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MANUAL OF STANDARDS
AND
RECOMMENDED PRACTICES
SECTION G-II
ISSUE OF 2004
Effective February 1, 2004
Compiled under the direction of the Committees responsible for the subjects shown herein.
Published by
Printed in U.S.A.
2/1/04
All rights reserved, including the right to reproduce this book in any
form. It is the AARs intention that this publication be used to pro-
mote the objectives of the AAR and its members for the safe, efficient,
and uniform interchange of rail equipment in North America. To this
end, only excerpts of a rule or specification may be reproduced by the
purchaser for their own use in promoting this objective. No portion of
this publication may be displayed or otherwise made available to
multiple users through any electronic distribution media including
but not limited to a local area network or the Internet. No portion may
be sold or used for advertisement or gain by any entity other than the
AAR and its authorized distributor(s) without written permission from
the AAR.
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
ORDERING INFORMATION
Copies of the various sections of this manual can be obtained as follows:
CIRCULAR Subscriptions to Circular Letters of the AAR Safety and Operations Technical Services are available in
LETTER hardcopy or electronic format (online access via AARs Web page at www.aar.org). Circulars are issued
SUBSCRIPTIONS at least monthly and include industry letter ballots and results, arbitration decisions, notification of rules
and standards revisions, industry early warning and maintenance advisories, and other information related
to mechanical rules and standards. Annual subscriptions commence on July 1 and terminate on June 30
of each year.
For ordering information, contact the following:
Phone: Toll-free 877-999-8824, Direct 719-584-0538
Fax: 719-584-7157
Email: pubs@ttci.aar.com
AAR Web page: www.aar.org
TTCI Web page: www.ttci.aar.com
TECHNICAL For technical questions regarding this manual, contact the following:
QUESTIONS Wheels, Axles, Bearings, and Lubrication Department
Transportation Technology Center, Inc.
P.O. Box 11130
55500 DOT Road
Pueblo, CO 81001
Email: wabl@ttci.aar.com
Phone: 719-584-0670
Fax: 719-585-1895
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TO THE USER
Section G, Part IIWheel and Axle Manual, Manual of Standards and Recommended Practices,
Association of American Railroads (AAR), contains standards and recommended practices for shop
maintenance of wheels and axles.
There are five segments:
1. Mandatory Rules Governing Wheel Shop Practices as Required by Interchange Rules
2. Recommended Wheel Shop Practices
3. General Requirements and Information
4. Figures for Segments 1., 2.0, and 3.0
5. GaugesWheel and Axle Shop
All segments contain editorial changes that increase clarity without changing context. In previous
versions of this manual, revisions and additions were identified by a bold, black, vertical line on the
unbound margin of the page adjacent to the affected change. The date of such revisions and addi-
tions was indicated by the date at the bottom of the page. With this edition, however, change bars
have been omitted. As a result, it is recommended that all segments be reviewed carefully to detect
possible changes.
USERS GUIDE
Section G, Part II, contains three standards and four recommended practices. It consists of the fol-
lowing:
Preface: A listing of the subjects covered in the 25 individual sections, the volumes mak-
ing up this manual. This preface is part of each section.
Table of Contents: A generalized subject listing that indicates applicable standards and
recommended practices.
Table of Contents in Alphabetical Sequence: A listing of the standards (S prefix) and
recommended practices (RP prefix).
Introduction: Explanation of the function of this volume.
Standards and Recommended Practices: The body of this volume deals specifically
with shop maintenance of wheels and axles.
Appendix A: Approved Materials
Appendix B: Revised Page Dates: The status of the pages making up Section G, Part II
with latest revision dates indicated is shown.
RELATED SECTIONS
Section DTrucks and Truck Details
Section D, Part IICode for Designating Design Features for Side Frames and Truck Bol-
sters
Section GWheels and Axles
Section HJournal Bearing and Lubrication
Section H, Part IIRoller Bearing (Shop) Manual
Section JSpecifications for Quality Assurance, M-1003
RESPONSIBILITY
The coverage of Section G, Part IIWheel and Axle Manual, is the responsibility of the AAR
Wheels, Axles, Bearings, and Lubrication Working Committee.
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PREFACE
The Manual of Standards and Recommended Practices of the Technical Services Division, As-
sociation of American Railroads, is issued by authority of the Management Committee of the Divi-
sion and includes all regularly adopted specifications, standards, and recommended practices of the
Association of American Railroads.
The manual is composed of the following sections:
Section A, Part ITable of Contents, Alphabetical and Numerical Index of Sections A
through N inclusive
Section A, Part IIMiscellaneous Specifications, Standards (010 Series), and Recom-
mended Practices (010 Series)
Section A, Part IIIVacant
Section BCouplers and Freight Car Draft Components (100 Series)
Section CCar ConstructionFundamentals and Details (200 and 2000 Series)
Section C, Part II, Volume 1Specifications for Design, Fabrication, and Construction of
Freight Cars, M-1001
Section C, Part II, Volume 2Appendices M-1001
Section C, Part IIISpecifications for Tank Cars, M-1002
Section DTrucks and Truck Details (300 and 3000 Series)
Section D, Part IICode for Designating Design Features for Side Frames and Truck Bol-
sters (300 and 3000 Series)
Section EBrakes and Brake Equipment (400 and 4000 Series)
Section E, Part IIElectronically Controlled Brake Systems
Section FVacant
Section GWheels and Axles (600 Series)
Section G, Part IIWheel and Axle (Shop) Manual (600 Series)
Section HJournal Bearings and Lubrication (700 Series)
Section H, Part IIRoller Bearing (Shop) Manual (700 Series)
Section H, Part IIILubrication (Shop) Manual (700 Series)
Section IIntermodal Equipment Manual
Section JSpecification for Quality Assurance, M-1003
Section KRailway Electronics
Section K, Part IIRailway Communications
Section LLettering and Marking of Cars (900 Series)
Section MLocomotives and Locomotive Equipment
Section NMulti-Level Manual
Specifications are designated with an M prefix (e.g., M-900). Standards are prefixed S (e.g.,
S-900). Recommended Practices carry the prefix RP( e.g., RP-900). The prefix S or RP will be
followed by a three- or four-digit number. The first digit, 0 through 9, indicates the section in which
the standard or recommended practice can be found, as shown in parentheses above.
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TABLE OF CONTENTS
Subject Standard Page
Rule 1. Mandatory Rules Governing Wheel Shop Practices as Required by S-659 G-II1
Interchange Rules
Rule 1.1 AxlesGeneral Practices S-659 G-II1
Rule 1.2 AxlesRoller Bearing Practices S-659 G-II2
Rule 1.3 WheelsBoring Mill Practices S-659 G-II5
Rule 1.4 WheelsMounting Press Practices S-659 G-II5
Rule 1.5 Wheel Lathe Practices S-659 G-II9
Rule 1.7 General Practices S-659 G-II10
Rule 1.8 Roller Bearing Mounting and Removal S-723 G-II12
2.0 Recommended Wheel Shop Practices RP-631 G-II17
2.1 Axle Lathe Practices RP-631 G-II17
2.2 Boring Mill Practices RP-631 G-II17
2.3 Wheel Mounting Press Practices RP-631 G-II18
2.4 Wheel Lathe Practices RP-631 G-II20
2.5 Wheel Shop Inspection RP-631 G-II21
2.6 Teardown RP-631 G-II24
2.7 MD-11 Reporting RP-631 G-II24
2.8 Steel Wheel Defects RP-631 G-II33
3.0 General Requirements and Information RP-632 G-II42
3.1 Wheel, Axle, and Bearing Failure Reports RP-632 G-II42
3.2 Handling, Shipment, and Storage of Wheels and Axles RP-632 G-II42
3.3 Wheel and Axle Specifications and Designs RP-632 G-II43
4.0 Figures for Segments 1., 2.0, and 3.0 RP-633 G-II46
5.0 GaugesWheel and Axle Shop RP-634 G-II117
Appendix A. Approved Materials S-727 G-II148
Appendix B. Revised Page Dates G-II149
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TABLE OF CONTENTS IN
ALPHABETICAL SEQUENCE
Subject Standard Page
Approved Materials S-727 G-II148
Axle Lathe Practices RP-631 G-II17
AxlesGeneral Practices S-659 G-II1
AxlesRoller Bearing Practices S-659 G-II2
Boring Mill Practices RP-631 G-II17
Figures for Segments 1., 2.0, and 3.0 RP-633 G-II46
GaugesWheel and Axle Shop RP-634 G-II117
General Practices S-659 G-II10
General Requirements and Information RP-632 G-II42
Handling, Shipment, and Storage of Wheels and Axles RP-632 G-II42
Mandatory Rules Governing Wheel Shop Practices as Required by S-659 G-II1
Interchange Rules
MD-11 Reporting RP-631 G-II24
Recommended Wheel Shop Practices RP-631 G-II17
Roller Bearing Mounting and Removal S-723 G-II12
Steel Wheel Defects RP-631 G-II33
Teardown RP-631 G-II24
Wheel and Axle Specifications and Designs RP-632 G-II43
Wheel Lathe Practices S-659 G-II9
Wheel Lathe Practices RP-631 G-II20
Wheel Mounting Press Practices RP-631 G-II18
Wheel Shop Inspection RP-631 G-II21
Wheel, Axle, and Bearing Failure Reports RP-632 G-II42
WheelsBoring Mill Practices S-659 G-II5
WheelsMounting Press Practices S-659 G-II5
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TABLE OF CONTENTS IN
NUMERICAL SEQUENCE
Standard Subject Page
RP-631 Recommended Wheel Shop Practices G-II17
RP-632 General Requirements and Information G-II42
RP-633 Figures for Segments 1., 2.0, and 3.0 G-II46
RP-634 GaugesWheel and Axle Shop G-II117
S-659 Mandatory Rules Governing Wheel Shop Practices as Required by G-II1
Interchange Rules
S-723 Mandatory Rules Governing Wheel Shop Practices as Required by G-II12
Interchange Rules (continued)
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INTRODUCTION
Wheel and axle work and roller bearing mounting are among the most important functions per-
formed by the Mechanical Departments on North American railroads. The purchase of wheels and
axles and the labor to machine, assemble, and maintain them require very large annual expendi-
tures. About one and one quarter million new wheels are purchased and mounted each year, and a
larger number of roller bearings are mounted along with new and secondhand wheels. These expen-
ditures justify special efforts to establish good workmanship and to maintain the best practices that
are currently available.
This manual has been prepared for employees who are responsible for in-shop wheel and axle work
and its on-line inspection and for roller bearing mounting. It is essential that they have a thorough
understanding of their work, and detailed study of this manual will aid them very much. It is de-
sirable for any employe having anything to do with wheel and axle work and roller bearing mount-
ing to have a general knowledge of the subjects in this manual even though the employees duties
may not involve all phases of the subject.
It also is to be expected that each railroad wheel manufacturer delivering mounted wheelsets, loco-
motive builder, or car manufacturing company will provide itself with the necessary gauges for its
own protection and will make spot checks, and any additional checks, that may be deemed neces-
sary to ensure proper fit of all truck components.
The wheel manufacturer, the locomotive builder or car builder, and the railroad shops or subcon-
tractors shall be responsible for the following:
Mounting of wheels
Mounting of bearings
Quality control program as to workmanship entering into the above steps
The purpose of this manual is to cover the best available practices in the field. There are methods
of performing certain classes of work other than those described, but the experience of many has
been assembled and is here made available to all.
AAR requirements and recommended practices for roller bearing repair shops are covered in the
AAR Manual of Standards and Recommended Practices, Section H-II, Roller Bearing Manual.
This Wheel and Axle Manual, the AAR Manual of Standards and Recommended Practices, and the
Field Manual of the AAR Interchange Rules are revised periodically. Frequent reference should be made
to each.
All approved freight and Amtrak passenger car wheel and axle shops, bearing mounting shops, and
bearing reconditioning shops are listed in Circular Letters that include the identifying marks to be
used in wheel mounting stamping and roller bearing marking. Each of these shops will be inspected
periodically in accordance with the general procedures established by the Field Manual of the AAR
Interchange Rules, Rule 120, Section A. Work done by shops that are not APPROVED is not ac-
ceptable in interchange service and is not considered as correct repairs for car repair billing. Lo-
comotive shops and passenger car shops, other than Amtrak, are listed for information only and are
neither inspected nor approved.
Requests for approval of wheel and axle shops and roller bearing mounting shops must be directed
to the Technical Services Division, Association of American Railroads, 50 F Street, NW, Washing-
ton, DC 20001, and must include the location of the facility and the name of the railroad or compa-
ny. This request should include a statement that the shop facility has been made ready for
inspection and is capable of meeting the minimum AAR requirements, in accordance with the
Wheel and Axle Manual.
In addition to the foregoing, all wheel and axle shops and roller bearing mounting shops must meet
the requirements of the AAR Manual of Standards and Recommended Practices, Section J, Quality
Assurance Specification (M-1003).
The shop also must be capable of demonstrating the ability to meet AAR requirements in a reason-
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able length of time, such as an 8-hour period for a complete wheel shop operation and a 4-hour pe-
riod for a partial wheel shop operation or for roller bearing mounting.
All nonmembers must remit a check for the amount shown in the Office Manual of the AAR Interchange
Rules, Rule 120, payable to the Association of American Railroads, prior to the inspection to defray
the expense for each inspection. Shops failing to qualify for certification will be assessed an addi-
tional amount for each visit until certification is granted. Approved shops shall be inspected peri-
odically by the AAR Field Operations Group, and failure to perform work in accordance with this
Wheel and Axle Manual would be justification for removal from the approved list until specific
conditions or violations are corrected.
Segment 1., Mandatory Rules Governing Wheel Shop Practices as Required by Interchange
Rules, has been adopted as standard, is made mandatory by the Field Manual of the AAR Inter-
change Rules 36, 41, and 43, and must be followed. Where reference is made in the mandatory seg-
ment to paragraphs in the recommended practice segment, any dimensions or tolerances given as
recommended practice become mandatory, but the method of accomplishing this may vary provided
that the intended end result is achieved.
Segments 2.0 to 4.0, inclusive, of this manual are to be considered as recommended practices.
Segment 5.0 contains gauges, some of which are Standard.
Drawings of a wheel and an axle are shown in Fig. 1 with the various parts identified. Fig. 2 shows
a drawing for Amtrak passenger car inboard bearing axles. This nomenclature should be used to
describe these various parts.
Most gauge figures in paragraph 4.0 are for purpose of illustration only and are not working draw-
ings unless so indicated. Refer to working drawings in paragraph 5.0 for tolerances on dimensions.
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THROAT OF FLANGE
TREAD FLANGE
HUB
BORE
CL
FRONT BACK
E D C B A
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A B C D E F G F D C B A
H H
AXLE AXLE
INBOARD ROLLER BEARING INBOARD ROLLER BEARING
(DISC BRAKE SEAT) (DRIVE DEVICE SEAT)
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SEGMENT 1. S-659
See paragraph 2.5.3 for recommended wet method inspection procedures. Alternate procedures are
acceptable providing they receive AAR approval.
Note: The test axle or test piece must be thoroughly cleaned of the last test indicators before test-
ing. This must be verified by light before the test is started.
Rule 1.1.9 Axles having drive devices or brake discs mounted on the body of the axle between
wheel seats must have the body of the axle magnetic particle tested by the wet method when such
wheel assemblies are processed through the wheel shop for driving device attention (see
paragraph 2.5.3). It is not necessary to remove the brake discs or drive devices before testing.
Rule 1.1.10 Welding on axles is not permitted, and any axle showing welding or cutting torch
damage is scrap. Only electrochemical metal deposition processes, covered in Rule 1.2.7, are
approved repair techniques.
Rule 1.1.11 Any nicks, gouges, or deep scratches less than 1/8 in. deep, as measured from the
original body contour, must be ground out to a smooth contour blended into the contour of the axle
body. Axle bodies may be machined providing surface defects can be removed without going below
specifications. Any axle body that has been machined must be magnetic particle tested by the wet
method after machined and be completely free of defects before application. Avoid placing nicks,
punch marks, chisel marks, or stamping, etc., in the bodies of axles, including axles having
as-forged bodies.
Rule 1.1.12 When axle markings consisting of the manufacturers brand, date, serial number,
heat number, and grade of axle (U, D, F, etc.) will be obliterated due to refinishing, a record of this
information shall be made and the marking restored after refinishing by cold stamping
1/4-in.-high figures as shown in Fig. 4.9.
Rule 1.1.13 Shops that finish machine new axles must mark these axles in accordance with
Fig. 4.9, Note 13.
RULE 1.2 AXLESROLLER BEARING PRACTICES
(Reference Figs. 4.4, 4.5, 4.7, 4.11, 5.12, 5.18, 5.19, and 5.24)
Rule 1.2.1 Maximum allowable run-out between the axle wheel seat and journal is 0.015 in. total
dial indicator reading (see Fig. 4.4). When run-out exceeds this, axle wheel seats must be turned or
centers corrected to bring the axle wheel seat and journal run-out within this tolerance.
Rule 1.2.2 Unmounted secondhand axles and any mounted axles involved in a major derailment
must be checked on centers or by the alternate method, as shown in Fig. 4.11, for bent condition
using a dial indicator on each journal and obtaining a reading near the end of the journal and near
the journal fillet. If the total dial indicator reading between the end and fillet on either journal dif-
fers more than 0.010 in. in one complete revolution, the axle must be scrapped. The journal must
be mutilated or the axle suitably marked to prevent reuse.
Rule 1.2.3 Roller bearing axles with mounted wheels that have been in derailment must be
checked for bent condition with roller bearings removed. This check, including tolerances, must be
the same as specified in Rule 1.2.2.
RULE 1.2.4 Cleaning
Before attempting to qualify axles, the axle ends, journals, journal fillets, dust guard seats, and
wear ring grooves must be thoroughly cleaned.
Abrasive method may be used provided it is 80 grit or finer.
Fillets with fretting that cannot be removed with abrasive cloth may be refinished by
grinding or machine cutting, providing the U dimension is not reduced below minimum
length as checked with the gauge shown in Fig. 5.24.
Indications of fretting checks on the periphery of the journal fillet within 3/8 in. of the dust
guard seat need not be removed as long as the filet is in compliance with Fig. 4.7.
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SEGMENT 1. S-659
1.2.7.5 Repaired axles must be stamped at one end of the axle with a letter V followed by one or
two sequential numbers, identifying symbol, and repair date month and year (See Fig. 4.9, Note 11
and Note 12.) A record of the axle stamping, in sequence of manufacturer, month and year, grade,
heat number, serial number, and electrochemical deposition solution batch number, must be main-
tained by the facility.
1.2.7.6 Buildup of the roller bearing axle journal or dust guard by electrochemical metal deposit
shall be performed only in facilities that have been certified according to the controlling MSRP
Section G, Specification M-967, and only by operators certified according to Specification M-967.
1.2.7.7 Under no circumstances shall an axle that shows signs of overheating or discoloration due
to an overheated bearing be repaired by the electrochemical metal deposition process. Any circum-
ferential steps or grooves encompassing the entire circumference of the axle journal in the bearing
seat area greater than 0.001 in. deep are a sign of a loose cone and their presence is considered an
overheated axle. Axles that have severe water etch more than 50% of the area of a bearing seat
may not be restored. Water etch less than 50% of the circumference may be restored.
1.2.7.8 The full length of the journal must be restored to the base of the journal radius. Restora-
tion of the entire journal is required on all repairs except those requiring only a seal wear ring
groove repair.
1.2.7.9 Dust guards must be no smaller than 0.004 in. under minimum. When, and only when,
fitted backing rings are applied to axles with toleranced H dimensions with the intent of produc-
ing a fitted application, the dust guards must be measured in a similar manner to axle journals as
described in Rule 1.2.4. Surface roughness shall not exceed 125 microinch. For plating area limits,
see Fig. 5.19.
Rule 1.2.8 Axles with grooved journals caused by inboard seal wear rings may be returned to
service provided there are no abrupt changes or sharp edges after repair. The following provisions
must also be met:
Groove averages no more than 0.002 in. deep and does not exceed 0.004 in. deep at any
point; or
Groove does not exceed 0.010 in. at any point and axle is used in conjunction with the AAR
Conditionally Approved or Approved parts listed in Table 1.1; or
Groove is repaired in accordance with Rule 1.2.7.
Notes:
1.2.8.1 Groove depth must be measured using a gauge with minimum resolution of 0.0001 in. and
a probe small enough to fit completely into the groove without interfering with the groove walls.
1.2.8.2 Average groove depth shall be determined by averaging no fewer than three equidistant
points.
Table 1.1 Components approved for use with inboard seal wear ring groove
Size
Manufacturer 5 1/2 in. 10 in. 6 in. 11 in. 6 1/2 in. 12 in. 7 in. 12 in.
Timken seal K151172 K150471 K147750 K150189
Timken sleeve K152373 K150491 K149549 K150483
Brenco seal wear ring with polymer insert 1106D 1206D 1306D
Timken Axle Saver seal wear ring K153392 K151590 K153391
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S-659 SEGMENT 1.
tion (false tonnage). If the interference fit is adequate, taper is correct, lubrication is proper, align-
ment is true, and wheel and axle finishes are compatible, tonnage will increase smoothly and
almost linearly from the beginning to the end of the mount at a slightly decreasing rate. This will
yield maximum area under the curve. The following accept/reject criteria apply:
1.4.1.3.1 Mounting diagrams that are within 2 ton of the limits shown in Fig. 4.19 must be ideal
mounts as shown in Fig. 4.22.
