *Year of manufacture. 4 *Cast identity. 5 Inspector s stamp (optional). * Indicates stamping to be done HOT. Fig 2: MANUFACTURE BRANDING OF TYRES R A I L T R A C K 9
Page 10 of 16 Withdrawn Document 10mm BRANDING Oil Injection Plug 1 2 3 4 5 6 8T TB 95 Y5694 UT 1 Grade of material. (Table 4 of GM/RM2525 INF). 2 Manufacturing Contractor s code (Table 2 of GM/RM2525 INF). 3 Year of manufacture. 4 *Cast identity. 5 Ultrasonic code (optional extra). 6 Inspector s stamp (optional). Notes: * Indicates stamping to be done HOT. Where possible branding should be located on the same radial line as the oil injection plug. Fig 3: MANUFACTURE BRANDING OF MONOBLOC WHEELS 10 R A I L T R A C K
Page 11 of 16 12 mm Z 6 2 3 4 5 SP 95 SC5761 Z 7 8 69323 R 140 (For Freight only) 2 Manufacturing contractor s code. (Table 2 of GM/RM2525 INF) } Stamping 3 Year of manufacture. light but 4 Cast identity. legible on 5 Inspector s stamp (optional). one end only. 6 For ready identification of 140mm diameter journals from 5½ diameter journals. (Freight vehicles only):- i) Stamp the number 140 on both ends. ii) Paint both ends with white paint to BR Catalogue No.28/44300. 7 Axle serial number. (From assembling contractor s number allocation). 8 Axle geometry code, if applicable, to be cold stamped after the serial number. (See Section 17 and Table 3 of GM/RM2525 INF). Before machining the wheel seat, markings 2, 3 and 4 shall be recorded. The axle serial number shown on the record shall be cold stamped on the finished machined axle end (at one end only) in the position Z appropriate to the axle concerned. For axles with axial end thrust pads, refer to fig 8 for position Z. In the case of driven axles this shall be at the gearwheel end of the axle. Fig 4: MANUFACTURE BRANDING OF ROLLER BEARING TYPE AXLES R A I L T R A C K 11
Page 12 of 16 Withdrawn Document 2 3 4 5 7 8 SP 95 SC5761 Z 69323 R 12 mm Z 2 Manufacturing contractor s code. (Table 2 of GM/RM2525 INF) Stamping 3 Year of manufacture. light but 4 Cast identity. legible on 5 Inspector s stamp (optional). one end only. 7 Axle serial number. (From assembling contractor s number allocation). 8 Axle geometry code, if applicable, to be cold stamped after the serial number. (See Section 17 and Table 3 of GM/RM2525 INF). } Before machining the wheel seat, markings 2, 3 and 4 shall be recorded. The axle serial number shown on the record shall be cold stamped on the finished machined axle end (at one end only) in the position Z appropriate to the axle concerned. For axles with axial end thrust pads, refer to fig 9 for position Z. In the case of driven axles this shall be at the gearwheel end of the axle. Fig 5: MANUFACTURE BRANDING OF PLAIN BEARING TYPE AXLES 12 R A I L T R A C K
Page 13 of 16 BRANDING See Fig 3 Oil Injection Plug BRANDING 7 8 9 10 11 5 12 M6 69323 R P8 3-69 M3 Notes: The Branding on the rim should be diametrically opposite the branding on the hub; where possible the branding on the hub should be diametrically opposite the oil injection plug. 5 Inspector s stamp (optional). 7 Original Assembling Contractor s code. 8 Axle serial number to be cold stamped on both wheels of a wheelset. 9 Axle geometry code to be stamped after the serial number and the axle end identification letter A if present. (See Section 17 and Table 3 of GM/RM2525 INF). 10 Tyre profile. 11 Date of assembly of wheelset. 12 Latest subsequent Assembling Contractor s Code (Table 1 of GM/RM2525 INF). To be used when a wheelset has been repaired by a different Contractor from the original Assembling Contractor. Fig 6: ASSEMBLY BRANDING OF MONOBLOC WHEELS R A I L T R A C K 13
