1. 1 DTE Rail Services, Inc. Railcar Maintenance Management Seminar Wheel Sets and Wheel Shop Practices May 23, 2008 Greenbrier Rail Services

2. 2 Greenbrier Rail Services is a unit of The Greenbrier Companies. We have a network of 12 wheel set reconditioning facilities throughout the US and Mexico. We provide over 350,000 wheel sets to the railroad industry annually, mostly for the freight car maintenance market. Our customers include Class I Railroads, Short Line and Regional Railroads, Utility Companies, Leasing Companies, Car Repair Shops and New Car manufacturers throughout North America.

3. 3 Greenbrier Rail Services Chicago Heights, IL Corsicana, TX Kansas City, KS Lewistown, PA Macon, GA Mexico City, MX Pine Bluff, AR Portland, OR Sahagun, MX San Bernardino, CA Tacoma, WA Washington, IL Wheel Shop Locations

4. 4 Greenbrier Rail Services Wheel Set Assembly Wheel (2) Roller Bearing (2)Axle (1)

5. 5 Greenbrier Rail Services A rail car wheel set consist of 3 components –2 Wheels Wheels come in 4 general sizes based on the capacity of the railcar they will be used under. These are 28”, 33”, 36” and 38”. –1 Axle Axles come in 7 sizes and are designated by Class. These Classes are D, E, F, G, K, L & M. –2 Roller Bearings Roller Bearings also come in 7 sizes utilizing the same Classes as the axles.

6. 6 Greenbrier Rail Services Plate Hub Rim TreadFlange

7. 7 Greenbrier Rail Services Wheel Seat Journal Bolt Holes Journal FilletDust Guard Body

8. 8 Greenbrier Rail Services Cone Assembly (Cage and Rollers) End Cap Backing Ring Seal Cup End Cap Bolt

9. 9 Greenbrier Rail Services Common Wheel Defects There are many defects that can cause a wheel set to be removed from service. These defects can be related to either the wheel, axle or roller bearing. Some common defects include: High Impact Wheels These are wheels sets that are putting excessive forces into the rail and are detected by recorders located at various high traffic areas on the railroads. Shelled Wheels This defect is caused by fatigue on the wheel tread surface and causes the metal to crack and break out of the tread. Worn out Wheels Simply reached the condemning limits set by the AAR.

10. 10 Greenbrier Rail Services Wheel Defects Related to Wear Vertical FlangeThin Rim High FlangeThin Flange

11. 11 Greenbrier Rail Services Non-Wear Wheel Related Defects Shelled TreadSlid Flat Grooved TreadBuilt Up Tread

12. 12 Greenbrier Rail Services Inbound Inspection Bearing Demount Wheel Demount and Axle Cleaning Axle Inspection and Magnaflux Wheel Mounting Wheel Turning and Ultra-Sonic Testing Bearing Mounting Wheel Shop Practices

13. 13 Greenbrier Rail Services The Association of American Railroads governs the requirements for wheel sets that are used in North American interchange service. These rules are covered in the AAR Manuals of Standards and Recommended Practices Section G-II, Wheels and Axles. AAR Requirements

14. 14 Greenbrier Rail Services Visual Inspection of wheels, axles and roller bearings for nicks, gouges or cracks. Gauging of wheel profile to determine whether wheels are turnable or scrap. Documentation of conditions found. Wheel Set Inspection

15. 15 Greenbrier Rail Services Visual Wheel Set Inspection Cracked Plate Gouged Axle Broken Bearing Cup

16. 16 Greenbrier Rail Services Wheel Set Gauging Wheels are gauged, using the AAR Finger Gauge, to determine if they can be re-profiled. All wheel sets that can’t be re-profiled are expedited for demounting.

17. 17 Greenbrier Rail Services All wheel sets are given are assigned a specific tracking number which is used throughout the process. All information regarding the condition of the wheel sets is documented. Wheel Set Inspection Documentation

18. 18 Greenbrier Rail Services Roller Bearing Removal

19. 19 Greenbrier Rail Services Wheel Demounting Wheel Sets are placed in a press which removes the wheels from the axle.

20. 20 Greenbrier Rail Services Axle Cleaning and Inspection Axles are cleaned and gauged

21. 21 Greenbrier Rail Services Axle Machining Axles are machined if required based on conditions found.

22. 22 Greenbrier Rail Services Axle Magnaflux All loose axles are Magnafluxed to check for surface cracks.

23. 23 Greenbrier Rail Services The wheel seat of the axle is measured to determine what the diameter of the wheel bore must be to insure proper interference fit and mounting pressure. Axle Wheel Seat Measuring

24. 24 Greenbrier Rail Services Wheel Boring and Chamfering Wheels are bored to fit a specific axle.

25. 25 Greenbrier Rail Services Axle Center and Wheel Compound The center of the axle length is found so that the wheels are mounted centrally with respect to the axle. A mounting lubricant is applied to the wheel bore and axle wheel seat to prevent scoring.

26. 26 Greenbrier Rail Services Wheel Mounting and Documentation The wheels are pressed on one at a time. The mounting pressure, travel distance and wheel serial number are documented. This record must be kept for 5 years.

27. 27 Greenbrier Rail Services Wheel Set Turning Wheel sets are placed in a lathe and machined, creating a new tread profile.

28. 28 Greenbrier Rail Services Turned Wheel Ultra-Sonic Testing Once the wheel set has been turned, the tread is Ultra-Sonically tested for subsurface defects.

29. 29 Greenbrier Rail Services Roller Bearing Mounting

30. 30 Greenbrier Rail Services Questions?