1.4.1.3.2 Mounting diagrams must continue to build tonnage at least until the wheel is 75% on.
Minor anomalies prior to this that may be caused by system fluctuations are acceptable provided
they do not exceed 2 ton.
1.4.1.3.3 A drop-off at the end of the mount (after 75% of the mount is complete) is acceptable
provided the tonnage after the drop-off exceeds the minimum tonnage shown in Fig. 4.19.
1.4.1.3.4 The entry spike at the beginning of the mount must not exceed 30 ton or three times
the tonnage after the drop-off, whichever is less. For example, if the spike is no greater than 30 ton
and the tonnage after the drop-off is no less than 10 ton, the mount is acceptable.
1.4.1.3.5 Pounding (also known as hammering, hunching, or slip stick) is allowed at the end of
the mount provided that the tonnage at the low end of the pound exceeds minimum tonnage shown
in Fig. 4.19 and the wheels are centered and still in gauge. This condition is a product of incompat-
ible surface finish between the wheel bore and axle seat and must not be allowed to persist. Once it
is identified, it must be located and resolved.
1.4.1.3.6 Mounting diagrams that reach required tonnage only as the result of a quick tonnage
buildup (usually during the last half of the mount) as shown in Fig. 4.28 are unacceptable. They
normally indicate a mechanical obstruction or an excessive positive taper of the wheel seat and/or
wheel bore. Note that the tonnage would have only reached 56 ton except for the undesirable con-
dition.
1.4.1.4 Misfits must be demounted and recorded in a log showing the misfit date, demounting
date, serial number of both wheels, and their disposition. Wheel mounting diagrams and misfit
logs must be kept on record for 5 years. Misfit wheels shall be demounted immediately or placed in
a designated holding area for demounting at a later time.
Rule 1.4.2 In mounting and demounting wheels, where damage could occur to the journals, both
journals of the axle must be protected during the entire operation to prevent nicking and scratch-
ing the journal surfaces and a suitable method must be used to prevent upset ends and high spots
on roller bearing journals.
Rule 1.4.3 The wheel seats and bores must be cleaned carefully to remove rust, grit, chips, and
grease. Both wheel seat and bore must be coated as necessary with an AAR-approved mounting
lubricant (see Appendix A on page G-II148) or with a mixture of basic carbonate white lead and
boiled (not raw) linseed oil, with boiled linseed oil only, or with caster oil. The entire bore and one
half of the wheel seat should be coated, including entry radius or taper. Once the mounting proce-
dure has begun, lubricant may not be removed or further applied. To avoid scoring of the mounting
surfaces, it is particularly important that the starting edges of the wheel seat and wheel bore be
thoroughly coated with the material used. If a mixture of white lead and boiled linseed oil is used,
the proportion should be 12 lb of white lead paste to 1 gal of boiled linseed oil, thoroughly mixed,
which will give a gravity of 58 to 62 Baume at 60 F to 80 F. Only a sufficient quantity for a few
days operation should be prepared due to the drying quality of the boiled linseed oil. A thicker
lubricant tends to reduce the pressure and cause misfits that would otherwise be correctly
mounted. Lubricant should be mixed at least 12 hours before using to give it the proper blend.
Ready-mixed white lead compound, as specified above, may be purchased. It should be stirred
before applying. If boiled linseed oil is used alone, the oil must meet the requirements of
ANSI/ASTM D-260, Type I, Standard Specification for Boiled Linseed Oil. Dirt, and grit should
be kept out of the lubricant and the brush with which it is applied. If castor oil is used, the oil must
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S-659 SEGMENT 1.
meet the requirements of ASTM D-960, Standard Specification for Raw Castor Oil. Do not use
raw linseed oil or lubricating oils either alone or for thinning.
Rule 1.4.4 Wheels must be mounted centrally with respect to the center of the axle within
mounting tolerances of 3/32 in. using wheel centering and mounting gauges in accordance with
specifications in this manual. With automated equipment, accuracy of centering of wheels on axles
shall be checked every tenth pair.
Rule 1.4.5 After wheels are mounted, they must be checked with a suitable mounting check
gauge at three equidistant points on the circumference, at a distance of 1 1/4 in. down from the
apex of the flange, to determine whether or not they are mounted within limits. With automated
equipment, every tenth pair must be checked. If measurement at any check point indicates that
wheels are not within limits, the wheel spacing must be adjusted to bring wheels within such lim-
its (see Figs. 4.29 through 4.33). Alternatively, if the gauge is correct at one place on the wheel set
and the radial and plane error is within specification, the wheel set is suitable for service. If radial
and plane error is not within specification, then wheels must be dismounted and the wheel bore
corrected. If the spacing cannot be adjusted within limits, the wheels must be dismounted and the
axle should be checked for bent condition and the wheel bores for out-of-plane.
Rule 1.4.6 New wheels mounted on the same axle must be the same tape size and bear the same
tape size marking. Secondhand wheels should be within one tape number in circumference as
measured with a standard wheel tape. Care must be taken to secure the greatest service life from
the metal in both wheel seat and hub bore.
Rule 1.4.7 In the selection of wheels for mating and in the machining and mounting of wheels
and axles for interchange service, the following must be observed. (See the Field Manual of the AAR
Interchange Rules, Rule 41, for additional restrictions).
1.4.7.1 New wheels must not be mated with secondhand wheels.
1.4.7.2 Wheels that are mounted on the same axle must meet the same AAR design criteria (i.e.,
the following attributes must match):
1.4.7.2.1 Manufacturer: See paragraph 3.3.7 (Note: Amtrak wheels may be of different manufac-
turers.)
1.4.7.2.2 Design designation: (e.g., CH-36, CJ-33, etc.) See Fig. 4.18.
1.4.7.2.3 Class of heat treatment: (e.g., U,A, B, C, L, etc.) See paragraph 3.3.6.
1.4.7.2.4 Plate shape: (Note: Mounting of straight plate wheels is prohibited.)
1.4.7.2.5 Tread profile: (Note: AAR-1B profile is mandatory on new or reprofiled wheels.)
1.4.7.2.6 Tape size: (Must be the same tape for new wheels and within one tape for reprofiled
wheels.)
1.4.7.3 If, for any reason, it is necessary to dismount from an axle one wheel of a pair of mounted
wheels, the mate must also be dismounted regardless of condition, and the axle must be handled
as a secondhand unmounted axle. This does not apply to wheels that are misfitted in mounting
operations, since only the misfit wheel needs to be removed in such cases.
1.4.7.4 The following wheels must not be returned to service:
1.4.7.4.1 Cast iron wheels
1.4.7.4.2 Davis cast steel wheels
1.4.7.4.3 Wrought steel wheels dated prior to January 1, 1927
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1.4.7.4.4 Wrought steel wheels having rims measuring 1 in. or less along with any of the follow-
ing:
Dated prior to January 1, 1939
No manufactured date markings
Illegible manufactured date markings
1.4.7.4.5 Wrought steel wheels that can be identified as being manufactured by ARMCO
1.4.7.4.6 Wrought steel, one-wear, 28-in. wheels with any of the following:
Of B-28, D-28, or Y-14 design as indicated by markings on wheels
No design markings
Illegible design markings
1.4.7.4.7 Cast steel wheels marked AAR X-2 or AAR X-4
1.4.7.4.8 Abex cast wheels marked SOUTHERN in raised letters on the back of the wheel plate
along with any of the following:
Dated prior to May 7, 1958
One-wear, 50-ton, with less than 1/4-in. flat back face of rim and dated May 7, 1958 to Sep-
tember 8, 1960
One-wear, 70-ton, marked 70T and dated May 7, 1958 to January 1, 1964
One-wear, 70-ton, marked CJ-33 and U1 or 70T and U1 and dated January 1, 1964
through December 31, 1969
1.4.7.4.9 Griffin cast-steel, 33-in., three-riser wheels with either of the following:
One-wear, 70-ton, ball rim design, marked AAR X-3 or AAR CS
Two-wear, marked AAR X-5 or AAR CS-2 and dated 1960 to 1963
1.4.7.4.10 Straight plate wheels, except A-28 and A-30
1.4.7.4.11 Straight-plate wheels with missing or illegible manufacturer identification
1.4.7.4.12 Valdunes, Creusot-Lorrie non-heat-treated, 36-in., straight-plate wheels marked F or
FW manufactured in 1980 and 1981
1.4.7.5 Do not mount 28-in. wheels on axles that have been converted from 6 1/2 in. 12 in. to
6 in. 11 in. journals unless the axle has been fully machined along its entire length to nominal
6 in. 11 in. axle dimensions.
1.4.7.6 The mounting or remounting of straight plate wheels to freight equipment used in inter-
change service is prohibited.
Rule 1.4.8 Wheels and axles should be at approximately the same temperature when mounted.
Any wheel that has been heated to aid in demounting must not be remounted.
Rule 1.4.9 A wheel must not be remounted if evidence of overheating from being in a fire is
present. A wheel having any evidence of welding or a wheel having holes in the plate must not be
remounted.
Rule 1.4.10 In handling pairs of mounted wheels, wheel sticks, chains, or hoods that catch the
axles on the journal surfaces or on roller bearings must not be used.
Rule 1.4.11 The wheel shop mark and mounting date (month and two-digit year) shall be cold
stamped on the outside hub face of one wheel of each wheel set. The latest stamping will indicate
the last shop where the wheel was mounted. Heights of characters shall be not less than 5/32 in.
and not more than 5/16 in. Stamping shall be arranged on a circular arc or straight line, and the
outer edge of the hub must not be intersected by any of the stamped characters. The wheel shop
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symbol shall consist of not more than four characters to identify the railroad, car owner, contract
shop, or car builder and not more than two additional characters to identify the particular shop
doing the work (see Fig. 4.34 for method of stamping).
Rule 1.4.12 Treads of each wheel of mounted wheel sets must be concentric with journal surfaces
within 0.030 in. total dial indicator reading, and flange throats of each wheel must be in plane
within 0.060 in. total dial indicator reading. Both readings must be measured as shown in
Fig. 4.35.
Rule 1.4.13 Alternate methods for measuring, collecting, displaying, and saving data, other than
those specifically outlined in this manual, must be approved by the AAR and a copy of the
approval must be maintained at the facility using the equipment. The measuring devices must be
calibrated against a known standard such as an electrical shunt calibration. This should be per-
formed at the beginning of each shift. If other calibration methods are provided by the manufac-
turer of the measuring devices, they should be performed as specified.
RULE 1.5 WHEEL LATHE PRACTICES
(Reference Figs. 4.35 through 4.52)
Rule 1.5.1 To qualify for reapplication to service without recontouring, all secondhand freight car
wheels must meet specifications of the Field Manual of the AAR Interchange Rules, Rule 41. Wheels
not meeting specifications that have sufficient service metal may be recontoured providing they
meet all specifications of this manual and the Field Manual of the AAR Interchange Rules, Rule 41,
after recontouring. When wheel lathes are not capable of producing wheels to these specifications,
lathes must be corrected.
Rule 1.5.2 Wheel tread and flange contours must be in accordance with Figs. 4.36 or 4.37, as
applicable, and measured with gauges shown in paragraph 5.0 (See also Figs. 4.43 through 4.52)
or other AAR-approved alternate standard.)
Rule 1.5.3 Freight car wheels must be checked for back-to-back measurement before contouring,
at a distance 1 1/4 in. down from the apex of the flange, to determine correct flange thickness.
After recontouring, wheels with over 53 3/32-in. back-to-back measurement should have flange
thickness of 1 5/32 in. (0 on AAR steel gauge NF finger). Wheels with 52 15/16 in. to 53 3/32 in.
must have flange thicknesses of 1 5/32 in. to 1 3/8 in., but both flanges of a pair must not vary
more than 2/16 in. Wheels with less than 52 15/16 in. or more than 53 3/16 in. back-to-back mea-
surement are out of gauge and should not be contoured. (Note: Passenger car wheels must be
53 3/32 in. to 53 3/8 in. and must always be machined to 1 5/32 in. +1/16 in. and 0 in. flange thick-
ness.) See Figs. 4.36, 4.37, and the Field Manual of the AAR Interchange Rules, Rule 41.E.9, for flange
thickness tolerances. See Fig. 5.27, Wheel back-to-back service limit gauge (typical).
Rule 1.5.4 To qualify for reapplication, recontoured wheels must have a flange thickness of
1 5/32 in. minimum to 1 3/8 in. maximum, and flange thicknesses on a wheel set must not vary
more than 2/16 in. Both wheels of a pair should be within one tape number in circumference.
Treads must be concentric with journal surfaces within 0.030 in. total dial indicator reading; and
flange throats in plane, at right angle to axis of axle, within 0.045 in. total dial indicator reading
when measured as shown in Fig. 4.35. Wheel tread and flange contours must be in accordance
with this manual (with exception, that the radius on the outside edge of the rim may be 3/8 in.)
unless wheel rims are reduced in thickness to such an extent that lathe drive dogs interfere with
the machining of the radius, in which case the radius may be reduced as necessary or a chamfer
used. Wheel surfaces must be machined using a cutting tool with no less than 5/32 in. nose radius.
Feed marks must not exceed 1/8 in. wide at any place on the wheel tread or flange contour.
Rule 1.5.5 New or reconditioned bearings must be applied any time a wheel set is processed
through a wheel shop, including shops with wheel-truing machine operations. (Exception: passen-
ger car wheel sets with inboard bearings and not removed from car.)
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Rule 1.5.6 In addition, an H shall also be paint stencilled on the front plate at least 1 in. high on
those wheels of curved-plate, heat-treated configuration that have yet to be stencilled or when the
stencilling has become illegible.
Rule 1.5.7 Recontoured wheels must be ultrasonically tested after turning in accordance with
paragraph 2.9, Ultrasonic Inspection of Reprofiled Wheels, to qualify for reapplication to inter-
change service.
RULE 1.6 STANDARD GAUGES
Rule 1.6.1 Wheel and axle shops must have gauges as shown in paragraph 5.0 or a suitable
method to verify specified tolerances as shown in this manual.
Rule 1.6.2 Gauges must be maintained within specified wear tolerances. When gauges are found
to be defective, they must be removed from service.
RULE 1.7 GENERAL PRACTICES
Rule 1.7.1 Machinery in continuous operation must be checked at least once each week and
machinery not in continuous operation must be checked at least once each month in accordance
with this manual to ensure that specified tolerances of this manual are met. A record must be kept
of inspections showing the date, condition of the machine, nature of the correction, if any is
required, and signature of inspector. When machinery is removed from service for any reason, the
machinery inspection report must show Out of Service and the reason for removal. Machinery
reentering service must be inspected at time of reentry. A copy of inspections must be on record at
wheel shops for at least 2 years. See the example in Fig. 4.71.
Rule 1.7.2 Wet method magnetic particle testing equipment must be checked in accordance with
this manual and a record kept in the wheel shop for 2 years. See Fig. 4.71 for the recommended
form to be used; Fig. 4.14 for the recommended method of checking bath solutions; and
paragraph 2.5.3 for recommended machinery specifications. The original certification of the centri-
fuge tube must be maintained for the life of the tube.
Rule 1.7.3 New or secondhand axles must not be coated between the wheel seats with heavy
asphaltic, tar, or cement-base coatings that prevent detection of flaws by ordinary inspection. If
axles are coated, only light-bodied materials may be used.
Rule 1.7.4 Journals and dust guards of all axles with wheels mounted must be completely coated
with a rust preventive that will provide proper protection and that can be readily removed. This
applies to wheels just mounted and to mounted wheels in storage and in transit for application.
Rule 1.7.5 Wheel sets must be arranged when stored so the wheel flanges cannot strike either
the roller bearing housing, the axle journal, or the body of the adjacent axle. Fig. 4.74 illustrates a
track arrangement for wheel and axle assemblies having roller bearings. When this arrangement
is not available, assemblies should be stored one behind the other on single tracks.
Rule 1.7.6 The same precautions must be used in placing mounted wheels on a car for shipment.
In addition, they shall be securely blocked to prevent rolling and end-sliding. Details of approved
methods are given in the current issue of the AAR Open Top Loading Rules Manual.
Rule 1.7.7 Mounted wheel and axle assemblies removed from cars for reasons other than con-
demnable defects, such as those removed from dismantled cars, must be carefully inspected before
they are placed in stock to determine if they are suitable for reuse. Any wheel and axle assembly
that does not meet the acceptable requirements of the Field Manual of the AAR Interchange Rules
must be handled in accordance with the requirements of this manual.
Rule 1.7.8 Building up slid-flat spots of worn flanges of wheels by welding, welding fractures, or
burning or drilling holes in the plate is prohibited.
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Rule 1.7.9 Wheels with less than 52 15/16-in. or more than 53 3/16-in. back-to-back measure-
ment are out of gauge and must not be returned to service (see Figs. 4.29 through 4.33). See
Fig. 5.27, Wheel back-to-back service limit gauge (typical).
Rule 1.7.10 The wheel shop mark and mounting date (month and two-digit year) shall be cold-
stamped on the outside hub face of one wheel set. The latest stamping will indicate the shop where
wheel was last mounted. Heights of characters shall be not less than 5/32 in. and not more than
5/16 in. Stamping shall be arranged on a circular arc or straight line, and the outer edge of the hub
must not be intersected by any of the stamped characters. The wheel shop symbol shall consist of
not more than four characters to identify the railroad, car owner, contract shop, or car builder and
not more than two additional characters to identify the particular shop doing the work (see
Fig. 4.34 for method of stamping). See the latest AAR Circular Letter for a listing of wheel shop
reporting works and shop locations.
Rule 1.7.11 The removing railroad is responsible for ensuring that each wheel set removed for
Why Made Codes 50, 51, 95, or 96 is inspected to determine the cause of overheating. Each active
bearing manufacturer and the last bearing reconditioner must be invited to participate in the
inspection. A form MD-11 must be completed and forwarded to the AAR Technical Services Divi-
sion for all confirmed inspection, teardown, and report. This procedure is designed to ensure con-
sistent, accurate, and orderly MD-11 reporting.
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RULE 1.
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S-723 SEGMENT 1.
ing bead should form at the juncture of the backing ring and the axle. If no sealing bead is formed,
apply a brush coat around the dust guard seat at the backing ring juncture.
1.8.2.7 Apply the bearing to the axle. Mounting pressure must be applied directly to the inner
ring or seal wear rings. Caution should be exercised in order not to apply pressure on the outer
ring, seals, or other parts of the bearing because damage will result. Caution should be exercised
that seals are not damaged and that seal wear ring does not slip out of place. Do not insert any tool
or instrument between the seal element and the seal wear ring because damage to the seal lip may
result.
1.8.2.8 Press the bearing in place using the proper mounting sleeve (Fig. 4.62) or telescoping pilot
and mounting sleeve (Fig. 4.63). Seating pressures (Fig. 4.64) must be used to ensure that the
backing ring is properly in contact with the journal fillet. Bearing or wheel presses used for mount-
ing roller bearings on axles must be equipped with relief valves so that a specified pressure can be
maintained for a short interval to ensure that the bearings are properly seated (rather than to
obtain the required pressure reading on the dial pressure gauge during the surge of the press
when the backing ring of the bearing contacts the axle fillet). The pressure relief valves must oper-
ate when the dial pressure gauge indicates the specified pressure. The dial pressure gauge must
read in tons and be checked by means of a dead weight tester, or an accurate master gauge, at
least once in each 6 months of service. A tag must be securely attached to the gauge showing the
date last tested and the date actually put into service. The seating pressure chart should be posted
at the pressing area.
RULE 1.8.3 Applying End Cap
1.8.3.1 New or secondhand end caps and new or secondhand cap screws can be intermixed with
new or reconditioned bearing assemblies.
Apply the end cap, cap screws, and a new locking plate to the end of the axle. End caps must be of
the same manufacturer and AAR approval number as the bearing being applied (Exception: see
Rule 1.8.6.2 concerning the interchangeability of end caps for certain bearings by certificate num-
ber and by size.) End caps must not have a lubricant fitting. See Fig. 4.66 for cap screw sizes and
torques. (Note: See Fig. 4.65 for Amtrak passenger car end cap application.)
1.8.3.2 Run up the cap screws to less than prescribed values. Finish tightening the cap screws
using a click-type torque wrench with a slow, steady, even force being applied to obtain the pre-
scribed AAR torque values. The cap screws must be retorqued in sequence until no further move-
ment of the cap screws results from the application of the specified torque. An AAR chart showing
torques must be posted (Fig. 4.66). Torque wrenches should be checked frequently (preferably
daily) to ensure correct readings and must be checked at least weekly with a record kept of the
checks. In order to check the torque of cap screws when defective roller bearings are inspected at
the shops, it will be necessary to maintain a dial or digital-type torque wrench at each bearing
shop.
Torquing devices other than click-type wrenches must be approved by the AAR and a copy of the
approval maintained in the facility using the equipment. If the approved device can be calibrated
against a known standard, this should be done at the beginning of each shift or at the appropriate
period as stated in the letter approving use of the device.
Torque wrenches must be permanently marked with a serial number for identification on the
weekly record of checks.
RULE 1.8.4 Checking Bearing Mounted Lateral
1.8.4.1 Tapered roller bearings must have mounted lateral play checked and must meet manufac-
turers tolerances (See Fig. 4.69). These tolerances must be posted in roller bearing mounting
shops.
If the bearing rotates freely when rotated by hand but does not indicate 0.001 in. on the dial indi-
cator, the application is satisfactory for service. Check mounted lateral with a magnetic-base dial
indicator as shown in Fig. 4.68. Force the bearing laterally toward the wheel hub, and zero the
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SEGMENT 1. S-723
indicator. Then pull the bearing laterally away from the wheel hub to obtain a lateral reading. The
use of metal bars to force the bearing laterally to obtain lateral readings is prohibited.