Page 14 of 16 Withdrawn Document 11 12 5 BRANDING See Fig 2 3-58 E6 8 mm BRANDING See Fig 1 9 M6 7 8 10 12 11 5 69323 R P8 E6 5-52 Note: The branding on the hub is to be diametrically opposite the branding on the rim as shown above. 5 Inspector s stamp (optional). 7 Axle serial number to be cold stamped on both wheel centres of a wheelset. 8 Axle geometry code to be stamped after the serial number. (See Section 17 and Table 3 of GM/RM2525 INF). 9 Original Assembling Contractor s code. 10 Tyre profile. 11 Date of assembly of tyre or wheel centre as applicable. 12 Latest subsequent Assembling Contractor s Code (Table 1 of GM/RM2525 INF) to be used when a wheelset has been repaired by a different Contractor from the original Assembling Contractor. 14 R A I L T R A C K
Page 15 of 16 Fig 7: ASSEMBLY BRANDING OF TYRED WHEELS R A I L T R A C K 15
Page 16 of 16 Withdrawn Document 12 mm ROLLER BEARING 9 7 8 5 12 M6 69323 R E6 See Note 2 Below ROLLER BEARING WITH AXIAL END THRUST PADS. 5 Inspector s stamp. (Applicable to initial assembly only). 7 Axle serial number 8 Axle geometry code to be stamped after the serial number. (See Section 17 and Table 3 of GM/RM2525 INF). 9 Original Assembling Contractor s code. (Table 1 of GM/RM2525 INF). 12 Latest subsequent Assembling Contractor s Code (Table 1 of GM/RM2525 INF). To be used when a wheelset has been repaired by a different Contractor from the original Assembling Contractor. e.g E6. Notes: 1 branding shall be dressed to remove any raised burrs, etc. 2 For hollow axles where the end cap is not removed for ultrasonic inspection of the axle, additional branding may be etched within the bore. Fig 8: ASSEMBLY BRANDING OF ROLLER BEARING AXLES 16 R A I L T R A C K
Page 17 of 16 12 mm PLAIN BEARING 9 7 8 5 12 M6 69323 R E6 R3 mm PLAIN BEARING WITH AXIAL END THRUST PADS. 15 mm 1.5 mm 5 Inspector s stamp. (Applicable to initial assembly only). 7 Axle serial number 8 Axle geometry code to be stamped after the serial number. (See Section 17 and Table 3 of GM/RM2525 INF). 9 Original Assembling Contractor s code. (Table 1 of GM/RM2525 INF). 12 Latest subsequent Assembling Contractor s Code (Table 1 of GM/RM2525 INF). To be used when a wheelset has been repaired by a different Contractor from the original Assembling Contractor. e.g E6. NOTE: BRANDING SHALL BE DRESSED TO REMOVE ANY RAISED BURRS, ETC R A I L T R A C K 17
Page 18 of 16 Withdrawn Document Fig 9: ASSEMBLY BRANDING OF PLAIN BEARING AXLES 18 R A I L T R A C K
Page 19 of 16 Related Documents GM/RM2525 INF GM/RT2027 GM/RT2450 GM/TT0083 BS 5892 (Parts 1 to 6) UIC 810-1 UIC 812-3 ISO 1005 (Parts 1 to 9) *BR Spec 100 *BR Spec 107 *BR Spec 108 *BR Spec 118 *BR Spec 167 Wheelsets Manual - Information Section Wheelsets: Off-Vehicle Repair and Overhaul Qualification of Suppliers of Safety Critical Engineering Products & Services Wheelset Records Materials for Railway Rolling Stock Technical Specification for the supply of rough rolled non-alloy steel tyres for tractive and trailing stock Technical Specification for the supply of rolled solid (monobloc) wheels of non-alloy steel for tractive and rolling stock Railway Rolling Stock Materials Steel Tyres Rolled steel disc wheel-centres Rolled steel solid wheels Steel Castings Wheel and Axle assemblies for High-Speed train power cars and class 87 AC Electric Locomotives *Note: These BR specifications are superseded by BS 5892, Parts 1 to 6 R A I L T R A C K 19