December 21, 1998

EW-162-S3

(c-8961)

Subject: Removal / UT Inspection of Mafersa Wheels

TO MEMBERS AND PRIVATE CAR OWNERS

File Number: TWBL-11.13

This Early Warning expands Early Warning EW-162 which was issued March 16, 1998, Supplement 1 which was issued March 24, 1998 and Supplement 2 which was issued March 27, 1998. The Wheels, Axles, Bearings & Lubrication (WABL) Committee and the Quality Assurance Committee have continued to investigate the failures. As a result of continuing investigation and two in-service failures on an AAR member railroad in the past two months, the WABL and Quality Assurance Committees have expanded EW-162 to encompass all wheels manufactured after 1993 by Mafersa.

The recent incidents involved J-33 wheels manufactured in October, 1994 and June, 1998.

Remove on sight: all wrought steel wheels manufactured after 1993 by MAFERSA (Identification Mark "MW").

We have now developed, from two car owners, car series of initial application Mafersa wheelsets covered by EW-162 and its various supplements. This listing is attached.

On some railroad, this may cause severe service disruptions to certain intermodal equipment, multi-level cars, and unit train operations.

The WABL Committee has determined that car owners having large numbers of the subject wheels in pools or captive, dedicated train service may petition the handling carrier to continue the wheels in service on an interim basis pending completion of ultrasonic testing provided a frequent 100% visual inspection of the front and back faces of the rim is conducted. The inspection should pay particular attention to indications, per Field Manual Rule 41 Section A, of spread rim, shattered rim and thermal cracks.

In all cases, handling carriers and car owners are encouraged to cooperate in facilitating the timely removal and ultrasonic testing of the subject wheels.

Repairing lines should continue to report the removed wheels as Why Made Code 23, Government Regulatory Requirement, unless you have a specific wheel defect to report in which case the actual Why Made Code should be reported. Report appropriate Job Code removed in all cases. The removed roller bearings and axles should be reported with appropriate Why Made Codes ("11" in most instances).

Car owners may elect to perform ultrasonic testing of removed wheels. Such testing must be performed in accordance with AAR Specification M-107, Section 18 (Section G of the Manual of Standards & Recommended Practices). The ultrasonic test should, of course, focus on the wheel tread. Any inclusions equal to or larger than ¹/₈" will condemn the wheel. The wheels must be pressed off the axle at an AAR certified wheel shop and scrapped.

Wheelsets having inclusions less than ¹/₈" or no inclusions may be reused / continued in interchange service provided the wheelsets have no other condemnable wheel, axle or roller bearing defects.

Wheelsets that have passed the ultrasonic inspection requirements must be stenciled, in two locations 180 degrees apart, on the front face of both wheel plates "UT" in 1½" white letters.

Wheels removed under EW-162 must be scrapped unless they have been ultrasonically inspected and passed the above UT criteria.

The subject wheels must be scrapped unless they have been ultrasonically inspected and passed the UT criteria.

Reprofiling of these wheels is allowed provided they have been ultrasonically inspected and passed the above UT criteria and all other AAR Wheel & Axle Manual requirements are met – including the application of reconditioned or new roller bearings.

The WABL Committee is ascertaining the expanded subject wheel population in the general interchange fleet and is working with the manufacturer. Car owners having significant numbers of the subject wheels are urged to self-identify and come forward with car series and an ultrasonic test plan. WABL Committee approval of the test plan will obviate the need for removal from service of wheels tested and determined free of defects.

Cars Covered by

Early Warning EW-162

Car Numbers

ADMX 19151, 19153-19160, 19162

ADMX 19176, 19177, 19180, 19190, 19193, 19198

ADMX 19200, 19201, 19203-19250

ADMX 28111, 28113, 28114, 28152, 28168, 28170

ADMX 28171, 28174, 28176, 28178-28181, 28183

ADMX 28184, 28186, 28187, 28190-28193, 28234

ADMX 28235, 28240, 28243, 28247

*ETTX 710000-710379

TTAX 553933, 553934, 553937, 553939

*TTAX 554047-554098

*TTAX 554120-554154

TTAX 554160-554196

TTAX 554198, 554199, 554201-554211

TTAX 554213-554261, 554263-554336

TTAX 554338-554353, 554355-554382

TTAX 554384-554386, 554388-554430

TTAX 554432-554442, 554444-554459

TTAX 753000-753201, 753023-753148

TTAX 753150-753211, 753213-753261

TTAX 753263-753270, 753272-753274

TTAX 753276-753299

TTRX 360163, 360180, 360185, 360187, 360194

TTRX 360195, 360202, 360205, 360207, 360213

TTRX 360220, 360257, 360261, 360263, 360509

TTRX 360511-360513, 360515, 360535, 360538

TTRX 360542, 360543, 360557, 360585

TTRX 360597, 360599, 360601, 360603

* = Not Continuous Series