1.8.4.2 Reconditioned or new bearings must not exceed manufacturers mounted lateral limits.
Whenever mounted lateral is more or less than allowed tolerances, the roller bearing should be
removed and corrections made.
1.8.4.3 Lock cap screws by bending all tabs of the locking plate flat against the sides of the cap
screw (Fig. 4.67).
RULE 1.8.5 Identification
1.8.5.1 For identification, each mounted roller bearing will be marked by a suitable means
(sticker, stencil, etc.) on the outer ring in 1 1/2-in. or larger letters, as follows:
Note: See latest AAR Circular Letter for a listing of wheel shop reporting marks and shop loca-
tions.
In instances where end caps and locking plates are removed only, all of the information from the
old locking plate shall be transferred onto the new locking plate. In addition, the company marks
of the shop removing and reapplying the end cap shall be applied along with the date of replace-
ment (mm/yy) and the letters EC (end cap removal only) (see Fig. 4.77).
Note: To ensure that the original mounting shop maintains accountability for journal size and
condition, end cap removal information should be applied in addition to, rather than in place of,
mounting shop information. The letters EC serve to prevent confusion in the field as to what
information represents original bearing mounting and what information represents end cap
removal only.
RULE 1.8.6 Interchangeable Parts
1.8.6.1 Cap screws (except for AAR-20 bearings) and cap screw locking plates are interchange-
able on all bearings.
1.8.6.2 Only end caps for Classes D-, E-, and F-size bearings with the part numbers listed below
may be interchanged. If the end cap applied is not of the same manufacturer and approval number
as the bearing to which applied, a distinctively colored locking plate will be used to identify the
bearings. If, for any reason, a colored locking plate is removed without also removing the bearing,
it must be replaced with one of the same color to maintain bearing identity. Devices that are to be
attached to standard locking plates and that are intended to be used in place of colored locking
plates for identification must be approved by the AAR.
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each shift but not less frequently than the periodic checking required in accordance with this man-
ual. Either method will satisfy the requirements of this manual to verify boring mill integrity and
condition. Irregularities exceeding prescribed tolerances must be corrected immediately. Fig. 4.16
indicates a satisfactory method for grinding boring mill chuck jaws. A true concentric disc is
chucked in a low position to hold the jaws in their normal operating position during the grinding
operation. An adjustable grinder is secured to the boring bar to perform the necessary jaw face
grinding.
2.2.3 With the boring mill itself accurately aligned, it is next necessary to align the wheel prop-
erly in position on the mill with regard to concentricity and to plane. The tread of the wheel must
be clean in order to permit concentric chucking and boring. Wheels having new tread and flange
contours will normally be aligned automatically with contact of the jaws. Worn wheels should be
aligned from the back face of the rim by means of shims under the contact points of the jaws. Steel
wheels that have the front face of the rim machined should be aligned by means of hard steel
blocks of equal height resting on the cleaned surface of the table and supporting the front face of
the rim of the wheel. This alignment should be checked in any case to ensure the required accu-
racy of the finished bore.
2.2.4 Axles with oversized wheel seats up to 1/8 in. greater in diameter than standard may be
used with wheels bored oversize. Wheels can be bored out for use on larger axles provided the load
capacity, maximum finish bore, and minimum hub wall thickness are not exceeded as per the AAR
Manual of Standards and Recommended Practices, Section G, Specifications M-107 or M-208.
2.2.5 In mating two worn or re-turned multiple-wear or two-wear steel wheels, it is preferable,
for economy in handling, to have the rim thickness of each approximately the same. If continued in
service, they will reach the condemning limit for rim thickness at the same time. This practice
should be followed except in emergencies.
2.3 Wheel Mounting Press Practices
2.3.1 The quality of the wheel mounting operation is dependent upon the skill and care with
which the axle lathe and boring mill operations are performed. However, good workmanship on
wheels and axles would be lost if the mounting operation were not performed properly. The wheel
seat and bore must not be damaged during the mounting operation. The wheels must be mounted
centrally on the axle and at the proper gauge distance. The following paragraphs in this section
describe recommended practices that should be employed to accomplish the desired results.
2.3.2 A soft block should be used on all roller bearing axles when wheels and inner races are
being mounted or dismounted. The use of the block will minimize upset ends and high spots on the
axle caused by uneven pressure applied to the ends of the axle. The end of the press ram, mount-
ing press sleeves, anvil block, and all auxiliary contacting parts should be maintained in good con-
dition to ensure that all surfaces involved contribute to the correct alignment for wheel press
operations.
2.3.3 Each mounting press must have a dial pressure gauge and a pressure recording gauge. Pro-
tection from shocks is afforded the recording gauges if they are mounted separate from the press.
The recording gauge may be of the type that traces the increase in pressure either by inch of ram
travel or by time per ram travel. The pressure diagram should be as shown in the Segment 4.0.
This gives a valuable graphic record of the operation that serves not only as a check on the quan-
tity and quality of the output but also provides protection for the shop if trouble develops later on
the road. These records should be checked daily by the foreman and filed in such a way as to be
easily available at any time. These records will be maintained for 5 years. One recording gauge is
sufficient if wheels are pressed on singly. It is advantageous to use two gauges with a two-ram
press and thus mount two wheels at the same time. With such an arrangement, the recording
gauges are mounted separate from the machine. The recording pen should be kept clean and
replaced when necessary in order to ensure a thin, clear line. If the same press is used for mount-
ing and dismounting the dial pressure gauge, then the pressure recording gauge should be discon-
nected when the press is being used for dismounting
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RP-631 SEGMENT 2.0
Car owners are to keep a record of the marking of wheels and axles under new cars. This record is
to be kept on file for a minimum period of 5 years.
2.3.4 All wheels must be mounted within the pressure limits as shown in Fig. 4.19. These limits
are of wide range and should therefore be strictly adhered to in all cases. If the pressures are con-
sistently too high or too low, the pressure gauge should be calibrated, the fit allowances should be
checked with micrometers, and the lubricant should be examined for proper consistency. Tests
have proven that in mounting wheels with the same fit allowance, one pair mounted with a lubri-
cant having too much white lead will develop a considerably lower tonnage than a pair mounted
with lubricant of the proper consistency.
2.3.5 The shape of the pressure diagram as well as the maximum pressure reached is an indica-
tion of the character of the fit. The mounting chart ensures that the tonnage required by the press
is actually being used to overcome the interference fit between the axle and wheel over the entire
length of the wheel bore. Other types of friction that contribute to false tonnage include
misalignment between the axle seat and the wheel bore
galling of wheel seat or bore
improper chamfer on the wheel seat or entry taper on the bore
excessive positive taper
not enough or the wrong type of lubricant
obstructions coming in contact with the press ram.
Conversely, conditions that contribute to tonnage drop-offs include
too much lubricant
incompatible finishes between the wheel and axle mating surfaces
negative taper
Were it not for these variables, the dial gauge would suffice as the sole accept/reject authority. For-
tunately, the shape of the mounting diagram indicates when these conditions exist. Figs. 4.22
through 4.29 give examples of both acceptable and unacceptable mounting charts and the condi-
tions they expose. Fig. 4.21 describes how to construct a GONO GO template that is recom-
mended for determining whether or not the mounts meet the accept or reject criteria given by Rule
1.4.1. The resultant template shown in Fig. 4.21, Step 5, is unique to the mounting press and
recording system on which it is constructed. It will only need reconstructing if dimension A
changes as the result of machinery or feed rate changes. Once constructed, simply overlay the tem-
plate onto the mounting chart and align with the origins and the top return lines. If the following
conditions are met, the mount is acceptable:
Doesnt touch the red lines
Builds tonnage up to the green line
Peak tonnage is on or inside box (c)
Wheels are in gauge and centered
Final tonnage at the return line is concise and within minimum and maximum tonnage
Once it crosses a blue line it does not cross back through it
2.3.6 The recorder must be maintained and kept properly adjusted at all times. Lost motion in
the recording mechanism will result in error in the length of the fit. Improper adjustment of the
zero reading will cause an error in the pressure records.
2.3.7 The journal protective guards should be of softer material than the axle or lined with soft
material so there will be no danger of their nicking or scratching the journal surfaces. A good form
of guard is made of 1/16-in. sheet steel sections hinged together with a 3-in. 3-in. steel butt hinge
welded to the shield. Six projecting bars 1/2 in. high and 3/4 in. wide, with a bevel at both ends, are
spot welded to the outside of the shield. These bars serve to guide the wheel as it is pressed on the
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SEGMENT 2.0 RP-631
axle, reducing the possibility of the wheel starting on the axle at an angle, which may result in
damage to the wheel bore or the axle wheel seat and in improper mounting of the wheel.
2.3.8 As protection against abnormal flange wear and interference with track structures, it is
necessary to have correct spacing of wheels on the axle. Wheels must be mounted equidistant from
the center of the axle, which is first located and marked by use of a suitable gauge similar to that
shown in Figs. 4.30 through 4.33. The first wheel is located on the axle by use of the gauge and
shown in Figs. 4.30 through 4.33, or equivalent. Separate gauges having a single length dimension
should be used, and the gauges must be properly marked to show the flange width (wide or nar-
row) for which they are intended. This gauge controls the measurement from the back of the flange
to the center of the axle and is dimensioned to provide the maximum permissible back-to-center
spacing as follows:
Freight car wheels and wide flange passenger car wheels26 35/64 in.
Narrow flange wheels other than freight car26 11/16 in.
The first wheel must be mounted by use of a gauge of this type that gauges from the center of the
axle. The mate wheel may also be mounted using the same gauge or can be spaced from the first
wheel by use of a mounting and check gauge (Figs. 4.30 through 4.33). In mounting the mate
wheel, it may be necessary to mount to some dimension under the above maximum because of
variation in the plane of the back face of the rim. In mounting narrow flange wheels, it may be
preferable to mount both wheels to a lesser dimension.
2.3.9 The wheel should not be cocked as it starts on the wheel seat. The taper at the entry end of
the wheel seat and chamfering of the entry end of the bore will usually correct any tendency of the
wheel to cock and jam. The ends of the rams and sleeves should be checked to ensure they are
smooth and properly squared.
2.3.10 Working drawings for suitable wheel mounting gauges are shown in paragraph 5.0.
Wheels are to be mounted and checked on the basis of back-to-back measurement using these or
similar gauges. The maximum back-to-back mounting distance for all freight car wheels and wide
flange passenger car wheels is 53 3/32 in. Narrow flange passenger car wheels may also be
mounted to this distance if desired. The maximum back-to-back distance for narrow flange wheels
on other than freight cars is 53 3/8 in. A minus tolerance is allowed to a minimum limit of 53 in.
back-to-back for all wheels. However, since 53 in. is the minimum permitted at any point on the
circumference of the wheels, it is desirable to mount toward the larger dimension (see Figs. 4.30
through 4.33). After the wheels are mounted, the gauge should be tried at three or more equidis-
tant points around the circumference to be sure the wheels are within the gauge limits.
2.3.11 Wheel mounting and check gauges should be checked weekly so excessive wear will not
allow improper mounting of wheels.
2.3.12 When boiled linseed oil only is used as mounting lubricant, it is recommended that a color-
ing agent be used in order to ensure proper coating of wheel seat and bore. Color 26105, ASTM
D-910, is suggested.
2.4 Wheel Lathe Practices
2.4.1 The restoring of wheel contours is to correct service defects such as thin flange, vertical
flange, high flange, worn tread, built-up tread, and slid-flat spots. It is important that only the
necessary service metal be removed to restore contours. A very small amount of wasted service
metal means a loss of considerable mileage.
2.4.2 It is very important to determine the wheel defect and the necessary amount of service
metal to remove to restore wheels to proper contour. The AAR steel wheel gauge, Figs. 5.1 and 5.4,
is very beneficial in determining this information. Proper use of the gauge is as follows:
2.4.2.1 The AAR steel wheel gauge is so calibrated that when applied with the leg flat against the
back of the rim and the end of the movable finger pressed against the face of the flange, the scale
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on the finger will read directly in sixteenths of an inch the amount of metal to be removed at the
center of the tread to restore full flange contour with a witness groove.
2.4.2.2 Apply the gauge to at least three points around the circumference of each wheel to deter-
mine where rim and flange are the thinnest, taking finger readings and rim thickness readings for
determination of tread removal at the thinnest point.
2.4.2.3 To restore flange thickness, the amount of sixteenths shown on the finger below 0 (on
NF finger) indicates number of sixteenths of service metal to be removed to restore flange to 0
(on NF finger). Deduct this amount from the rim thickness reading on the scale of the back leg to
determine the remaining amount of service metal after turning.
2.4.2.4 Wheels requiring recontouring for other defects with flange thicknesses greater than 0
(on NF finger) should have enough service metal removed only to correct the defect, leaving the
flange as near 1 3/8 in. maximum as possible.
2.4.2.5 When restoring contours to wheels with defects such as slid-flat, built-up tread, shelling,
or grooving, before determining the amount of service metal to be removed, flange thicknesses
should be taken into consideration. That is, to restore the contour to a wheel that has a slid-flat
spot (or spots), a reading should be taken with the steel wheel gauge in the center of the slid-flat
spot noting the thickness of the rim on the back leg of this gauge. Another reading should be taken
in the good part of the wheel, and the difference between these two readings is the amount of ser-
vice metal necessary to remove the slid flat spot. At the same time, a reading should be taken with
the movable finger to determine flange thickness as per paragraph 2.4.2.3 above. The greatest of
these two readings will determine the actual amount of service metal to be removed to restore the
wheel to acceptable contour.
2.4.3 The witness groove in the flange serves two purposes (see figures in paragraph 4.0 of this
manual). First, its presence in the finish-turned wheel shows the lathe operator has not wasted
service metal by turning more off the tread than necessary. Second, it permits the saving of about
1/8 in. of service metal each time a wheel is turned, if the wheel has a thin or vertical flange. This
witness groove, however, must not be more than 3/64 in. deep and must not extend into the
throat of the flange, gauged as shown in Figs. 4.47 and 4.48. Due to the importance of the throat in
wheel service and safety, it is essential these limits for the witness groove be observed.
2.4.4 Wheels not meeting profile limits must be scrapped or recontoured.
2.5 Wheel Shop Inspection
2.5.1 One of the most important functions in the wheel shop is inspection. Inspection requires
good judgment and a knowledge of all the phases of wheel and axle work. All wheels and axles that
enter the wheel shop should be inspected for defects. Any wheel or axle with a defect that cannot
be removed by machining within the prescribed tolerances should be scrapped immediately to pre-
vent loss of time and money in attempts to machine it. Wheels and axles that are to be machined
must be segregated with respect to the work to be performed. All wheels and axles that have been
reconditioned should be inspected to ensure the defects have been removed and they are within
the prescribed tolerances for further service. When testing axle journal finish with an electronic
microinch tester, the cut-off switch must be set at 0.030, or an equivalent measuring
method/device should be used.
2.5.2 Axles should be demagnetized before bearings are reapplied. If it is necessary or desired to
magnetic particle test the body of the axle, the best results can be obtained when the surfaces of
the axles are cleaned of rust, oil, paint, and dirt prior to testing. Such cleaning can be accom-
plished by a rotary wire brush, sand or shot blasting, or by flame cleaning. Flame cleaning should
be performed on a machine designed for that purpose to avoid excessive localized heating.
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to the ultraviolet range of 3650 units (365 nm). The latter type meters are calibrated in micro-
watts per square centimeter. The meter should be held a fixed distance of 15 in. from the light
source (from the black light filter surface to the meter sensing element) and should have a mini-
mum meter reading of 525 W/cm2. The conversion factor from footcandles (for sight meters) to
microwatts per square centimeter is 5.7 times the footcandle reading (at 15-in. distance).
2.5.3.5 The maximum allowable footcandles will be left to the discretion of the user dependent on
the degree of brilliance desired to obtain satisfactory inspection conditions. Before taking a read-
ing, it should be known that the glass black light filters are clean. Reports of this test are to be
shown on a regular form.
2.5.3.6 A regular form should be prepared embodying the information to be shown on monthly
and weekly tests as outlined above, and this form should be on hand at the wheel shop and avail-
able to AAR inspectors. If desired, this form may be incorporated with the regular equipment
inspection form outlined in this manual.
2.5.4 Form MD11A is a recommended format; other formats that collect equipment data may be
used. Also attached are helpful hints and a bearing inspection flowchart to assist in collecting
these data. Data on Form MD11A will be transferred to Form MD11, which will be filed with the
AAR. The following steps should be followed in conjunction with collecting data as shown on Form
MD11A (Recommended Bearing Inspection Report).
2.5.4.1 Check the wheel set for wheel and axle defects. Report and record defects per Why Made
Codes in the Field Manual of the AAR Interchange Rules, Rules 41 and 43. Inspect the narrow adapter
for excessive wear according to the Field Manual of the AAR Interchange Rules, Rule 37, and for other
abnormal conditions.
2.5.4.2 Record the roller bearing condition, such as fused, missing, burn-off, blued, bolts or end
cap missing; or seal missing, cocked, or damaged.
2.5.4.3 Record the certificate number, date of manufacture, end cap manufacturer, and locking
plate information of each bearing. Missing or illegible information should be noted. Do not leave
boxes blank.
2.5.4.4 Check the backing ring for looseness by lightly tapping it with a 1-lb hammer. Check and
record the lateral of each bearing. Measure the break-away torque (in the clockwise direction) for
each cap screw. The preferred method for checking torque is as follows:
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2.6 Teardown
2.6.1 Roller Bearing and Journal Inspection
2.6.1.1 Visually check the exterior of the bearing, cap screws, axle end cap, and backing ring for
evidence of damage.
2.6.1.2 Disassemble the roller bearing, ensuring that components are kept together as a unit.
Inspect the seals for wear, nicks, etc., and record the seal manufacturer name and the date.
2.6.1.3 Visually check and record the condition of the grease for quantity, distribution, consis-
tency, color, and evidence of water or other contamination.
2.6.1.4 Degrease, clean, and visually inspect roller assemblies, outer rings, and other component
parts.
2.6.1.5 Measure and record inboard and outboard cone back face wear depth. Visually inspect for
fretting wear or wear due to relative movement.
2.7 MD-11 Reporting
After the Form MD11A has been completed and the information transferred, submit Form MD-11
to the AAR in accordance with Rule 1.7.11. Analyze all information to determine the defect that
initiated the failure. Do not confuse symptoms with the root causes.
EXAMPLES
Initial Cause
Helpful Hints for Causes of Hot Boxes
Defect of Heat
1. A loose cap screw, loose backing ring, undersize journal, or worn cone face CA1 CN4
may allow cones to move on the journal and possibly cause the roller to spall
or fracture.
2. Water etch brinelling, etc., may result in heavy damage to seal lips. Grease CU3 LU1
that will leak from the bearing and foreign matter will enter.
3. A journal with an upset end may stretch the cone bores causing the cone to JR2 CN4
fracture or move on the journal.
4. Seal loose, cut, ruptured, worn, or casing dented will allow grease to leak out SE1 LU1
of the bearing and foreign matter to enter.
5. A bearing overheated from an external heat source will show signs of seal BE2 LU1
rubber embrittled and the grease may have a hardened or dry appearance.
6. A defective adapter will cause an uneven load distribution on the bearing AD1 CU2
assembly.
7. A cap screw too long or a defective cap screw hole (dirty, rusty, partially CA2 CN4
closed, or faulty threads) will not provide adequate clamping force. There-
fore, the bearing will become loose on the journal while in service.
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BEARING
SEIZED
GREASED,
DRY, HARD,
CAKED A
See
Fig. 2.2
GREASED B
HAS See
BURNED Fig. 2.3
ODOR
HOT See
C
BEARING Fig. 2.4
SEAL LIPS D
HARD AND See
BRITTLE Fig. 2.5
E
See
CAGE Fig. 2.6
CONTACT
WITH SEAL
CASE
BEARING Abbreviations:
CONCLUSION: CONCLUSIONS:
AXLE FLEXURE IMPROPER GROUNDING FOR WELDING
THAWING SHED DAMAGE
EXTERNAL HEAT
BROKEN PARTS
OBSERVATION: OBSERVATION:
CUP CRACKED/BROKEN BRINELLING
BACKING RING OD DAMAGED BARLINE SPALLS
END CAP OD DAMAGED CAGE BROKEN
IRREGULAR ADAPTER CONTACT ROLLER(S) BROKEN
OBSERVATION: OBSERVATION:
DISPLACED ADAPTER HIGH IMPACT LOADS
ADAPTER BORE OUT OF WHEEL DEFECTS
TOLERANCE IMPROPER CAR HANDLING
WRONG SIZE ADAPTER
ADAPTER SEVERELY WORN
EXTERNAL MECHANICAL DAMAGE
LUBRICANT PERFORMANCE
MISSING DEPLETED
OBSERVATION: OBSERVATION:
ROLLER END WEAR OR SCORING ROLLER END WEAR OR SCORING
HEAT DISCOLORATION WATER ETCHING
ROLLER SPACED BARLINE SPALLS
HEAT DISCOLORATION
CONCLUSION: CONCLUSION:
INADEQUATE CHARGE SEAL DAMAGED
SEAL LOOSE OR DISPLACED
SEAL EXCESSIVELY WORN
CONTAMINATED
OB:
Cone Renamed: IB: OB: Cone Plated By: IB: Shop:
Date Cone Plated: IB: OB: Cone Plated By: IB: Shop:
Cone Reground: IB: OB: Cone Reground Date: IB: OB:
Cone: IB-Date: Cond:
Face Wear:
OB-Date: Cond:
Face Wear:
IB Seal Mfg: IB Seal Date: IB Cond:
OB Seal Mfg: OB Seal Date: OB Cond:
WR IB-Mfg: Date: Cond:
OB-Mfg: Date: Cond:
Spacer Condition
Grease Condition
O Rings: O Rings Removed: By: Hot: ID No.
Comments/Conclusions:
* (Enter journal size if found to
be out of specification.)
Fig. 2.7 AAR MD-11A Recommended Bearing Inspection Report
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2.8.7.3 If a wheel is found with a radial crack on the back or front face of the rim, it should be
removed from service under the thermal crack rule. Such cracks often originate in hot stamp
marks, lathe dog or chuck marks, or miscellaneous nicks or surface defects on the rim faces. They
tend to progress and may ultimately lead to wheel failures as shown in Fig. 4.55.
2.8.7.4 In classes of service where excessive thermal cracking occurs in wheels, heat-treated
wheels of lower carbon content have proven helpful in overcoming the defect.
2.8.7.5 Brake shoe heating frequently produces a fine network of superficial lines or heat checks
running in all directions on the surface of the wheel tread (see Fig. 4.54). This is sometimes associ-
ated with small skid burns. It should not be confused with true thermal cracking and is not nor-
mally a cause for wheel removal.
2.8.7.6 Another tread condition is known as spalling. Spalling is the result of small portions of
metal breaking out between or adjacent to fine thermal checks that, in turn, may be associated
with small skid marks or chain sliding. While spalling is not considered a condemnable defect,
many railroads remove such wheels from their own equipment and machine the treads down to
sound metal. This would apply particularly to multiple-wear wheels and relatively new one-wear
wheels.
2.8.8 Slid Flat
A slid flat wheel is condemnable when the flat spot is 2 in. or over in length, measured circumfer-
entially, or if there are two or more adjoining flat spots 1 1/2 in. or over in length (see Fig. 4.57).
This applies to all kinds of wheels in freight car service.
2.8.9 Built-Up Tread
A built-up tread is caused by metal from the tread or the brake shoe being heated to the plastic
state and then dragged or built-up around the tread. The condition is generally associated with
sliding on the rail. Such wheels must be removed from service when buildup is 1/8 in. or higher.
Examples of this defect are shown in Fig. 4.57. Turning the treads of such wheels requires special
attention and is hard on cutting tools. Experience indicates the cut will have to be made at least
1/16 in. and preferably 3/32 in. to 1/8 in. below the lowest point on the tread.
2.8.10 Thin Flange
The minimum flange thickness for steel wheels in service is 15/16 in. as determined by the gauge
shown in Figs. 5.8 and 5.10.
2.8.11 Vertical Flange
A wheel is condemnable for vertical flange when the gauge applied, as in Figs. 4.51 and 4.52. con-
tacts the throat side of the flange 1 in. above the tread.
2.8.12 High Flange
The maximum flange height for steel wheels in service is 1 1/2 in. measured as shown in Figs. 4.51
and 4.52.
2.8.13 Cracked or Broken Flange
Cracked or broken flanges are rare on steel wheels. When they do develop, the wheel is condem-
nable and must be removed immediately.
2.8.14 Cracked or Broken Rim
Chips broken from the uniform curling over of the outer edge of the rim around the entire wheel
are not considered a defect.
2.8.15 Cracked or Broken Plate
A wheel with a cracked plate must be condemned. Cracks in the plate develop due to stresses from
service loads and braking in combination with internal stresses in the wheel and possibly surface
defects in areas subject to high stresses. Most plate cracks are progressive in nature and it is
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important they be detected in their early stages. Fig. 4.59 shows a typical plate crack that has not
extended into the rim section at either end.
2.8.16 Holes in Plate
Wheels with holes in the plate or showing evidence of application of a torch or electric arc are con-
demnable and must be withdrawn from service.
2.8.17 Loose or Out of Gauge
2.8.17.1 Wheels must be removed from service if they show indications of being loose on axles.
Indications of a loose wheel may be back-to-back measurement exceeding the limits of 52 15/16 in.
minimum to 53 3/8 in. maximum and movement on the wheel seat.
2.8.17.2 Wheels must have gauge measurements in accordance with Figs. 4.30 through 4.33.
2.8.18 Grooved Tread
Wheels that have circumferential groove or grooves in tread to a depth of 1/8 in. or more must be
removed from service (see Fig. 4.58). Wheels having this defect may be reclaimed by turning, pro-
vided the grooves are completely removed.
2.8.19 Scrape, Dent, or Gouge in Wheel Surfaces
Wheels with a scrape, dent, or gouge more than 1/8 in. deep are condemnable (see Fig. 4.60). These
defects create stress risers that can cause wheel failures.
2.8.20 Wheels That Have Been Overheated
2.8.20.1 Wheels that have been overheated as a result of being in a fire must be scrapped. Care
must be exercised not to overheat wheels and axles if an open flame is used to thaw out contents of
cars. Such overheated wheels would be condemnable.
2.8.20.2 Wheels removed from service as a result of Why Made Code 23 shall be immediately
stenciled in 1-in. letters OVERHEATED SCRAP on the inside of both wheel plates and be
scrapped at the wheel shop.
2.8.20.3 Wheel out-of-round is detected by a wheel impact load detector reading greater than
90,000 lb for a single wheel and verified by an AAR-approved gauge or other suitable device. The
detector used must reliably measure peak impacts and provide a printed record of such measure-
ments. The verified out-of-round runout must exceed 0.070 in. Wheels with condemnable slid flat
spots are handling line responsibility and must not be billed as out-of-round.
2.9 Ultrasonic Inspection of Reprofiled Wheels
For detecting internal discontinuities in the rim of all freight car railroad wheels, ultrasonic
inspection shall be made by either the procedures shown below or by an AAR-approved equivalent.
Equipment used in these procedures shall comply with the following requirements.
Each wheel shop having a status code of 5, 6, or 6A shall maintain a documented test method and
procedures for ultrasonic inspection of all freight car railroad wheels manufactured under the
AAR Manual of Standards and Recommended Practices, Section G, Specification M-107/208.
2.9.1 Equipment
2.9.1.1 The equipment used shall be an ultrasonic pulse echo broadband instrument.
2.9.1.2 The transducer used shall operate at a frequency of 5 MHz nominal and shall be of the
type whose composition and dimensions are appropriate for the test method used.
2.9.1.3 The ultrasonic inspection shall be performed with a system incorporating an automatic
flaw alarm. The system shall produce indications from all rejectable flaws with a signal-to-noise
ratio of 15 dB or greater at all depths between 1/2 in. and 2 in.
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2.9.1.4 A suitable couplant shall be used between the test surface and the transducer. The cou-
plant shall be free of air bubbles. Rust inhibitors, softeners, and wetting agents may be added to
the couplant.
2.9.2 Time of Inspection
Inspection shall be performed after final machining.
2.9.3 Calibration
2.9.3.1 Calibration shall be conducted using a reference standard of a wheel or portion of a wheel
rim containing simulated defects or other AAR-approved procedure.
2.9.3.2 For radial testing, the reference standard shall include 1/8-in.-diameter flat-bottom holes
generated from the inside diameter of the rim perpendicular to the tread surface. A minimum of
three holes will be located 1 in., 2 1/4 in., and 3 1/2 in. from the front face of the rim to ensure cov-
erage over the width of the tread. See Fig. 2.8.
3"
2"
1"
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2.9.3.3 A distance amplitude correction (DAC) shall be used for radial testing of wheels. Holes
shall not be located close to each other so as to impede the response from each hole individually.
The holes for the DAC generation shall be located at depths to accommodate the individual sys-
tems response including at least two holes at 1 in. and 2 in. deep. See Fig. 2.9.
Typical Reference Standard for Rim Tread Ultrasonic Test
2" "
"
2"
"
FLANGE
TREAD
2"
FRONT RIM
FILLET
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2.9.4 Recalibration
Conduct ultrasonic calibration to ensure system conformance to required specifications. Check the
ultrasonic system and calibration of the instrument per documented procedures using calibration
standard when any of the following occurs:
Damage to any part of the ultrasonic system
Change in transducers, cables, and other accessories
Loss of power or equipment malfunction
Whenever ultrasonic instrumentation is first turned on
2.9.5 System Verification and Test Results Validation
2.9.5.1 Conduct ultrasonic calibration checks to ensure system conformance to required specifica-
tions.
2.9.5.2 System calibration must duplicate normal practices, including surface condition and cou-
plant, and be verified per documented procedures using calibration standard at least every 8 hours
of operation. If the results from system verification are outside of system tolerance, assessment of
previous inspections must be made and appropriate action taken. Action taken is to be supported
by wheel reinspection data.
2.9.5.3 Records shall be maintained of system calibration and system verification.
2.9.6 Scanning
2.9.6.1 Wheels shall be inspected radially from the tread surface.
2.9.6.2 One or more transducers shall be designed and located to give maximum volumetric cov-
erage of the rim cross-section radially.
2.9.6.3 Scanning speed shall permit detection of reference standards at calibration level for auto-
mated or semi-automated systems. Manual scanning techniques shall result in the detection of the
reference standards at all times.
2.9.7 Rejection
2.9.7.1 Any wheel with a flaw indication equal to or larger than 50% of the reference standard at
the estimated discontinuity depth shall be cause for rejection. All rejected wheels must be
scrapped.
2.9.7.2 Ultrasonic indications that result from wheel geometry or spurious electrical signals shall
not be valid cause for rejection.
2.9.8 Ultrasonic Nondestructive Testing Personnel Requirements
2.9.8.1 All personnel engaged in nondestructive testing will be qualified to NDT Level I according
to the qualification requirements as defined by the American Society for Nondestructive Testing
Recommended Practice SNT-TC-1A, latest edition.
2.9.8.2 All personnel conducting inspection setups and machinery setups will be trained and
qualified to meet the criteria for NDT Level II for nondestructive testing as defined by the Ameri-
can Society for Nondestructive Testing Recommended Practice SNT-TC-1A, latest edition.
2.9.8.3 Each wheel shop will employ the services of an individual who will be trained and quali-
fied to meet the criteria for NDT Level III for nondestructive testing as defined by the American
Society for Nondestructive Testing Recommended Practice SNT-TC-1A, latest edition.
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100%
Example of a typical signal from a condemnable
defect shown on a display where the ultrasonic
device was calibrated to show 1/8-in.-diameter
flat-bottomed hole reflections at 100% screen
height. The bottom scale is in inches and
represents the depth of the defect giving the 50%
ultrasonic reflection.
100%
Example of a typical signal near a shelled or
spalled area on the tread (not always visible on the
surface). This defect is not condemnable since it
is present at a depth of 1/8 in. below the tread
surface.
50%
The 56% peak is a multiple reflection from the
1/8-in.-deep shell or spall. Wheels cannot be
rejected where there is a screen indication present
at a depth of less than 3/8 in.
0
0 0.5 1.0 1.5 2 2.5
8"
3
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3.3.2 Wrought steel wheels are made to AAR Specification M-107. Cast steel wheels are made to
AAR Specifications M-208. Both specifications cover four classes of heat-treated wheels (A, B, C,
and L, designating the carbon content of the steel). Class A indicates a relatively low carbon steel
wheel; Class B, an intermediate carbon steel wheel; Class C, a relatively high carbon steel wheel;
and Class L, a carbon content lower than Class A. Heat treatment of steel wheels is by quenching
the rim only. The quenching is followed by tempering. Rim-quenched steel wheels formerly were
identified by stamping or casting the letter R following the class letter (except this was omitted
on steel wheels for locomotives). Since 1967, the R has been omitted on steel wheels.
3.3.3 The service for which the various classes of wrought and cast steel wheels are generally
intended is described in Specification M-107/208.
3.3.4 The information included in the markings applied to wheels and the location of such mark-
ings is shown in Fig. 4.73.
3.3.5 The tape size of wheels is paint-stencilled on the back plate with figures at least 1 in. high.
3.3.6 The markings to designate the class and the method of heat treatment are as follows:
U Class U, untreated (not produced for interchange service after March 31, 1989)
A Class A, rim treated
AEa/ Class A, entire wheel treated (wrought only)
B Class B, rim treated
BEa/ Class B, entire wheel treated (wrought only)
C Class C, rim treated
CEa/ Class C, entire wheel treated (wrought only)
L Class L, rim treated
LEa/ Class L, entire wheel treated (wrought only)
a/ Note: E designation is not used after 4/1/78.
Untreated wheels (Class U) were not marked for class prior to April 1, 1978. The marking require-
ments for wheel designs are shown in Fig. 4.73.
2/1/04 G-II43
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 3.0 RP-632
3.3.7 The following abbreviations have been used to designate the brand of manufacturer; how-
ever, in 1978, the letter W was added after all single-character brands (for wrought steel wheels)
(e.g., EW for Edgewater).
Aa/ Armco
AW SCAW Metals Ltd. (South Africa)
B a/ Bethlehem (BW)
C a/ U.S. Steel Corp.Pittsburgh Plant (Carnegie) (CW)
DW Zelezarny Adratovny (Czech Republic)
E Edgewater (EW)
F ValdunesDunkerque Plant (France) (FW) (previously Creusot-Loire)
FM a/ Fundiciones De Hierro y Acero (Mexico)
G a/ U. S. Steel Corp.Gary Plant
J Sumithmo (Japan) (JW)
KWb/ Kiockner (W. Germany)
L Lovere (Italy) (LW) (previously Italsider) (previously Term) MW Mafersa (Brazil)
P a/ British SteelTempleborough and Icides Work (England)
PT ABB British Wheelsets
QW Construcciones y Auxiliar de Ferrocarriles (Spain)
RW SMR Rolling Stock Assemblies (Romania)
S Standard Steel Division (SW)
T ADtranz (previously British Steel)Trafford Park Works (England) (TW)
V ValdunesValenciennes Plant (France) (VW) (previously Usinor) (see F above)
WI Ministry of Railways (India)
Za/ Canadian Steel Wheel Division (ZW)
The following cast abbreviations are used on the plate to designate the brand of the manufacturer;
however, after about April 1,1978, two characters are used.
GCa/ Griffin, Chicago Plant
GC Griffin, Columbus Plant
GL a/ Griffin, Colton Plant
GY a/ Griffin, St. Hyacinthe Plant GI Griffin, Kansas City Plant
GT Griffin, Winnipeg Plant
GB a/ Griffin, Bensenville Plant GS Griffin, Bessemer Plant
GK Griffin, Keokuk Plant
SJ a/ Abex, Johnstown Plant CZ IochpeMaxion, (Brazil)
SO ABC Rail (previously Abex), Calera Plant
Ca/ Abex Rail, Calera Plant
The letters C, S, or T directly precede the wheel serial number
Sa/ Abex, St. Louis Plant
for wheels manufactured prior to about April 1978
Ta/ Abex, Toledo Plant
a/ Note: No longer in production.
b/ Note: No longer AAR approved.
G-II44 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-632 SEGMENT 3.0
3.3.8 Axles were formerly identified by stamping on the wheel seat collar. However, current spec-
ifications require stamping on the end face for freight car roller bearing designs and stamping on
an undercut shoulder at the journal end for passenger car roller bearing designs. Stamping details
are shown in Fig. 4.9.
3.3.9 The loading rating of the designs of freight car axles, when used under freight cars, should
be as follows:
Table 3.1 Load ratings for freight car axles
Load Carried by Each Axle Maximum Weight on Rail of Car and
AAR Axle Journal Size (Two Four-Wheel Trucks) Load Based on Four Wheel Trucks
Designation (in.) (lb) (lb)
E 6 11 52,500 220,000
F 6 1/2 12 68,750 286,000
G 7 12 76,000 315,000
K 6 1/2 9 68,750 286,000
L 68 52,500 220,000
M 79 76,000 315,000
Cars with rail loads in excess of 65,750 lb per axle cannot be operated in unrestricted interchange.
However, they may be permitted under controlled conditions where special agreement has been
reached between participating railroads to so handle.
3.3.10 When axles corresponding to the passenger car axle design, as shown in paragraph 4.0,
are used on new cars in passenger car service, the load rating of the individual axles should be as
follows:
Table 3.2 Load ratings for passenger car axles
AAR Axle Journal Size Capacity for Axles for Normal Maximum Operating Speeds of
Designation (in.) Up to and Including 85 mph 86 mph to 100 mph
D 5 1/2 10 36,000 lb 34,000 lb
E 6 11 45,000 lb 42,500 lb
F 6 1/2 12 54,000 lb 51,000 lb
2/1/04 G-II45
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
STAMP
J
IDENTIFICATION MARKS
ON THIS SURFACE
K
G
I
Y AXLES SHALL BE MACHINED TO 250
X B C D 2" MICRONS MAX. BETWEEN WHEEL SEATS
MACHINE CHAMFER +0"
(*L) 47 " "
TO 250 MICRONS MAX. W
M 16"
1
1
" R. MIN. TO 1 8 " R. MAX
16
U 16"
1
120
120
TU.N.C.2B TAP
3-HOLES COUNTERSINK 8 "
1
STAMP
IDENTIFICATION MARKS 120 LARGER THAN BOLT DIA. T. * THE L DIMENSION NEED NOT BE CORRECTED FOR
ON THIS SURFACE. REMOVE SHARP CORNERS. LENGTH EACH TIME THE WHEEL SEATS ARE TURNED
Dimensions of raised wheel seat roller bearing axles for freight cars
Rule 1.1.2
Fig. 4.1
G-II46 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
CL TO CL OF JOURNAL
BREAK P +0"
N
SHARP 1 " 1
16"
" R 1"R E E
CORNER V 1
+0"
" 1 16"
F 0.005"
STAMP
J
IDENTIFICATION
MARKS ON
G
H
THIS SURFACE 1
"R
K
II
I
8
A B1 B2 C D DI AS FORGED BETWEEN
BREAK SHARP P DJ WHEEL SEATS.
CORNER L
+0"
" M 1
16"
+0"
U 1
16"
3
"
G
64 1
" R MIN TO 1 8 " R MAX
16
R T U.N.C. 2B TAP
3-HOLES COUNTERSINK 8 " NOTE: DIMENSION V DESIGNATES MINIMUM LENGTH
1
Notes:
1. Dimension I tolerance is 0.015. 7. When black collar axles are being machined, the end chamfer shall be
2. Maximum allowable runout between G and H is .006 in. total dial indicator. machined to the tolerances shown in Fig. 4.1.
3. Maximum allowable runout between G and I is .008 in. total dial indicator. 8. Journal finish must not exceed 63 microinch, if turned or ground only. If turned
4. When required for press fit of roller bearing backing ring, the H diameter is and rolled, the turned finish must not exceed 125 microinch and the rolled
toleranced. finish must not exceed 16 microinch.
5. Check converted axles with gauge shown in Fig. 5.26.
6. Runout on journal surface G, when rotated on centers, must not exceed
.015 in. total dial indicator.
Dimensions of raised wheel seat roller bearing axles for freight cars
Rule 1.1.2
Fig. 4.2
2/1/04 G-II47
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
CORNER.
120
120
R FOR AXLE
CENTER F 0.005"
SEE
SEPARATE
H
PLATE. 1
"R
I
8
Journal dimensions for raised wheel seat roller bearing passenger car axles
Rule 1.1.2
Fig. 4.3
G-II48 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
SEE NOTE #4
U
1
"R
16
1
"R
16
G
I
K
H
G
I
1 " R
1 " R " R
A A
B D
ROLLER BEARING (BC) BLACK COLLAR ROLLER BEARING (RWS) RAISED WHEEL SEAT
A B D I K U
Axle Journal Black Collar, Raised Wheel Seat
Class Size Minimum Minimum Freight Car, Freight or Passenger
Minimum Cars, Minimum
D 5 1/2 10 11 13/16 19 15/16 19 7/16 6 3/4 7 3/16 5 3/4 65 7/8
E 6 11 12 3/4 21 3/8 20 3/8 7 3/8 7 7/8 6 5/16 66
F 6 1/2 12 13 9/16 22 3/16 21 3/16 7 7/8 8 3/8 6 3/4 66
G 7 12 13 3/8 21 9 1/4 7 7/8 67
K 6 1/2 9 12.238 19.953 8 3/8 6 3/4 69.169
Notes:
1. See paragraph 5.0 for wheel seat, journal, dust guard, and seat and 4. See Fig. 4.5 for the method of measuring roller bearing journals,
fillet gauges. Dimension G.
2. A smooth cutting file or other suitable tool should be used to break 5. Maximum allowable runout between G and H is .008 in. total dial
corners where 1/16 in. radius is shown. indicator.
3. Secondhand black collar axles, when remachined, may not exceed 6. Maximum allowable runout between G and I is .015 in. total dial
Dimension A by more than 1/4 in. indicator.
2/1/04 G-II49
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
A D
JOURNAL GROOVING FROM INBOARD SEAL WEAR MEASURING FOR UPSET JOURNAL ENDS
RING Dial or digital snap gauge must be rotated 180 around the
Rule 1.2.8 gives the accept/reject criteria and process for area where upsets occur. In order for a journal to be
repairing grooves in journals caused by inboard seal wear acceptable, the diameter in the area where upsets occur
rings. must never exceed 0.003 in. above maximum tolerance in
the table above, but may be below the minimum tolerance.
Upset ends over 0.003 in. may be corrected per Rule 1.1.5.
.750
.125 (MAX)
WHEEL FLANGE MARKS
(.14 sq. in.)
.375 sq. in.
1.500
A
.500
A
REPAIRED GALL: RADIUS OF THE DEPRESSIONS MUST BE GREATER THAN OR EQUAL
TO 8 " TO MINIMIZE STRESS CONCENTRATION. (SMOOTHLY BLENDED INTO THE CONTOUR
1
JOURNAL SURFACE
.500 NOTE:
FEATURES SHOWN ON THIS JOURNAL ARE EXAMPLES FOR CALCULATING THE
TOTAL COMBINED AREA OF ALL DEPRESSIONS IN JOURNAL SEATING AREAS.
(THE TOTAL COMBINED AREA OF ALL FEATURES SHALL NOT EXCEED 1 sq. in. PER CONE SEAT.)
SECTION AA
.062 (MAX) SCALE: 2X
2/1/04 G-II51
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
5 " (MIN)
*1.
5" R +
.0.000
05
AXLE FILLET GAGE
1 " MATERIAL: " STEEL
1
"
16
2 "
NOTE: GAUGE TO BE RELIEVED
*WEAR TOLERANCE TO BE +0.00 64" FOR THIS DIMENSION ONLY.
1
16" 2 " AS SHOWN
1
0.005" MAX
3
8 "
Note: The journal fillet area of a roller bearing axle is critical. To ensure proper fit and proper seating of the backing ring on the
axle fillet, the journal fillet gauge must be used to check the fillet radius. If a 0.005-in. feeler gauge can be inserted more than
8 in. down from the dust guard seat at all points around the periphery, the axle fillet must be corrected.
G-II52 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
FINISHED DIMENSIONS
AXLE SIZES
AXLE SIZES E - 6" 11" FOR AXLE WITH
D - 5 " x 10" F - 6 1/2 " 12" SPLINE BUSHING
FREIGHT ROLLER G - 7" 12"
BEARINGS
60
60
+ .000"
1" 8 "
1
1 8" 8"
5 1
2.000" .001" REAM
BREAK SHARP
CORNER
1 8 " 16"
1
1 " 16"
1
1
2 8 " 32"
" + 0""
1
7 16
1
16
PASSENGER
" + 0""
1
ROLLER 7
3
16
16
1 8 " MAX.
5
BEARINGS
2"MAX.
1/8" +1/32"
1 16" MIN.
9
+ 32"
0"
0"
1 16" MIN.
15
1
" 8
1 8" 8"
5 1
1" 8 "
1
1
3 8"
3
60 60
1
8 "R
1 8 " 16"
1
1 " 16"
1
1
1"
" + 0""
1
7 16
16
" + 0""
1
7 16
16
1 "
Axle centers
Rules 1.1.2 and 1.1.4
Fig. 4.8
2/1/04 G-II53
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
01
NOTE 13
00
NOTE 12 V1BW
A0
00
F
T
66
0
ROLLER BEARING 5-89 Y-AT
L
FREIGHT CARS NOTE 6 NOTE 1
ONLY
11 66 X-BN-H
USS H 8-85
NOTE 4 NOTE 8
NOTE 3 NOTE 9
Note 1. Laboratory acceptance stampfor use by purchaser to signify acceptance of axles so marked prior to shipment
by producer.
Note 2. Serial number when specified (required after 1980)
Note 3. Manufacturer name or brand:
BF Bumar Fablok S.A. (Poland)
BS a/ Bethlehem Steel Corporation, Johnston Plant
CAF Construcciones y Auxiliar de Ferrocarriles (Spain)
CBa/ Cobrasma (Brazil)
CF Valdunes, Dunkerque Plant (France) (previously Creusot-Loire)
CHT Norinco-Jinxi (China)
DDAP Dneproderzhinsk Axles (Ukraine)
DSS JSC DneproSpetsStal (Ukraine)
HM Huta Gliwice [previously Huta 1 Maya (Poland)]
JAW Standard Forged ProductsJohnston
KWa/ Kiockner (W. Germany)
L Lucchini [previously Lovere (Italy)] (previously Italsider) (previously Terni)
LCKZ LugCentroKuZ (Ukraine)
LP Lucchini Poland (Poland)
MKa/ Makrotek (Mexico)
MRF Standard Forged ProductsMcKees Rocks Forgings
MWa/ Mafersa (Brazil)
SCOT Scot Forge
SFC or SFa/ Standard Forgings
SSD Standard Steel Division
SMI Sumitomo Metal Industries Ltd. (Japan)
SPT a/ British Steel, Templeborough & Ickles Works (England)
SW SWASAP (South Africa)Dorbyl
Ta/ British Steel, Trafford Park Works (England)
THM Taiyuan Heavy Machinery (PRC)
a/No longer in production.
G-II54 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
TW plusa/ Letter T and a number in a diamond. Hawker Siddeley Canada Inc., Trenton Works
UF Ural Forge (Russia)
USS-Fa/ United States Steel Corporation Fairfield Works
USS-Ga/ United States Steel Corporation Gary Works
USS-Ha/ United States Steel Corporation, Homestead Works
V Valdunes, Valenciennes Plant (France) (previously Creusot-Loire)
WAP Ministry of Railways (India)
ZB Zelezarny A Dratovny (Czech Republic)
Note 4. Month and year made
Note 5. Letter T stamped adjacent to the heat number or the serial number. Axle has been ultrasonically inspected by
the manufacturer (stamping not required after 1980).
Note 6. Grade of axle:
U Untreated
G Quenched and tempered
F Double normalized and tempered
H Normalized, quenched, and tempered
Note 7. Heat number
Note: Stamping mounting information on axles in these locations was
Note 8. Conversion date
discontinued October 1, 1972.
Note 9. X (wheel shop symbol)
Note 10. Converted axles must be stamped with the conversion date (Note 8. location) and the letter X followed by the
wheel shop symbol (Note 9. location). Manufacturers pertinent information must be reapplied to the end of axle,
if available (Note 1. through Note 7.)
Note 11. Axles repaired by Specification M-967 processes must be stamped with the letter V followed by one or two
sequential numbers identifying the journals repaired and by the AAR-assigned identifying marks (Note 11
location). Sequential odd numbers will be used to identify journal repairs and the end of axle on which markings
are applied; sequential even numbers will be used for the other end. For example, V1BW, V23BRX means
journal at marking end of axle repaired and followed later by both journals being repaired with journal at marking
end being repaired a second time.
Note 12. Month and year repaired
Note 13. Shops that finish-machine new axles, excluding wheel seats, will show the letter Y followed by the wheel shop
symbol (Note 12 location). Axle manufacturers that finish-machine axles will use the brand shown in Note 3
above.
General Notes:
All marks will be deeply and legibly stamped with characters not less than 1/4 in. high.
Manufacturer must finish turn one end of the axle for stamping.
All elevations or irregularities should be filed or ground after stamping.
The above are the minimum marking requirements, but the locations or individual items may vary from those
illustrated.
For marking Amtrak inboard roller bearing passenger car axles, see Fig. 4.13.
Markings illustrated in the figure for roller bearing axles for freight cars show markings that may be on either new
or old axles, depending on requirements in effect at the time the markings were applied.
a/No longer in production.
2/1/04 G-II55
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
3
32 " R .010"
ROLLER BEARINGS
5 8 " DIA
4" DIA.
5
3 8"
3
11
" R .010"
16
16" R .010"
11
3
" R .010"
32
0- 49'
1"
1 8" 1 16"
1 3
G-II56 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
Operation:
1. Remove protective covers from rollers.
2. Place the axle in the fixture so that rollers support the journal surface at a point as close as possible to the fillet.
3. Attach the dial indicator to the stand and set it up to record readings about 1/4 in. to 1/2 in. from the end of the journal.
Plunger of indicator should be normal to the longitudinal centerline of the axle.
4. Rotate the axle one or two turns to locate the low or minimum reading and set the dial indicator to zero at this point.
5. Continue to rotate the axle in the same direction, noting indicator variation. At the end of each revolution, the dial will
return to zero if it has been set up properly.
6. A maximum runout of 0.010-in. total indicator reading is allowed.
2/1/04 G-II57
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
K
G
J
I
OVERALL
H
O
Notes:
1. Oversize axles may be 0.030 in. larger than shown under Dimension I.
2. Dimension O may be +1/32 in. or 3/63 in.
3. Other axle dimensions are to be the same as for the inboard bearing axle, Fig. 4.13
Road Limits (in.)a/ Shop Limits (in.)b/
Journal When Less Than New Dimensions (in.)c/
When Less Than
Size (in.)
I K I U O K I J K G H O U
6 1/2 12 5 7/8 6 1/8 5 7/8 35 7/16 70 61/64 6 1/8 6 1/8 6 5/8 6 1/4 6.1915 6.502 71 35 1/2
6.1905 6.500
a/ Requires the removal of the axle from service.
b/ Axles must not be applied in passenger service or under foreign equipment if not within these limits.
c/ See Note 1 and Note 2.
Table of new and limiting dimensions for inboard roller bearing axle
Rule 1.1.2
Fig. 4.12
G-II58 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
FINISHED AXLE
A .03 TYP
B 5.90 C
5.69 .015 DIA. 3.00 R .38 TYP
6.502 DIA. 1.25 7.00
5.81 .015 DIA. 6.500 17.75.015
35.50.015
15.95
46.00 JOURNAL CENTERS REF
71.00 +.052
.046
METHOD OF COLD ROLLING RELIEF GROOVES LABORATORY ACCEPTANCE, MANUFACTURERS NAME OR BRAND,
NOTES: MONTH & YEAR, HEAT NUMBER, SERIAL NUMBER, GRADE OF AXLE
1. MATERIAL AAR, M-101 GRADE F, THE AXLE OTHERWISE MUST AND PART NUMBER TO BE STAMPED ON ONE END OF AXLE TUBE
BE IN COMPLIANCE WITH AAR SPECIFICATION M-101, LATEST BY MANUFACTURER & TRANSFERED TO FINISH AXLE IN THE
REVISION. PRESENCE OF RAILROAD COMPANY INSPECTOR UNLESS, WAIVED
2. ROUGH MACHINED AXLE TO BE SUB CRITICALLY QUENCHED BY RAILROAD COMPANY.
FROM 1000 TO 1050F IN WATER. ALLOW .187" OVER FINISHED DATE OF APPLICATION AND PLACE WHERE MOUNTED TO BE
DIAMETERS. RELIEF GROOVES TO BE MACHINED AND COLD STAMPED ON OPPOSITE END OF AXLE BY BUILDER OR RAILROAD
ROLLED AFTER SUB CRITICAL QUENCHING. COMPANY.
3. FINISH MARKS REMOVED IN 1982 REVISION.
Journal dimensions for Amtrak inboard roller bearing passenger car axles
Rule 1.1.2
Fig. 4.13
2/1/04 G-II59
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
50
25
20
15
10
8
6
4
3
2
15
10
DEPTH OF SETTLING
INDICATES BATH STRENGTH
Recommended procedure for checking magnetic particle solution for concentration and contamination
Rules 1.1.8 and 1.7.2
Fig. 4.14
G-II60 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
RADIAL ERROR
SEE INSET -
GAGE END OFFSET
BORING BAR
PLANE ERROR
WELDED
TO TOOL SHANK
G-II62 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
2/1/04 G-II63
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
G-II64 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
Table 4.2 Mounting pressures for WC-10 wheel mounting compounds only
Steel Wheels
Class of Axle Journal Size (in.)
Min Max
D 5 1/2 10 92 150
E and L 6 11 92 150
F and K 6 1/2 12, 6 1/2 9 98 160
G and M 7 12 108 170
F Passenger Car 6 1/2 12 inboard bearing axle 70 120
Note: Mounting pressures outside the limits shown above indicate improper interference fit or improper
lubricant ,and corrections must be made.
2/1/04 G-II65
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
180
160
140
120
100
80
60
40
20
G-II66 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
0 30 90 160
3. Draw the following diagram on a piece of mylar or other suitable dear plastic. Use a black pen for the coordinates and
return line (solid lines) and a pencil for all other lines (dashed).
B
A
0 30 Minimum Maximum
Tonnage Tonnage
4. Using a red pen, draw in the dashed lines shown in the figure below. Draw in the dash-dotted line with a green pen and
the dotted lines with a blue pen.
75% fit
0 30 Minimum Maximum
Tonnage Tonnage
2/1/04 G-II67
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
C.
0 30 Minimum Maximum
Tonnage Tonnage
0 Minimum Maximum
Tonnage Tonnage
Example of an ideal mount. There are no discontinuities and the tonnage builds up smoothly and fairly linearly throughout
the mount. Note that the slope starts out near zero to slightly positive for the first 10%20% and then gradually increases
until mounting is complete.
An example of an ideal mount
Rule 1.4.1 and Paragraph 2.3.5
Fig. 4.22
75% fit
0 Minimum Maximum
Tonnage Tonnage
Example of an acceptable amount whose tonnage dropped off in excess of 15 ton but not until after 75% of the fit was
achieved. The shape of this chart is indicative of too much mounting compound or a negative taper near the end of the
wheel seat and/or bore. Distribution of the radial clamping force over the length of fit is more important than the degree
of fit lost at the end of the mount. The jog in the middle of the mount is transient in nature, drop-off less than 2 ton, and
is imperceptible on most mounting charts.
Example of an acceptable amount
Rule 1.4.1 and Paragraph 2.3.5
Fig. 4.23
G-II68 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
75% fit
0 10 30 Minimum Maximum
Tonnage Tonnage
Example of an acceptable mount that exhibits both slip-stick and spiking. Slip-stick is a product of incompatible
surface finish between the wheel bore and axle seat. It does not cause false tonnage or alter the dependability of the
mount in any way. It is acceptable provided the wheels are centered and in gauge, the lowest concise tonnage is above
minimum allowed, and it does not occur until after the wheel is over 75% mounted.
Depending on surface finish and lubrication, it is normal for the coefficient of static friction to be as much as three times
the coefficient of sliding friction. This difference accounts for some level of acceptable spiking (historically about 30 tons).
Any misalignment multiplies this difference and compounds the amplitude of the spike. Tonnage will typically increase to
the value needed to overcome static friction and the wheel will start to slide onto the axle. Almost immediately after
motion begins tonnage will drop back to the value required to overcome sliding friction. The tonnage at the peak of the
spike should not exceed three times the drop-back tonnage or 30 tons, whichever is smaller.
Example of an acceptable mount
Rule 1.4.1 and Paragraph 2.3.5
Fig. 4.24
0 Minimum Maximum
Tonnage Tonnage
Example of a misfit that appears to have achieved minimum tonnage but the final tonnage is not concise. The dark area
assumed to be slip-stick could have been drawn in. The highest tonnage that is concise is below minimum tonnage.
Example of a misfit where the final tonnage is not concise.
Rule 1.4.1 and Paragraph 2.3.5
Fig. 4.25
2/1/04 G-II69
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
0 Minimum Maximum
Tonnage Tonnage
Example of a misfit whose peak tonnage exceeds the minimum tonnage but the tonnage where motion stopped was less
than the minimum tonnage. The false tonnage generated by the spike provides no additional energy to overcome in the
demount process. The area bounded by the dotted line represents the energy loss associated with the false tonnage.
Example of a misfit whose peak tonnage exceeds the minimum tonnage
Rule 1.4.1 and Paragraph 2.3.5
Fig. 4.26
75% fit
0 Minimum Maximum
Tonnage Tonnage
Example of a misfit that does not continue to build tonnage up to the 75% fit line. Note that there is no tonnage drop off.
This energy was lost due to lack of fit over more than 25% of the wheel seat.
Example of a misfit where tonnage does not build up to the 75% fit line
Rule 1.4.1 and Paragraph 2.3.5
Fig. 4.27
This is the false This area represents the energy
energy generated difference between this mount and
by the obstruction an ideal mount of the same tonnage.
0 Minimum Maximum
Tonnage Tonnage
Example of a misfit caused by an obstruction or by excessive positive taper in the second half of the wheel seat and/or
bore. Were it not for the obstruction or taper problem, the chart would not have made minimum tonnage.
Example of a misfit caused by an obstruction or by excessive positive taper
Rule 1.4.1 and Paragraph 2.3.5
Fig. 4.28
G-II70 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
0 10 30 Minimum Maximum
Tonnage Tonnage
Example of a misfit that indicates an alignment problem. The spike exceeded 30 ton, and the peak tonnage was more
than twice the fall-back tonnage indicating that the coefficient of static friction was more than three times the coefficient
of sliding friction. An undetermined amount of the energy applied was needed to overcome the misalignment and cannot
be attributed to fit.
Example of a misfit indicating an alignment problem
Rule 1.4.1 and Paragraph 2.3.5
Fig. 4.29
CL AXLE
Scribe mark at center from each end of axle, adjusting scribe until exact center is found.
Axle centering gauge
(for working drawings of gauges, see paragraph 5.0)
Rule 1.4.5 and Paragraphs 2.3.8 and 2.3.10
Fig. 4.30
CL
Mount first wheel until gauge contacts scribe mark at center of axle. Second wheel may be mounted with this gauge, but
wheels must be checked with back-to-back mounting gauge.
Gauge for locating first wheel
(For Working Drawings of Gauges, See Rule 5.0)
Rule 1.4.5 and Paragraphs 2.3.8 and 2.3.10
Fig. 4.31
2/1/04 G-II71
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
1 "
1 "
Gauge for mounting second wheel
(for working drawings of gauges, see paragraph 5.0)
Rule 1.4.5 and Paragraphs 2.3.8 and 2.3.10
Fig. 4.32
MOUNTING DIMENSIONS
WHEELS ARE OUT OF GAGE IF THIS DIMENSION
FOR ALL FREIGHT CAR
WHEELS AND WIDE FLANGE FOR OTHER THAN
PASSENGER CAR WHEELS FREIGHT CAR WHEELS
53 32" IN.
3
IS LESS THAN 53 IN.
53 8 " IN. 53 8 " IN.
3 3
EXCEEDS
Gauge limits for mounting wheels for freight cars and passenger equipment cars
Rules 1.4.5, 1.5.3, and 1.7.9 and Paragraphs 2.8.2 and 2.8.17.1
Fig. 4.33
SHOP CODE
YEAR
B
COMPANY 72
GW
MONTH
6
Note: Mounting stamping should be of sufficient depth that it will not disappear easily due to wear and/or corrosion.
Method of permanently stamping front face of wheel hub at wheel mounting shop
Rules 1.4.11 and 1.7.10
Fig. 4.34
G-II72 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
Plane
2/1/04 G-II73
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
5.7188 + 0.1250
0.1250
3.0625
+ 0.0313
R 1.5000 + 0.0625
0.0625
1.3750 0.0938
0.0370 75 R 0.6250
R 0.6875
R 0.3750
GAUGE
0.3754 POINT
1.0000+ 0.0625
0.0000
TAPER 1:20
(1:17 1:23)
1.8232 BASELINE
R 0.5625+ 0.0625
0.0625
TAPE LINE
R 2.6250
R 0.6250
5.0938
F
Centers of Radii Relative to
R 0.6250 Gauge Point
R 0.6875
R 0.3750
Point X Y
GAUGE POINT A 1.1969 1.1499
B B 0.5890 0.2496
E D
C 0.5890 0.3121
C
R 0.5625 D 0.3622 0.0971
E 0.5803 0.0075
R 1.5000 R 2.6250
F 1.0603 0.8128
A Intersection Points
Relative to Gauge Point
GAUGE POINT 3
Point X Y
4
5 2
1 1.3750 0.6246
2 1.1471 0.0318
6
3 0.5890 0.3754
7 BASELINE 1 4 0.0901 0.1610
9 8 5 0.0000 0.0000
6 0.0370 0.1381
7 0.2923 0.4757
8 0.6314 0.6246
9 0.9854 0.6853
5.7188 + 0.1250
0.1250
3.0625
R 1.5000 + 0.0625
0.0625
1.1563 + 0.0625
0.0000
0.0084
0.0370 75
R 0.6875 R 0.3750
R 0.3750
0.3750
1.0000+ 0.0625
0.0000
TAPER 1:20 GAUGE
(1:17 1:23) POINT
BASELINE R 1.3750
1.8030
R 0.5625+ 0.0625
0.0625
TAPE LINE
R 0.6250
5.0938
Intersection Points
Relative to Gauge Point
GAUGE POINT 3
Point X Y
4
5 1 1.1563 0.4434
2
2 0.8501 0.2407
6
3 0.5625 0.3750
7 1 4 0.1403 0.2301
8 BASELINE 5 0.0084 0.0312
9
6 0.0286 0.1069
7 0.2840 0.4445
8 0.7485 0.6250
9 0.9771 0.6542
5 " 8 "
1
+
1
"
1
11
"
16 1 32" 0"
5 16
GAGING POINT
31
32 " 1 " 5
8 "
TAPER 1" IN 20"
5
8 "R
5
8 "R
+ 16"
1
11
" R
16
1
"
16
1" 0"
5
8 " 29
32 "R
BASE LINE
1 8" R
7
TAPING LINE
2
31
"R
32 1
16 "
5
8 "R
3
64 "
VERTICAL
REFERENCE
LINE
Narrow flange tapered tread contourlocomotive and Amtrak (formerly Standard S-621-79)
5 " 8 "
1
+
1
"
1 32" 0"
5 16
2" 1 " 5
8 "
CYLINDRICAL TREAD
1
11
"
16
31
32 "
TAPER 1" IN 20" GAGING
POINT 5
"R
5
8 "R 8
+ 16"
1
11
16 " R 1
"
16
1" 0"
5
8 " 29
32" R
1 8" R
7
TAPING LINE
2
31
"R
32 1
16 "
5
8 "R
VERTICAL 3
64 "
REFERENCE
LINE
6.500
3
8 " 1.469
3
8 "
A
WHEEL CONTOUR ACCEPTANCE GAUGE
FOR AAR 1B NARROW & WIDE FLANGE
INTERSECTION POINTS
1 (0.0841873, -1.49764) R1.500
2 (0.4289, -1.4374) B 5 1.094
3 (0.769141, -1.2878) 2.8624 4
4 (1.02338, -0.950724)
5 (1.0603, -0.8128) BASELINE 3
1 2 R.5625 4.000
CENTERS OF RADII
A (0.000, 0.000) 1.987
B 0.480, -0.8053)
VERIFY WITH CONTOUR MAPPING MATERIAL:
MAX MANUFACTURE DEVIATION: .003" STAINLESS STEEL 17-7
8 " THICKNESS
1
MAX RECERTIFICATION DEVIATION: .005"
HARDENED
.750
Acceptance gauge for AAR 1B narrow and wide flange steel wheels
Rules 1.5.2 and 1.5.3
Fig. 4.38
2/1/04 G-II77
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
NOTE: 1/32-IN. PIN MUST NOT PASS UNDER GAUGE AT ANY POINT.
G-II78 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
NOTE: 1/32-IN. PIN MUST NOT PASS UNDER GAUGE AT ANY POINT.
2/1/04 G-II79
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
R.3750 R.5875
F 3 R.6250
R1.5000 4 2
5
E B 1.000
6 D
2.8624 C
1.8232
BASELINE 7 1
9 8
R2.6250
R.5625
R 8"
5
A
R R
2
5.0938
5.7188
G-II80 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
F R.5875 R.3750
R1.5000 3
R.3751 4 2
5
C 1.000
TAPER 1:20 E D
6
(1:17 1:23) 2.8624
7 B
BASELINE 8 1
9 A
R1.3750 R.5625
R 8"
5
2 32"
11
R R
2
5.7188
2/1/04 G-II81
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
NOMINAL AAR 1B
CONTOUR
.357
BASELINE
2.876
CONDEMNING LINE
(FREIGHT CAR SERVICE)
MEASURING POINT
The pointer indicates amount of metal in sixteenths of an inch to be turned off tread to restore full
flange contour with a witness groove. The side scale shows amount of metal on tread above
measuring line before turning. In this illustration, 7/16 in. must be turned off tread to restore full flange
contour. The amount of service metal available after turning is 6/16 in. A finger marked NF or a
finger having no identifying marking is used for gaging the flanges of steel wheels used on freight
cars, passenger cars and locomotives. The WF finger may be used when restoring wide flange
contour to wheels.
G-II82 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
65
4
3
2
1
0
9 8
6
4
2
0 0
3
8 "
BASELINE
2 8"
7
3 FRT
4 SCRAP
PASS
1 ---
SCRAP
1 12
2
2 12
65
4
3
2
1
0
9 86
0 4
2
0
7
16 "
3
8 " 3 FRT
4 SCRAP
CONDEMING LINE PASS
1 ---
" (FREIGHT CAR SERVICE) SCRAP
1 12
MEASURING POINT 2
2 12
The pointer indicates amount of metal in sixteenths of an inch to be turned off tread to restore full
flange contour with a witness groove. The side scale shows amount of metal on tread above
measuring line before turning. In this illustration, 7/16 in. must be turned off tread to restore full flange
contour. The amount of service metal available after turning is 6/16 in. A finger marked NF or a
finger having no identifying marking is used for gaging the flanges of steel wheels used on freight
cars, passenger cars and locomotives. The WF finger may be used when restoring wide flange
contour to wheels.
2/1/04 G-II83
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
"A"
GAUGE APPLIED
TO OUTSIDE OF
FLAT SPOT
CONDEMNING LINE
(FREIGHT CAR SERVICE)
MEASURING POINT
"B"
GAUGE APPLIED
IN FLAT SPOT
CONDEMNING LINE
(FREIGHT CAR SERVICE)
MEASURING POINT
Method of applying AAR steel wheel gauge to measure amount of metal to be turned off tread to remove flat spot and
also extra metal to be turned off to restore flange contour
AAR steel wheel gauge
Rule 1.5.2
Fig. 4.45
G-II84 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
65
4
3
2
1
0
9 86
0 4
2
0
7
16 "
3
8 " 3 FRT
4 SCRAP
CONDEMING LINE PASS
1 ---
" (FREIGHT CAR SERVICE) SCRAP
1 12
MEASURING POINT 2
2 12
SKETCH A
GAUGE APPLIED OUTSIDE OF FLAT SPOT
65
4
3
2
1
0
9 86
4
0 2
0
5
16 "
3
8 " 3 FRT
CONDEMING LINE 4 SCRAP
PASS
" (FREIGHT CAR SERVICE) 1 ---
SCRAP
1 12
MEASURING POINT
2
2 12
SKETCH B
GAUGE APPLIED IN FLAT SPOT
Method of applying AAR steel wheel gauge to measure amount of metal to be turned off tread to remove flat spot and
also extra metal to be turned off to restore flange contour
AAR steel wheel gauge
Rule 1.5.2
Fig. 4.46
2/1/04 G-II85
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
NOT3 MORE
THAN 64" DEEP
Method of applying AAR steel wheel gauge to check depth of witness groove in flange
AAR steel wheel gauge
Rule 1.5.2 and Paragraph 2.4.3
Fig. 4.47
NOT LESS
THAN 8 "
3
Method of applying AAR steel wheel gauge to check location of witness groove in flange
AAR steel wheel gauge
Rule 1.5.2 and Paragraph 2.4.3
Fig. 4.48
G-II86 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
9 86 4
0
2
0
65
4
3
2
1
0
NOT MORE THAN
64" DEEP
3
3
4 SCPASS---
FRT P
1 SCRA
RA
P
12
1
2
2 2
1
3
Method of applying AAR steel wheel gauge to check depth of witness groove in flange
AAR steel wheel gauge
Rule 1.5.2 and Paragraph 2.4.3
Fig. 4.49
3
2 21
2
1 21
SCRAP
1 ---
PASS
4 SCRAP
3 FRT
0 0
2
4
6
9 8
NOT LESS 0
1
THAN 8 "
3 2
3
4
65
BASELINE
Method of applying AAR steel wheel gauge to check location of witness groove in flange
AAR steel wheel gauge
Rule 1.5.2 and Paragraph 2.4.3
Fig. 4.50
2/1/04 G-II87
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
1"
Condemning limit for flange height using AAR steel wheel gauge when apex of flange contacts underside of horizon-
tal member, wheel is condemnable
AAR steel wheel gauge
Rule 1.5.2 and Paragraphs 2.8.2, 2.8.11, and 2.8.12
Fig. 4.52
2/1/04 G-II89
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
G-II90 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
2/1/04 G-II91
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
G-II92 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
2/1/04 G-II93
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
G-II94 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
G-II96 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
ADAPTER SHOE
REACH RODS
PRESS RAM
PILOT SLEEVE SOLID
PULLING RING
PULLING RING ADAPTER
DUST GUARD RING
BEARING ASSEMBLY
2/1/04 G-II97
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
A 64"
1
1
" 45 CHAMFER
8
DRILL ONE
A HOLE F DIA.
BOTH ENDS
DRIVE FIT
3"
.000"
DIA. + .002"
1 " 1 "
CIR BOLT " R "
DIA. .002"
E "
CL
1 "
.
1"
D DIA
C
30
DIA.
DRILL E DIA.
G
A
" 45 CHAMFER
1 SECTION AA
8
PILOT SLEEVE
BOTH ENDS
N " P
1 " 3
"
16 1"
DIA.
DIA.
M
12" R
" R
DIA. .002"
1"
DIA.
" 3"
J
TO 190242 BRINELL L H
MOUNTING SLEEVE
Spring loaded pilot and assembly sleeve for application to press ram for mounting bearings
2/1/04 G-II99
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
Note: Amtrak inboard bearing seating pressure is 50 5 ton maximum for all sizes. Seating pressures shown are the final
pressure gauge reading that is required to properly seat the bearing backing ring against the axle fillet radius.
Seating pressures to be posted in work area in roller bearing mounting shops
Rule 1.8.2.8
Fig. 4.64
CAP SCREW
CAP SCREW
LOCKING PLATE
LOCKING PLATE
REDUCING
BUSHING
LUBRICANT
FITTING
CA-PLUG
NEOPRENE
GASKET
LUBRICANT
FITTING
CLASS EE CLASS G
Comparison of Amtrak axle end cap assemblies
Rule 1.8.3.1
Fig. 4.65
G-II100 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
Cap Screw
Class Journal Size (in). Size Torque (ftlb)a/
For Freight Cars
D 5 1/2 10 7/89 160
E 6 11 18 290
F 6 1/2 12 1 1/87 420
G 7 12 1 1/47 490
K 6 1/2 9 1 1/87 420
L 68 18 290
M 79 1 1/87 420
For Amtrak Cars
6 1/2 diameter 7/89 315
G (High Strength)
7/89 145
EE 6 diameter 7/89 145
EE 5 1/2 diameter 3/410 115
a/ Torque wrenches must be accurate within 4 %.
Cap screw torque is in ftlb. It is to be posted in the work area in roller bearing mounting shops.
Tabs bent against alternate flats Preferred bending when one tab is centered on corner
Note: After proper torque is attained, cap screws must never be repositioned for alignment of tabs to flats.
Proper method for securing locking plate
Rule 1.8.4.3
Fig. 4.67
2/1/04 G-II101
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
Using a magnetic base dial indicator, place the base on its outer ring with the dial indicator anvil
resting on the bearing cap screw or the wheel hub.
G-II102 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
Notes:
1. Mounted lateral is 0.006 .020 for Amtrak F (6 1/2 12) inboard, G (6 1/2-in. diameter), EE (6-in. diameter) and
EE (5 1/2-in. diameter) bearing applications.
2. If a tapered bearing rotates freely by hand but indicates less than .001-in. lateral on the dial indicator, the application is
satisfacory for service.
2/1/04 G-II103
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
G-II104 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
Torque Wrenches
S/N _____________ Set at ________________ ftlb Tested__________________ Date By _________________
S/N _____________ Set at ________________ ftlb Tested__________________ Date By _________________
G-II106 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
01
NOTE 13
00
NOTE 12 V1BW
A0
00
F
T
66
0
ROLLER BEARING 5-89 Y-AT
L
FREIGHT CARS NOTE 6 NOTE 1
ONLY
11 66 X-BN-H
USS H 8-85
NOTE 4 NOTE 8
NOTE 3 NOTE 9
2/1/04 G-II109
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
Instructions: This report is to cover wheels which are removed for defects, represented by the following WHY MADE CODES 66, 68,
71, and 83 (see Field Manual of AAR Interchange Rules, Rule 41). All items should be completed. If the numbers or letters are illegible,
draw a horizontal line in the box or boxes affected.
G-II110 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
YEAR YEAR
8
8-20-78
DESIGN MFGR.
90 C
MONTH
SERIAL YEAR MFGR.
PLATE MARKING (ABEX)* NUMBER
CLASS RIM STAMPING
SERIAL
NUMBER 731
133 CW 62247 B J36
94
MONTH 06 74 CW
62247
O6
12
SERIAL
B MFGR.
NUMBER
YEAR
78 CW B
DESIGN
J36
DESIGN
B
CLASS
J 36
Measure, as shown to the left, with a steel wheel When wheel plates are marked as above, enter SO
gauge or simplified wheel gauge. Check the for ABEX (Southern) under manufacturer.
appropriate plate type in box on reverse.
4 " 4 "
56 "
56 " 56 "
Storage track arrangement for wheel and axle assemblies having applied roller bearings
with housing end covers that rotate
Rule 1.7.5 and Paragraph 3.2.3
Fig. 4.74
7" 12"
11.063"
11.563"
7" 14"
NOTES:
1. A 7" 12" BEARING APPLICATION USES A BACKING RING FITTED ON THE DUST GUARD DIAMETER.
2. A 7" 14" BEARING APPLICATION USES A NONFITTED BACKING RING.
3. AXLE END CAPS ARE MARKED ARE MARKED 7" 12" AND 7" 14", BUT ARE INTERCHANGEABLE BETWEEN ASSEMBLIES.
THE BACKING RING DESIGN SHOULD THUS BE THE DETERMINING FACTOR FOR PROPER JOURNAL APPLICATION.
4. IMPORTANT: THE 7" 14" BEARING APPLICATION IS NOT AN APPROVED AAR STANDARD.
5. THE 7" 12" BEARING APPLICATION UTILIZES EITHER A ONE PIECE OR A TWO PIECE BACKING/WEAR RING,
DEPENDING UPON THE MANUFACTURER SUPPLYING THE BEARING.
Differentiation between 7 12 and 7 14 bearing application
Rule 1.8.2.1
Fig. 4.75
G-II112 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-633 SEGMENT 4.0
Examples
Cause of
Helpful Hints for Causes of Hot Boxes Initial Defect
Heat
1. Either a loose cap screw, loose hacking ring, undersize journal, or worn cone face will C A 1 C N 4
allow cones to revolve on the journal and possibly cause rollers to break or spall.
2. Heavily spalled or worn cone raceway or spalled or worn rollers will cause heavy dam- C U 2 L U 1
age to seal lips. Grease will leak from the bearing and foreign matter will enter.
3. A journal with an upset end will stretch the cone bores, allowing the cone to break or J R 2 C N 4
revolve on the journal.
4. Seal loose, cut, ruptured, or worn, or casing dented will allow grease to leak out of the S E 1 L U 1
bearing and foreign matter to enter.
5. A bearing overheated externally will show signs of the seal rubber embrittled and the B E 2 L U 1
grease hardened or the oil evaporated from the grease leaving the soap behind.
6. A defective adapter will cause an uneven load distribution on the bearing cone assem- A D 1 C U 2
blies.
7. A cap screw too long or the cap screw hole defective with rust, partially closed, or hav- C A 2 C N 4
ing faulty threads will prevent the end cap from seating properly against the outboard
seal wear ring. Therefore, insufficient clamp will be provided and the bearing will be-
come loose on the journal while in service.
Explanation of Initial Defect and Cause of Heat
The Cause of Heat is the detect that obviously caused the bearing to be reported hot.
This obvious defect may be the result of another defect called Initial Defect. Always try
to determine the Initial Defect. If the Initial Defect cannot be determined, list the same
cause code under both Cause of Heat and Initial Defect.
Part IVProbable Factors/Parties Contributing to Bearing Failure
The information used to trace contributing factors/parties can be found on locking plates, R E 6
internal cup markings, and/or by identifying the RR handling the equipment. One or more 157 158 159
categories may apply.
Example
Improper bench lateral combined with poor clamp/inspection techniques B M 4
160 161 162
QSXK
RBXM
6/88
R
EC
1/94
BNSQ
2/1/04 G-II115
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 4.0 RP-633
Manufacturer Class A-28 E-28 A-30 J-33 M-33 P-33 H-36 J-36 B-38 E-40 C-42
Standard Steel A
Manufacturer Class CA-28 CE-28 CA-30 CJ-33 CM-33 CP-33 CH-36 CJ-36 CB-38 CE-40 CC-42
ABC Rail A
2/1/04 G-II117
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 5.0 RP-634
" 6
5
4
GAGE
AAR STEEL WHEEL
16"
3
" 3
2
1
COUNTERSINK 3
" 32 0
1
3 16
GAGE BODY
"R
1
3 16
A TOL.
1.3987
1.5451
1.6941
1.7318
1.8838
2.0384
2.1959
"
.005 1
8 "
30
CL
1380
3
8 "
1
"
64 MEASURING LINE
49
64" 0 AT 4 1.250
3
"
21
" 9
16 " 7
"
3 16"
11 32 32
3
16 " 8 0 AT 3 1.1875
3
16" R
0 AT 2 1.1719
2 64"
23 9
16 "R 0 AT 1 1.1094
1
64 "
2.013 0 AT 0 1.0469
2.015
.250 REAM 58 1
"R
1 " 15 ' 16
.251
.007
.380
.370
.456
.458
65
"R
.876
.848
.877
.873
.005
1.002
0.998
7
8 "R 4
3 45 TO BE CALIBRATED
2.378
2.376
1
2
AS FOLLOWS:
0
0 TO 2 .056
"R
" R
1.921
1.919
7
"R
16
9
16
1" +.005
.003
.248 NF 2 TO 3 .043
2.255
2.245
1
" .252
2"
25
" 4 TO 5 .051
32 1
16 " 10 8
6
4
5
" NUMERIALS
64 5 TO 6 .037
60 2 1
" 6 TO 7 .041
FRT SCRAP
1
"
16 "R 0 16
3.755
3.745
1
"
16 2.877 7 TO 8 .045
2.873 38 .007 8 TO 9 .058
10 53 50' "
3
.005 32
20 16
07
24 60
.002 BETWEEN
2 "
" 28
5 43 64"
32
1
8 "
40
44 3
"
48
3
"
64
64 TO BE CALIBRATED
AS FOLLOWS:
1
" 1
" 1
" WF 0 TO 2 .079
8 16 8 1
8 "
1
"
8 2 TO 3 .047
" LETTERS 810 3 TO 4 .042
16" 46
1
3
" 2 4 TO 5 .042
8 5
" NUMERALS 0
.752 64 5 TO 6 .037
.748 1
"
16
6 TO 7 .047
8 16' 46" 7 TO 8 .063
4" 8 TO 9 .068
33' 1 9 TO 10 .084
30
10 TO 11 .107
TOL .002 BETWEEN
ANY TWO POINTS
.251A
Finger Radii Centers R1.3125 R.3125
0.3125 (0.00, 0.00) R.7656
0.251A (0.00, 0.00) .251B
NF
WF
0.251B (0.755726, 0.685488) R.1875
1.3125 (0.0536604, 0.999073) 9 8
6
4 R.5625 8
10
4 6
0
2
1.562 (0.00, 0.00) .126
0
R1.562
0.126 (0.00, 1.49899) WIDE FLANGE
0.5625 (0.0332779, 20.874367) MARKINGS
(OPTIONAL)
0.1875 (1.24331, 0.610423)
3.39
2.36
2.014
.188 1.139 .157
R.88
2.375 17
1
.719 R.50
3.129 1.562
1.918
1.500
0
.781 1.63
R.50 38.833 MATERIALS:
0 RIVET & THUMB KNOB
.063 5.125 303 STAINLESS STEEL
SCRAP
.063
R.25
FRT
2.876 8
BODY & FINGER
3
12 7 4 STAINLESS STEEL 17-7
16 8 HARDENED
1
20
1
.34 .125 24
1
.14 TYP. 28
.14 .50 2.543 32
2 .25 IN. LINE
.0625 36
.25 TYP. 40
2 .125 IN. LINE
.19 44
1.00 .13
.047 48
STAINLESS STEEL RIVET
STAINLESS STEEL
THUMB KNOB
BLACK SPRING
WASHER
21
20
19
A 18 2.203
0
4 2
0 AT 22 1.375 17
1 2.045
9 8 6
0 AT 21 1.313 1.730
0 AT 20 1.250
0 AT 19 1.188 1.581 1.882
0
0 AT 18 1.125 A 1.434
0 AT 17 1.063
0
21
20
19
18
PROVIDE RELIEF
17 WHEN MARKED
1 FOR WIDE FLANGE
9 8
6
4
2
6
0
4
0
2
0
B C
AT C
0 1.483
AT B 2 1.408
0 1.264 3 1.364
2 1.210 4 1.323
3 1.168 5 1.283
4 1.120 6 1.248
5 1.070 7 1.203
6 1.034 8 1.142
7 0.995 9 1.077
8 0.951 10 0.997
9 0.894 11 0.896
5
"R
16
1 16"
5
3 16"
11
1.562
2 64"
1
1 " 1.267
9
"7
16 1.270
8 "
3
16 "R "
5
" " R 3
8 "
.872
.878
16
5R
.87
9
"R 45
.442
.424
16
1
64 "
" R
2.375
.007
1.5 562
2.500
58
67
1.
.005
"R
45
16
7
38 50'
3.750
" R 0
2 "
1.498
1.500
1
16 "
0
60
SCRAP
1
"
16
" R
FRT
THUMB KNOB " DIAMETER
1
"
.751
.753
16
12 "
2.875
NF 16
" LETTERS 20
1
16 "
90 3
8 "
24 60
9 8 " NUMERALS
6 5
64 28
4
2 32
5 8"
"
0
64
5
29
2
N.F. FINGER 36
.007
38 50' .005 SPRING WASHER 40
53
" 44
TO BE CALIBRATED
3
"
16 " 48 1
8 "
AS FOLLOWS: .047*
0 TO 2 .056 GAGE BODY 1
8 "
2 TO 3 .043 1
8 "
3 TO 4 .049
1
16 "
4 TO 5 .051 3
8 "
5 TO 6 .037
.750"
6 TO 7 .041
*WEAR LIMIT FOR THIS DIMENSION
7 TO 8 .045 ONLY IS 0.037-IN.
8 TO 9 .058
TOL = .002 BETWEEN ANY
TWO POINTS
NOTE: "STEEL WHEEL GAUGE1976" TO BE SUITABLY MARKED ON BACK SIDE OF GAUGE IN APPROXIMATELY 8 " LETTERS
1
MATERIAL: .093" STAINLESS STEEL FOR BODY OF GAUGE AND .050 STAINLESS STEEL OF SUITABLE HARDNESS FOR GAUGE
FINGER. TOLERANCES FOR DECIMAL DIMENSIONS ARE TO BE .005" AND FRACTIONAL DIMENSIONS ARE TO
BE 64" UNLESS OTHERWISED SPECIFIED. REMOVE BURRS AND SHARP EDGES.
1
2/1/04 G-II121
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 5.0 RP-634
3
11
"
16
1 "
" R SIMPLIFIED 7
8 "R
WHEEL GAUGE
2 8"
3
19
"
32 " R 7
"R
16
1.505"
1.500"
" R 2 "
25
32 "
" R
1
16"
1.000"
.995"
.875"
.870"
.750"
.745"
1
"
16
"
7
"
5 8"
8 5
1"
2 8"
7
STENCIL
" HOLE
"
(FOR GROOVED TREAD MEASUREMENT)
MATERIAL: .093 STAINLESS STEEL. UNLESS OTHERWISE STATED ALL TOLERANCES ARE .010" . REMOVE
BURRS AND SHARP EDGES.
G-II122 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-634 SEGMENT 5.0
11 9
1
8 "
9 10
1
8 " 3
8 12
1
8 "
6 1
4 5 1 "
45 CHAMFER 9 8"
5
1
8 "
5 2 8"
5 HARDEN TIP
47 8 "
5
WITH ANY HARD
1 TUBING 5 GAGE TIP SURFACE METAL
1
16 " FINISH ALL OVER
13
16 " 1
32 "
7
" 3 3 "
" DIA.
32
3
8 " 8 "
5
8 " DIA
HARDEN TIP WITH ANY
1
8 "
3
8 " HARD SURFACE METAL
3
"
16
2 GUIDE
15
"
32 1" "
64" DIA. HOLE "
17 1
8 "
HOLE DIA. TO BE .001"
SMALLER THAN DIA. OF ROD 1
" R "R R
"
5
8 " 8 5
"
32
7
"
16
5" 1
8 "R
7
"R
16
"
7 MAKE FROM
9
"
16 20 H.C. THDS
1 8 " O.D. TUBING
1
" DIA.
1
13
32 " 1
8 "R 8 THUMB SCREW
APPLY ANY HARD SURFACE
METAL TO THIS SURFACE ONLY
O. H. STEEL 3
8 " 38 "
AAR SPECN. M-116
GRADE B 6 16"
5
9 BRACE
Bill of Material
Number Item
Material Description Required Number
Tubing, 5/8 in. I.D. 13/16 in. O.D. 47 5/8 in. long 1 1
Guide 1 2
Guide bar 1 3
Guide bar 1 4
Gauge tip 1 5
Steel
Calibration rod 1 6
Guide washer 1 7
Thumb screw 1 8
Brace 2 9
Gauge tip bar, 3/8 in. 3/8 in. square 6 in. long 1 10
Bronze Spring, 0.0725-in. diameter wire 19/32 in. O.D. 6 3/8 in. long 36 coils 1 11
Steel Std. washer, 1/4 in. 1 12
5
" THUMB SCREW
16
AXLE CL
2"
METHOD OF APPLICATION
3 " 1
8 " STEEL PLATE
8"
"64
35
26
8 8"
7
*26 64"
ANGLE 27"
35
LONG
1 "
ANGLE 26" LONG
1
8 " STEEL PLATE
6"
5
3 " R 1 8"
5
6 "
1
8
3 8"
5
38"
" TOOL STEEL PLATE
1
8 WELDED OR RIVETED CONSTRUCTION PERMISSIBLE
HARDEN AND TEMPERED
GAUGE FOR LOCATING FIRST WHEEL
G-II124 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-634 SEGMENT 5.0
3 8"
5
"
1" "
2 " DRILL " 1 "2 "
COUNTERSINK FOR
" " FLAT HEAD
MACHINE SCREW DRILL 64"
13
THEN TAP
13 8 "
5
13 8 "
5 28 THDS/IN.
"
*26 8 "
24 8 "
5
18 8 "
5
34 " R
15 "
11 "
FRAMESTAINLESS STEEL "
INTERSECTS AT
1 16"
3
36 "
CL
* Wear limit for this dimension only is 26 19/32 in. Manufacturing tolerance for this dimension is 0.015 in.
Unless otherwise specified, all other manufacturing tolerances are +1/8 in., 1/16 in.
2/1/04 G-II125
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 5.0 RP-634
3.880
3.870
3.380
2.380 3.370
2.370
1.630
1.620
1.370 3
16" LONG SCRIBE LINE
1.380 BOTH SIDES OF GAUGE
1.002 .248
.998 .252
.877 1
16"
.873 45
3
"
32 5
8 " EQUAL SPACES
45
3
16" R G G G G
G
" 5
8 "
.876
R
.874 5
16 "
" 3
"
3
"
32
1 "
1
16 15
"
16
8
G "
2 "
7
8"
9
16 "R " R 3
8 " REAM
1 "
1
64 " 45 CHAMFER
G-II126 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-634 SEGMENT 5.0
7
4 64
2.500 .005
R .250 .005 TYPICAL
.500 .005 TYPICAL 5
R 16
50.173 1 1 1
22 2 12 1 2 0
.125 .005 R
7 5
9
16
R 16 8
3
28 .063 1 1.500 .005
1
R8
.125 8
15
16
1 R .938 .005
R 1
1 64 7
.781 18 5
1
8
27
32
.125
1.000 .005 .875 .005 .750 .005
1.250 .005 1.125 .005
1
8
3
4 7
8
1 1.000 .005
35
1 14 R 64
3
32
1 18
5
2.876 1 8
A
B
COMBINED 1.000 .005
R.015
WHEEL GAGE .875 .005
KNOTCH DETAIL
3
0 (A= 16 , B=) 7
1 1 R8
3
R8
(A= 8 , B= 8 ) 2
1 3
(A= 8 , B= 16 )
1 1
(A= 8 , B= 8 ) UNLESS OTHERWISE SPECIFIED
3
1 (A= 16 , B=) MANUFACTURE TOLERANCES : .010
1 1
1 (A= 8 , B= 8 ) MATERIAL: BOXED DIMENSIONS ARE MINIMUM
1 3
1 (A= 8 , B= 16 ) STAINLESS STEEL 304 CHARACTERISTICS TO BE VERIFIED
3
1 1
1 (A= 8 , B= 8 ) THICKNESS: 32 FOR RECERTIFICATION.
3
2 (A= 16 , B=) RECERTIFICATION TOLERANCES .015"
1 1
2 (A= 8 , B= 8 )
1 3
2 (A= 8 , B= 16 )
2/1/04 G-II127
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 5.0 RP-634
5.130
5.120
3 "
2 "
16" LONG SCRIBE LINE
3
1 8"
5
1 " " BOTH SIDES OF GAUGE
1" 3
8 " 1"
5
8 " EQUAL SPACES
8" " 45
7 3
32
3
"R
16
"
2" 5
8 "
7
8 "R 3
" DIA
8 5
16 "
" 3
"
7
8 " 15
"
16
8
"
2 "
9
"R
16
" R
1 "
1
"R
1
8 "R
3
8 "R 8
5
"R
16 STAMP SIZES OF
SLOTS ON EACH
"R "R SIDE OF GAUGE
5
8"
5
8 "
.874
1 32"
7
.876
15
" .936
2 16
.938
GAUGE NUMBER 34401A
MATERIAL: 0.093 STAINLESS STEEL.
UNLESS OTHERWISE STATED, ALL TOLERANCES ARE 0.010".
NOTE: THIS GAUGE CAN BE USED FOR 8 " OR LESS FLANGE ON LOCOMOTIVE WHEELS.
7
G-II128 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-634 SEGMENT 5.0
7
4 64
2.500 .005
R .250 .005 TYPICAL
.500 .005 TYPICAL 5
R 16
50.173 1 1 1
22 2 12 1 2 0
.125 .005 R
7 5
9
16
R 16 8
3
28 .063 1 1.500 .005
1
R8
.125 8
15
16
1 R .938 .005
R 1
1 64 7
.781 18 5
1
8
27
32
.125
1.000 .005 .875 .005 .750 .005
1.250 .005 1.125 .005
1
8
3
4 7
8
1 1.000 .005
35
1 14 R 64
3
32
1 18
5
2.876 1 8
A
B
COMBINED 1.000 .005
R.015
WHEEL GAGE .875 .005
KNOTCH DETAIL
3
0 (A= 16 , B=) 7
1 1 R8
3
R8
(A= 8 , B= 8 ) 2
1 3
(A= 8 , B= 16 )
1 1
(A= 8 , B= 8 ) UNLESS OTHERWISE SPECIFIED
3
1 (A= 16 , B=) MANUFACTURE TOLERANCES : .010
1 1
1 (A= 8 , B= 8 ) MATERIAL: BOXED DIMENSIONS ARE MINIMUM
1 3
1 (A= 8 , B= 16 ) STAINLESS STEEL 304 CHARACTERISTICS TO BE VERIFIED
3
1 1
1 (A= 8 , B= 8 ) THICKNESS: 32 FOR RECERTIFICATION.
3
2 (A= 16 , B=) RECERTIFICATION TOLERANCES .015"
1 1
2 (A= 8 , B= 8 )
1 3
2 (A= 8 , B= 16 )
2/1/04 G-II129
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 5.0 RP-634
"
DIA + .005"
7
8
G G
" DIA
1
" R MAX
32
PARTS TO BE HARDEN AND SURFACES MARKED
REF
THREE HOLES 0.5000" NOMINAL DIAMETER FOR PRESS FIT WITH PINS.
HOLES EQUALLY SPACED WITHIN 0.001" OF TRUE
POSITION IN ANT DIRECTION. 2" DRILL THREE INSPECTION HOLES
LOCATED IN LINE WITH PIN HOLES
" DIA
A 1
" R OR 1 8 " 45 CHAMFER 5
"
8 1
8 "R 8
1
"R
8
5
8 "
G
1
" R MAX
16
120 120
+ .001"
C .000"
DIA D
DIA A
DIA B
1 "
A SECTION A A
G-II130 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-634 SEGMENT 5.0
3"
1.263
1.261
1
8 " "
O FINGER
READING
7
"
16
5
8 "
.951
.946
15
" NO GO
16
4 "
7
8 " NO GO
0.890
0.885
Limit wear gauge for standard wheel gauge, simplified wheel gauge and wheel defect gauge
(Working drawing)
Paragraph 5.3
Fig. 5.13
2/1/04 G-II131
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 5.0 RP-634
SIMPLIFIED
WHEEL GAUGE
1 " HIGH
MUST NOT SEAT
O FINGER
READING
15
" NO GO
16
7
8 "
1
7
8 " NO GO
Use of limit wear gauge (Fig. 5.13) for checking simplified wheel gauge, 1 1/2-in.-high flange condemning limit
Paragraph 5.3
Fig. 5.14
G-II132 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-634 SEGMENT 5.0
15
16
" NO GO
"16
15
Use of limit wear gauge (Fig. 5.13) for checking wheel defect gauge, 7/8-in. flange condemning limits
Paragraph 5.3
Fig. 5.15
1 " HIGH
MUST NOT SEAT
O FINGER
READING
15
" NO GO
"
16
16
15
7
8 " NO GO
Use of limit wear gauge (Fig. 5.13) for checking wheel defect gauge, 15/16-in. flange condemning limits
Paragraph 5.3
Fig. 5.16
2/1/04 G-II133
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 5.0 RP-634
65
4
3
2
IF READING HERE IS PAST O, 1
THEN END OF FINGER HAS 0
EXCESSIVE WEAR. 9 8 1 " HIGH
6 MUST NOT SEAT
4
2
0
O FINGER
READING
15
" NO GO
16
3 FRT
4 SCRAP
PASS
1 ---
SCRAP
Use of limit wear gauge (Fig. 5.13) for checking steel wheel gauge for 1 1/2-in.-high flange limits and finger gauge
readings
Paragraph 5.3
Fig. 5.17
G-II134 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-634 SEGMENT 5.0
*1.5"R + 0.000
6 11 0.005
CRITICAL AREA CRITICAL AREA
1 " BEARING SEAT MUST BE BEARING SEAT MUST BE
WITHIN TOLERANCE WITHIN TOLERANCE
E
1 "
A 1
"
16
BA
C
D
Manufacturing tolerance for dimensions A, B, C, D, and E are 1/32 in. All other dimensions are 1/16 in.
GAGE GAGE
2/1/04 G-II135
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 5.0 RP-634
PLATING AREA
U
DUST GUARD DIAMETER AS
PER MSRP-G, Part II, FIG. 4.1.
PLATING FEATHERED OUT IN THIS
AREA. NO PLATING BEYOND BASE
OF RADIUS.
.375
THICKNESS AS REQUIRED
(0.002-IN. MAXIMUM)
Notes:
1. Repairs to be in accordance with the AAR Manual of Standards and Recommended Practices, Specification M-967latest
revision, except as noted below.
2. The length of the repair on the dust guard shall not exceed 0.375 in., except as shown.
3. Repaired dust guards shall not be roll burnished.
"
5
32
"
3
8
"
" 5 32"
"16
1"
7
8
"
1
8
5
4"
"
"R
8
7
0
32
5
37 "
4.180
" RIVETS
300
"R
"R
"16
16
1
32
5
"
295
"
8
7
8"
"R
2 16"
3
" 32
1
16
7
5
38" DIA. WHEEL
1
290
"
"
"
8
16
16
3
" 16
7
7
1
"
7
16
285
"
8
3
280
" 32
275
5
4
.
1R
6.283
245
1 8"
1 1
4
3
1 8"
36" DIA. WHEEL
5
240
24 "
TO BE ON CASTING
125.680
" RIVET HOLES
"
"
235
"
8
84.180
32
"
3
8
1
1
90
" RIVETS
230
1"
"
1
16
32
225
85
5
32
5
170
6 "
"
9.425
32
80
24 "
11 " R
5
2"
"32
33" DIA. WHEEL
165
5
1 8"
5
" 32
"
29
8
160
1
"R 16
24 "
7
155
"R
"
16" R
16
"
1 8"
"
1
7
7
"
5
150
9.425
"R
" RIVETS
"R
"
"
"
16
16
16
90
3
7
3
32
"
32
5
5
6 "
85
"
"
"
1"
16
"
" "
16
1
80
9
7
94.443
"
16
"
3
" 8
1 16"
3
"
"
16
1
8
30
1
5
"
7
8
2 16"
7 2 16"
9
Note: The scale on the wheel tape can have a tolerance of .005 between any two points on the scale with no accumulative variation. Linear dimensions
shown represent measurements of actual circumference of the wheel and not straight length of the tape. Graduations to be spaced 8 " apart with tape
1
laid flat.
Wheel circumference gauge (tape) for steel wheels27-in. to 38-in. diameters
(Working drawing)
(See Fig. 5.22 for diameters and circumferences corresponding to tape sizes)
Paragraph 5.3
Fig. 5.20
2/1/04 G-II137
106.681"
3
2/1/04
8 " 1" 3 3
16" 8 " " .031"
180 185 205 210 230 235 255 260
1 7
" 8 " 8 "
" 35 36 37
3
16 "
" 36" DIA. WHEEL
5
THESE SPACES ARE 1 8 " APART
32
" RIVET HOLES C. BORE = 45 WHEN TAPE IS FLAT
EXTRA LENGTH FOR WORKING PURPOSES 35" DIA. WHEEL
REMOVE AFTER GRADUATING 37" DIA. WHEEL
SEE NOTE NO. 1 BELOW
280 285 305 310 330 335 355 360 380 385 405 410 430 435 455 460 480 485 505 510 530 535
38 39 40 41 42 43 44 45 46 47 48
020"
39" DIA. 41" DIA. 43" DIA. 45" DIA. 47" DIA.
WHEEL WHEEL WHEEL WHEEL WHEEL
38" DIA. 40" DIA. 42" DIA. 44" DIA. 46" DIA. 48" DIA.
WHEEL WHEEL WHEEL WHEEL WHEEL WHEEL
NOTE 1:
555 560 565 580 585 610 615 630 635 650 655 MARK WHEEL DIAMETERS IN 1 8 " FIGURES
Fig. 5.21
EXTRA LENGTH FOR ON TAPE AS SHOWN ABOVE AND AS
G-II138
WORKING PURPOSES INDICATED IN FOLLOWING TABLE.
Paragraph 5.3
49 50 51 52 REMOVE AFTER WHEEL DIA. TAPE SIZE
(Working drawing)
3
GRADUATING. 35 207 1/2
020 1" 8 "
50" DIA. 52" DIA. 36 233
WHEEL WHEEL 37 258
4"
Wheel and Axle Manual
1"
9 3
8
"
16
" "R OF .005 BETWEEN ANY TWO POINTS ON THE SCALE WITH 47 509
NO ACCUMULATIVE VARIATION. LINEAR DIMENSIONS SHOWN
"R
7 7 48 534
8
8
3
" 15 8 " 8 " REPRESENT MEASUREMENTS OF ACTUAL CIRCUMFERENCE
AAR Manual of Standards and Recommended Practices
OF THE WHEEL AND NOT STRAIGHT LENGTH OF THE TAPE. 49 559 1/2
"R 5 3 50 584 1/2
5 1" 1" 8 " GRADUATIONS TO BE SPACED 1 8 " APART WITH TAPE LAID FLAT.
1 8" 1 8" 3
1" 3
(See Fig. 5.22 for diameters and circumferences corresponding to tape sizes)
Wheel circumference gauge (tape) for steel wheels38-in. to 52-in. diameters
8 " 1 8 " BRASS 51 610
" 111 16" 8 " 5
5 1 8 " 5 52 635
1 8 "
9 1 8 " 8 " 8 "
2 " 16 5 8 "
8 " "R
5 1 1
8 " RIVETS 30 8 " 8 "
" 5
8 " TAPE
15 R.
8 R.
1 11 16"
16
" 7
8 " 19 16"
ALL HOLES C'S'R' FOR 3 8 " RIVETS
2/1/04
RP-634
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-634 SEGMENT 5.0
Tape Diameter Circum. Tape Diameter Circum. Tape Diameter Circum. Tape Diameter Circum.
No. in. 64ths (in.) No. in. 64ths (in.) No. in. 64ths (in.) No. in. 64ths (in.)
0 26 47 84 43 28 29 89 3/8 87 30 13 94 7/8 131 31 61 100 3/8
1 26 50 84 1/8 44 28 31 89 1/2 88 30 15 95 132 31 63 100 1/2
2 26 52 84 1/4 45 28 34 89 5/8 89 30 18 95 1/8 32 0 100 17/32
3 26 55 84 3/8 46 28 36 89 3/4 90 30 20 95 1/4 133 32 2 100 5/8
4 26 57 84 1/2 47 28 39 89 7/8 91 30 23 95 3/8 134 32 4 100 3/4
5 26 60 84 5/8 48 28 41 90 92 30 26 95 1/2 135 32 7 100 7/8
6 26 63 84 3/4 49 28 44 90 1/8 93 30 28 95 5/8 136 32 10 101
27 0 84 53/64 50 28 47 90 1/4 94 30 31 95 3/4 137 32 12 101 1/8
7 27 1 84 7/8 51 28 49 90 3/8 95 30 33 95 7/8 138 32 15 101 1/4
8 27 4 85 52 28 52 90 1/2 96 30 36 96 139 32 17 101 3/8
9 27 6 85 1/8 53 28 54 90 5/8 97 30 38 96 1/8 140 32 20 101 1/2
10 27 9 85 1/4 54 28 57 90 3/4 98 30 41 96 1/4 141 32 22 101 5/8
11 27 11 85 3/8 55 28 59 90 7/8 99 30 43 96 3/8 142 32 25 101 3/4
12 27 14 85 1/2 56 28 62 91 100 30 46 96 1/2 143 32 27 101 7/8
13 27 16 85 5/8 29 0 91 7/64 101 30 48 96 5/8 144 32 30 102
14 27 19 85 3/4 57 29 1 91 1/8 102 30 51 96 3/4 145 32 32 102 1/8
15 27 21 85 7/8 58 29 3 91 1/4 103 30 54 96 7/8 146 32 35 102 1/4
16 27 24 86 59 29 5 91 3/8 104 30 56 97 147 32 38 102 3/8
17 27 27 86 1/8 60 29 8 91 1/2 105 30 59 97 1/8 148 32 40 102 1/2
18 27 29 86 1/4 61 29 11 91 5/8 106 30 61 97 1/4 149 32 43 102 5/8
19 27 32 86 3/8 62 29 13 91 3/4 107 30 64 97 3/8 150 32 45 102 3/4
20 27 34 86 1/2 63 29 16 91 7/8 31 0 97 25/64 151 32 48 102 7/8
21 27 37 86 5/8 64 29 18 92 108 31 2 97 1/2 152 32 50 103
22 27 39 86 3/4 65 29 21 92 1/8 109 31 5 97 5/8 153 32 53 103 1/8
23 27 42 86 7/8 66 29 23 92 1/4 110 31 7 97 3/4 154 32 55 103 1/4
24 27 44 87 67 29 26 92 3/8 111 31 10 97 7/8 155 32 58 103 3/8
25 27 47 87 1/8 68 29 28 92 1/2 112 21 12 98 156 32 60 103 1/2
26 27 49 87 1/4 69 29 31 92 5/8 113 31 15 98 1/8 157 32 63 103 5/8
27 27 52 87 3/8 70 29 33 92 3/4 114 31 18 98 1/4 33 0 103 43/64
28 27 55 87 1/2 71 29 36 92 7/8 115 31 20 98 3/8 158 33 2 103 3/4
29 27 57 87 5/8 72 29 39 93 116 31 23 98 1/2 159 33 4 103 7/8
30 27 60 87 3/4 73 29 41 93 1/8 117 31 25 98 5/8 160 33 7 104
31 27 62 87 7/8 74 29 44 93 1/4 118 31 28 98 3/4 161 33 9 104 1/8
28 0 87 31/32 75 29 46 93 3/8 119 31 30 98 7/8 162 33 12 104 1/4
32 28 1 88 76 29 49 93 1/2 120 31 33 99 163 33 14 104 3/8
33 28 3 88 1/8 77 29 51 93 5/8 121 31 35 99 1/8 164 33 17 104 1/2
34 28 6 88 1/4 78 29 54 93 3/4 122 31 38 99 1/4 165 33 19 104 5/8
35 28 8 88 3/8 79 29 56 93 7/8 123 31 40 99 3/8 166 33 22 104 3/4
36 28 11 88 1/2 80 29 59 94 124 31 43 99 1/2 167 33 24 104 7/8
37 28 13 88 5/8 81 29 61 94 1/8 125 31 46 99 5/8 168 33 27 105
38 28 16 88 3/4 82 30 0 94 1/4 126 31 48 99 3/4 169 33 30 105 1/8
39 28 19 88 7/8 83 30 3 94 3/8 127 31 51 99 7/8 170 33 32 105 114
40 28 21 89 84 30 5 94 1/2 128 31 53 100 171 33 35 105 3/8
41 28 24 89 1/8 85 30 8 94 5/8 129 31 56 100 1/8 172 33 37 105 1/2
42 28 26 89 1/4 86 30 10 94 3/4 130 31 58 100 1/4 173 33 40 105 5/8
a/Diameters are expressed to the nearest 1/64 corresponding to the exact circumference stated.
Diameters and circumferences corresponding to tape sizes
Paragraph 5.3
Fig. 5.22
2/1/04 G-II139
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 5.0 RP-634
Tape Diameter Circum. Tape Diameter Circum. Tape Diameter Circum. Tape Diameter Circum.
No. in. 64ths (in.) No. in. 64ths (in.) No. in. 64ths (in.) No. in. 64ths (in.)
174 33 42 105 3/4 217 35 24 111 1/8 260 37 5 116 1/2 304 38 53 122
175 33 45 105 7/8 218 35 26 111 1/4 261 37 8 116 5/8 305 38 56 122 1/8
176 33 47 106 219 35 29 111 3/8 262 37 10 116 3/4 306 38 58 122 1/4
177 33 50 106 1/8 220 35 31 111 1/2 263 37 13 116 7/8 307 38 61 122 3/8
178 33 53 106 1/4 221 35 34 111 5/8 264 37 16 117 308 38 64 122 1/2
179 33 55 106 3/8 222 35 37 111 3/4 265 37 18 117 1/8 39 0 122 33/64
180 33 58 106 1/2 223 35 39 111 7/8 266 37 21 117 1/4 309 39 2 122 5/8
181 33 60 106 5/8 224 35 42 112 267 37 23 117 3/8 310 39 5 122 3/4
182 33 63 106 3/4 225 35 44 112 1/8 268 37 26 117 1/2 311 39 7 122 7/8
34 0 106 13/16 226 35 47 112 1/4 269 37 28 117 5/8 312 39 10 123
183 34 1 106 7/8 227 35 49 112 3/8 270 37 31 117 3/4 313 39 12 123 1/8
184 34 4 107 228 35 52 112 1/2 271 37 33 117 7/8 314 39 15 123 1/4
185 34 6 107 1/8 229 35 54 112 5/8 272 37 36 118 315 39 17 123 3/8
186 34 9 107 1/4 230 35 57 112 3/4 273 37 38 118 1/8 316 39 20 123 1/2
187 34 11 107 3/8 231 35 59 112 7/8 274 37 41 118 1/4 317 39 22 123 5/8
188 34 14 107 1/2 232 35 62 113 275 37 44 118 3/8 318 39 25 123 3/4
189 34 17 107 5/8 36 0 113 3/32 276 37 46 118 1/2 319 39 28 123 7/8
190 34 19 107 3/4 233 36 1 113 1/8 277 37 49 118 5/8 320 39 30 124
191 34 22 107 7/8 234 36 3 113 1/4 278 37 51 118 3/4 321 39 33 124 1/8
192 34 24 108 235 36 6 113 3/8 279 37 54 118 7/8 322 39 35 124 1/4
193 34 27 108 1/8 236 36 8 113 1/2 280 37 56 119 323 39 38 124 3/8
194 34 29 108 1/4 237 36 11 113 5/8 281 37 59 119 1/8 324 39 40 124 1/2
195 34 32 108 3/8 238 36 13 113 3/4 282 37 61 119 1/4 325 39 43 124 5/8
196 34 34 108 1/2 239 36 16 113 7/8 283 37 64 119 3/8 326 39 45 124 3/4
197 34 37 108 5/8 240 36 18 114 38 0 119 3/8 327 39 48 124 7/8
198 34 39 108 3/4 241 36 21 114 1/8 284 38 2 119 1/2 328 39 50 125
199 34 42 108 7/8 242 36 23 114 1/4 285 38 5 119 5/8 329 39 53 125 1/8
200 34 45 109 243 36 26 114 3/8 286 38 8 119 3/4 330 39 56 125 1/4
201 34 47 109 1/8 244 36 29 114 1/2 287 38 10 119 7/8 331 39 58 125 3/8
202 34 50 109 1/4 245 36 31 114 5/8 288 38 13 120 332 39 61 125 1/2
203 34 52 109 3/8 246 36 34 114 3/4 289 38 15 120 1/8 333 39 63 125 5/8
204 34 55 109 1/2 247 36 36 114 7/8 290 38 18 120 1/4 40 0 125 21/32
205 34 57 109 5/8 248 36 39 115 291 38 20 120 3/8 334 40 2 125 3/4
206 34 60 109 3/4 249 36 41 115 1/8 292 38 23 120 1/2 335 40 4 125 7/8
207 34 62 109 7/8 250 36 44 115 1/4 293 38 25 120 5/8 336 40 7 126
35 0 109 61/64 251 36 46 115 3/8 294 38 28 120 3/4 337 40 9 126 1/8
208 35 1 110 252 36 49 115 1/2 295 38 30 120 7/8 338 40 12 126 1/4
209 35 3 110 1/8 253 36 51 115 5/8 296 38 33 121 339 40 14 126 3/8
210 35 6 110 1/4 254 36 54 115 3/4 297 38 36 121 1/8 340 40 17 126 1/2
211 35 9 110 3/8 255 36 57 115 7/8 298 38 38 121 1/4 341 40 20 126 5/8
212 35 11 110 1/2 256 36 59 116 299 38 41 121 3/8 342 40 22 126 3/4
213 35 14 110 5/8 257 36 62 116 1/8 300 38 43 121 1/2 343 40 25 126 7/8
214 35 16 110 3/4 37 0 116 15/64 301 38 46 121 5/8 344 40 27 127
215 35 19 110 7/8 258 37 2 116 1/4 302 38 48 121 3/4 345 40 30 127 1/8
216 35 21 111 259 37 3 116 3/8 303 38 51 121 7/8 346 40 32 127 1/4
a/Diameters are expressed to the nearest 1/64 corresponding to the exact circumference stated.
Diameters and circumferences corresponding to tape sizes
Paragraph 5.3
Fig. 5.22 (Continued)
G-II140 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-634 SEGMENT 5.0
Tape Diameter Circum. Tape Diameter Circum. Tape Diameter Circum. Tape Diameter Circum.
No. in. 64ths (in.) No. in. 64ths (in.) No. in. 64ths (in.) No. in. 64ths (in.)
347 40 35 127 3/8 390 42 16 132 3/4 44 0 138 15/64 477 45 46 143 5/8
348 40 37 127 1/2 391 42 19 132 7/8 434 44 0 138 1/4 478 45 48 143 3/4
349 40 40 127 5/8 392 42 21 133 435 44 3 138 3/8 479 45 51 143 7/8
350 40 43 127 3/4 393 42 24 133 1/8 436 44 5 138 1/2 480 45 54 144
351 40 45 127 7/8 394 42 27 133 1/4 437 44 8 138 5/8 481 45 56 144 1/8
352 40 48 128 395 42 29 133 3/8 438 44 11 138 3/4 482 45 59 144 1/4
353 40 50 128 1/8 396 42 32 133 1/2 439 44 13 138 7/8 483 45 61 144 3/8
354 40 53 128 1/4 397 42 34 133 5/8 440 44 16 139 484 45 64 144 1/2
355 40 55 128 3/8 398 42 37 133 3/4 441 44 18 139 1/8 46 0 1443 3/64
356 40 58 128 1/2 399 42 39 133 7/8 442 44 21 139 1/4 485 46 2 144 5/8
357 40 60 128 5/8 400 42 42 134 443 44 23 139 3/8 486 46 5 144 3/4
358 40 63 128 3/4 401 42 44 134 1/8 444 44 26 139 1/2 487 46 7 144 7/8
41 0 128 13/16 402 42 47 134 1/4 445 44 28 139 5/8 488 46 10 145
359 41 1 128 7/8 403 42 49 134 3/8 446 44 31 139 3/4 489 46 12 145 1/8
360 41 4 129 404 42 52 134 1/2 447 44 34 139 7/8 490 46 15 145 1/4
361 41 7 129 1/8 405 42 55 134 5/8 448 44 36 140 491 46 18 145 3/8
362 41 9 129 1/4 406 42 57 134 3/4 449 44 39 140 1/8 492 46 20 145 1/2
363 41 12 129 3/8 407 42 60 134 7/8 450 44 41 140 1/4 493 46 23 145 5/8
364 41 14 129 112 408 42 62 135 451 44 44 140 3/8 494 46 25 145 3/4
365 41 17 129 5/8 43 0 135 3/32 452 44 46 140 1/2 495 46 28 145 7/8
366 41 19 129 3/4 409 43 1 135 1/8 453 44 49 140 5/8 496 46 30 146
367 41 22 129 7/8 410 43 3 135 1/4 454 44 51 140 3/4 497 46 33 146 1/8
368 41 24 130 411 43 6 135 3/8 455 44 54 140 7/8 498 46 35 146 1/4
369 41 27 130 1/8 412 43 8 135 1/2 456 44 56 141 499 46 38 146 3/8
370 41 29 130 1/4 413 43 11 135 5/8 457 44 59 141 1/8 500 46 40 146 1/2
371 41 32 130 3/8 414 43 13 135 3/4 458 44 62 141 1/4 501 46 43 146 5/8
372 41 35 130 112 415 43 16 135 7/8 ... 45 0 141 3/8 502 46 46 146 3/4
373 41 37 130 5/8 416 43 19 136 459 45 0 141 3/8 503 46 48 146 7/8
374 41 40 130 3/4 417 43 21 136 1/8 460 45 3 141 1/2 504 46 51 147
375 41 42 130 7/8 418 43 24 136 1/4 461 45 5 141 5/8 505 46 53 147 1/8
376 41 45 131 419 43 26 136 3/8 462 45 8 141 3/4 506 46 56 147 1/4
377 41 47 131 1/8 420 43 29 136 1/2 463 45 10 141 7/8 507 46 58 147 3/8
378 41 50 131 1/4 421 43 31 136 5/8 464 45 13 142 508 46 61 147 1/2
379 41 52 131 3/8 422 43 34 136 3/4 465 45 15 142 1/8 509 46 63 147 5/8
380 41 55 131 1/2 423 43 36 136 7/8 466 45 18 142 1/4 47 0 147 21/32
381 41 57 131 5/8 424 43 39 137 467 45 20 142 3/8 510 47 2 147 3/4
382 41 60 131 3/4 425 43 41 137 1/8 468 45 23 142 1/2 511 47 4 147 7/8
383 41 63 131 7/8 426 43 44 137 1/4 469 45 26 142 5/8 512 47 7 148
42 0 131 61/64 427 43 47 137 3/8 470 45 28 142 3/4 513 47 10 148 1/8
384 42 1 132 428 43 49 137 1/2 471 45 31 142 7/8 514 47 12 148 1/4
385 42 4 132 1/8 429 43 52 137 5/8 472 45 33 143 515 47 15 148 3/8
386 42 6 132 1/4 388 42 54 137 3/8 473 45 38 143 1/8 516 47 17 148 1/2
387 42 9 132 3/8 431 43 57 137 7/8 474 45 38 143 1/4 517 47 20 148 5/8
388 42 11 132 1/2 432 43 59 138 475 45 41 143 3/8 518 47 22 148 3/4
389 42 14 132 5/8 433 43 62 138 1/8 476 45 43 143 1/2 519 47 25 148 7/8
a/Diameters are expressed to the nearest 1/64 corresponding to the exact circumference stated.
Tape Diameter Circum. Tape Diameter Circum. Tape Diameter Circum. Tape Diameter Circum.
No. in. 64ths (in.) No. in. 64ths (in.) No. in. 64ths (in.) No. in. 64ths (in.)
520 47 27 149 562 49 6 154 1/4 605 50 52 159 5/8 647 52 31 164 7/8
521 47 30 149 1/8 563 49 9 154 3/8 606 50 54 159 3/4 648 52 33 165
522 47 32 149 1/4 564 49 11 154 1/2 607 50 57 159 7/8 649 52 36 165 1/8
523 47 35 149 3/8 565 49 14 154 5/8 608 50 59 160 650 52 38 165 1/4
524 47 38 149 1/2 566 49 17 154 3/4 609 50 62 160 1/8 651 52 41 165 3/8
525 47 40 149 5/8 567 49 19 154 7/8 51 0 160 7/32 652 52 44 165 1/2
526 47 43 149 3/4 568 49 22 155 610 51 1 160 1/4 653 52 46 165 5/8
527 47 45 149 7/8 569 49 24 155 1/8 611 51 3 160 3/8 654 52 49 165 3/4
528 47 48 150 570 49 27 155 1/4 612 51 6 160 1/2 655 52 51 165 7/8
529 47 50 150 1/8 571 49 29 155 3/8 613 51 8 160 5/8 656 52 54 166
530 47 53 150 1/4 572 49 32 155 1/2 614 51 11 160 3/4 657 52 56 166 1/8
531 47 55 150 3/8 573 49 34 155 5/8 615 51 13 160 7/8 658 52 59 166 1/4
532 47 58 150 1/2 574 49 37 155 3/4 616 51 16 161 659 52 61 166 3/8
533 47 61 150 5/8 575 49 39 155 7/8 617 51 18 161 1/8 660 52 64 166 1/2
534 47 63 150 3/4 576 49 42 156 618 51 21 161 1/4 53 0 166 1/2
48 0 150 51/64 577 49 45 156 1/8 619 51 24 161 3/8
535 48 2 150 7/8 578 49 47 156 1/4 620 51 26 161 1/2
536 48 4 151 579 49 50 156 3/8 621 51 29 161 5/8
537 48 7 151 1/8 580 49 52 156 1/2 622 51 31 161 3/4
538 48 9 151 1/4 581 49 55 156 5/8 623 51 34 161 7/8
539 48 12 151 3/8 582 49 57 156 3/4 624 51 36 162
540 48 14 151 1/2 583 49 60 156 7/8 625 51 39 162 1/8
541 48 17 151 5/8 584 49 62 157 626 51 41 162 1/4
542 48 19 151 3/4 50 0 157 5/64 627 51 44 162 3/8
543 48 22 151 7/8 585 50 1 157 1/8 628 51 46 162 1/2
544 48 25 152 586 50 3 157 1/4 629 51 49 162 5/8
545 48 27 152 1/8 587 50 6 157 3/8 630 51 52 162 3/4
546 48 30 152 1/4 588 50 9 157 1/2 631 51 54 162 7/8
547 48 32 152 3/8 589 50 11 157 5/8 632 51 57 163
548 48 35 152 1/2 590 50 14 157 3/4 633 51 59 163 1/8
549 48 37 152 5/8 591 50 16 157 7/8 634 51 62 163 1/4
550 48 40 152 3/4 592 50 19 158 52 0 163 23/64
551 48 42 152 7/8 593 50 21 158 1/8 635 52 0 163 3/8
552 48 45 153 594 50 24 158 1/4 636 52 3 163 1/2
553 48 47 153 1/8 595 50 26 158 3/8 637 52 5 163 5/8
554 48 50 153 1/4 596 50 29 158 1/2 638 52 8 163 3/4
555 48 53 153 3/8 597 50 31 158 5/8 639 52 10 163 7/8
556 48 55 153 1/2 598 50 34 158 3/4 640 52 13 164
557 48 58 153 5/8 599 50 37 158 7/8 641 52 16 164 1/8
558 48 60 153 3/4 600 50 39 159 642 52 18 164 1/4
559 48 63 153 7/8 601 50 42 159 1/8 643 52 21 164 3/8
49 0 153 15/16 602 50 44 159 1/4 644 52 23 164 1/2
560 49 1 154 603 50 47 159 3/8 645 52 26 164 5/8
561 49 4 154 1/8 604 50 49 159 1/2 646 52 28 164 3/4
a/Diameters are expressed to the nearest 1/64 corresponding to the exact circumference stated.
Diameters and circumferences corresponding to tape sizes
Paragraph 5.3
Fig. 5.22 (Concluded)
G-II142 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-634 SEGMENT 5.0
6.5000"
R1.5000"
.0010"
+
R.6250"
.0010" F R.6875"
+ .0010" E+
R.3750"
.0010"
.6250"
.0010" 3
+ 4
R.5625"
.0010"
.0010" E 5
.2306"
.0010"
+
1.0000"
6 +D B F+
7 + C
BASE LINE
4.0000"
8 1
9 R2.6250"
.0010"
A
GAUGING POINT
TAPER 1:20
2.0000"
(REF.)
.0010"
.5243"
2.0064"
.0010"
2.5721"
.0010"
NOTES: + +
1. HANGING HOLE(S) OPTIONAL.
2. ALL DIMENSIONS ARE NOMINAL.
3. MINIMUM 0.120" STEEL WITH MINIMUM 55 RC HARDNESS.
4. UNLESS NOTED, ALL OTHER TOLERANCES ARE 0.0250. R.0625" .7500" R 0.0625"
2/1/04 G-II143
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
SEGMENT 5.0 RP-634
SHOP LIMIT
NEW AXLE MIN
A
3
16 " STEEL
3
" STENCIL
16
2 3
8 "
SHOP LIMITS
NEW AXLE MINIMUM
1
" FOR AMTRAK
32
21
"
32
1
16 "
PASSENGER CARS 1
8"
1" 4"
A
G-II144 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-634 SEGMENT 5.0
1
" THICK STEEL
16
HARDENED
LATHE CENTER
60
2"
1112
78910
1.125 MIN
APPLY GRADUATIONS 60
AT DIMENSIONS SHOWN.
Notes:
1. Depth of counterbore in rough axle shall be increased from that shown to compensate for stock allowed to face axle. When
secondhand axles are recentered, diameter and depth may be increased sufficiently to produce accurate 60 degree center.
2. All other manufacturing tolerances are 1/32 in.
" 3 "
3 "
" +.000
" " DIA. 1"R .005
1 "
" DIA.
0.030" OVER MAXIMUM ALLOWED
FOR SECOND-HAND AND " DIA. HOLES-FRONT
GAGING ROD " 20 UNC THREAD-REAR 2 GAGE, AXLE FILLET
RECONDITIONED AXLES
MATL - 5/8" DIA. STAINLESS STEEL ROD
Fig. 5.26
G-II146
3 1 "
Paragraph 5.3
11 16" 7" 12" G (.498 LINE)
7
11 8 " 6 " 12"F (.670 LINE)
1 1 +.000
11 16" 6" 11"E (.670 LINE) 3 CENTERING BOOT 8 " .005
Wheel and Axle Manual
3
10 16" 5 " 10"D (.592 LINE) MATL.-COLD ROLLED STEEL
7
9 8 " 5" 9"C (.592 LINE)
2/1/04
RP-634
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
RP-634 SEGMENT 5.0
GAUGING PADDLE
STAINLESS STEEL 17-7
8 " THICK
1
HARDENED
HANDLE
ALUMINUM
1 (2 REQ'D)
REFERNCE PADDLE
STANLESS STEEL 17-7
8 " THICK
1
HARDENED
SUPPORT ALUMINUM
1
ALIGNING PLATE
STAINLESS STEEL 17-7
16" THICK
3
HARDENED
4 5 8"
7
2/1/04 G-II147
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
APPENDIX A
APPENDIX A
APPROVED MATERIALS
1.0 APPROVED RUST PREVENTIVES USED AS SEALING COMPOUNDS
(Apply per Rule 1.8.2.6)
Tectyl 506 EH-WDAshland Petroleum Company
Texacoat 1044 Texaco Company
Rust Veto 342.1E.F. Houghton & Co.
CN-471-Perolin-Bird Archer, Ltd.
Keystone Sealing CompoundPennwalt, Inc.
Keycote 601Pennwalt, Inc.
Tectyl 517Ashland Petroleum Company
RP-103Diversey Corporation
2.0 AAR-APPROVED WHEEL MOUNTING LUBRICANTS/COMPOUNDS
(Apply per Rule 1.4.3)
RMI LB-0749 Custom Product and Service
WM-10 Wheel Mounting CompoundMuscle Products Corp.
G-II148 2/1/04
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
APPENDIX B
APPENDIX B
REVISED PAGE DATES
Shown below are the current dates applicable to each page of Section G-II of the AAR Manual of Standards and Rec-
ommended Practices. The printed page date is shown in either the lower left or lower right-hand corner of the page. In
the event a new specification, standard, or recommended practice does not include an effective date, the printed page
date will constitute the effective date.
Page Numbers Page Numbers
2/1/04 G-II149
AAR Manual of Standards and Recommended Practices
2/1/04 Wheel and Axle Manual
APPENDIX B
G-II150 2/1/04