Engineering Procedure

Rolling Stock

Engineering Procedure

EPR 0026

STATIC VEHICLE WEIGH TEST

Version 1.1

Issued March 2013

Owner: Chief Engineer Rolling Stock

Approved Stephen White, Authorised Michael Uhlig,

by: A/Manager, by: A/Chief Engineer
Rolling Stock Access Integrity Rolling Stock

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This document was prepared for use on the RailCorp Network only.
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Static vehicle weigh test EPR 0026

Document control

Version Date Summary of change

1.0 August 2011 Based on ESR 0001 Appendix C – New procedure
1.1 March 2013 Minor change in Section 8.2.5

Summary of changes from previous version

Summary of change Section
Revised the Lmin formula to indicate (L + R - E) 8.2.5

Contents

1 Purpose ....................................................................................................................................3

2 Scope........................................................................................................................................3

3 Objective ..................................................................................................................................3

4 References ...............................................................................................................................3

5 Weighing test procedure ........................................................................................................3

6 Vehicle inspection...................................................................................................................4

7 Vehicle weighing procedure ..................................................................................................4

8 Analysis of measured results ................................................................................................5

8.1 Total vehicle ..............................................................................................................................5

8.2 Individual wheels.......................................................................................................................6

8.2.1 Wheel load P .............................................................................................................6

8.2.2 Driving axles – axle to axle load ................................................................................6

8.2.3 Non driving axles- axle to axle load...........................................................................7

8.2.4 Wheel load across an axle.........................................................................................7

8.2.5 Vehicle mass side to side ..........................................................................................8

9 Static vehicle weigh test recording form..............................................................................9

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Static vehicle weigh test EPR 0026

1 Purpose
A static vehicle weigh test is performed to ensure that the vehicle is constructed within
allowable load limits for the particular type of rolling stock and corridor/s along which the
vehicle is to operate.

For the vehicle to pass the test, the maximum axle load for any vehicle on the RailCorp
network shall be as specified in standard ESR 0001 or agreed between RailCorp and the
owner/operator, considering the type of vehicle proposed, vehicle operating conditions
and the area of operation, whichever is most restrictive.

2 Scope
A weigh test shall be performed on each of the following occasions (Refer to RSU 282
Section 20.2):

• Acceptance testing of new or substantially modified vehicles.

• Derailment damage (where practical)

A weigh test is recommended on each of the following occasions (Refer to RSU 282
Section 20.3):

• Bogie change on locomotive and passenger rolling stock

• Removal / replacement, modification, or adjustment of suspension equipment
• Investigation for overloading
• Investigation of derailment cause

3 Objective
To determine the weight of the vehicle and its wheel load distribution.

4 References
ESR 0001 Minimum Operating Standards for Rolling Stock

RSU 282 Static Vehicle Weigh Test

ESR 0001-C Static Vehicle Weigh Test

5 Weighing test procedure

The weight of the vehicle in working order and the vertical load exerted by each wheel on
the track shall be measured, with due regard as to the accuracy of the measuring
equipment.

Either conventional mechanical or electric/load cell weighing methods may be used.

Track at the weighing site must be level in the horizontal plane within 1 mm for at least
20m either side of the site and nominally tangent.

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6 Vehicle inspection
Prior to the weighing operation, the following shall be checked:

• All axle box clearances must be equal to or greater than the minimum allowable
dimension. This may be checked using sufficiently long feeler gauges or by running
the vehicle over an obstruction placed on the railhead, and observing free motion of
the axle boxes relative to the hornguides.

• All equipment fitted to the bogies of vehicles must be in the running condition, which
includes the correct fitment of all dampers, traction rods, torsion bars, and levelling
valves which are applicable.

• Vehicles with semi-permanent couplers shall remain coupled throughout the weighing
operation.

• The car body of the vehicle must be located centrally in the lateral direction with
respect to both bogies and track.

• For vehicles fitted with an air spring secondary suspension, the spring height at each
side of each bogie, when on level track, must be set at the correct spring design
height as specified by the spring manufacturer.

Note: Prior to and during the weighing process, air springs shall be kept fully
inflated at the correct level by a vehicle main reservoir air supply. Air spring isolation
cocks shall be open and levelling valve arms shall be connected.

• Vehicle heights shall be measured from railhead to a reference point on the car body
and must be within allowable limits for the vehicle being weighed.

Note: Vehicle height shall not be altered by adjustment of levelling valves on

vehicles so equipped, unless the air spring height is incorrect.

• All brakes must be released on the vehicle being weighed. Brakes shall not be
applied on any vehicle being weighed, at any time during the weighing operation,
including shunting on and off the weighbridge.

Note: Particular attention shall be given to ensure that spring parking brakes are
released either manually or by maintaining a main reservoir air supply on the vehicle,
for vehicles so equipped.

7 Vehicle weighing procedure

For consistency in the method of weighing vehicles, it is recommended that the following
procedure shall be followed.

• The vehicle shall be run at reduced speed on to the weighbridge.

• Whilst the vehicle is on the weighbridge, no alteration or adjustment shall be made to

the state of the vehicle (body or suspension) including artificial blows, shaking or
other procedure unless the vehicle is run over a minimum distance of 200 m after the
above mentioned adjustment is carried out and immediately prior to reweighing the
vehicle.

Note: No personnel are to be permitted in the vehicle during the weighing process.

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Static vehicle weigh test EPR 0026

• The weighing procedure shall consist of four independent weighings as follows:

− Weigh (1) – direction A

− Weigh (2) – direction B

− Weigh (3) – direction A

− Weigh (4) – direction B

That is, the direction which the vehicle approaches the weighbridge shall alternate
between successive weighings.

Also where possible, the vehicle must be run over a minimum distance of 200 m

immediately before each weighing.

This will eliminate, as far as possible, errors resulting from friction in the vehicle
suspension system.

8 Analysis of measured results

8.1 Total vehicle

The weighing uncertainty, E shall be calculated as follows:

• After calculating the total vehicle mass for each of the four weighings, the weighing
uncertainty shall be determined by taking the difference between the maximum total
vehicle mass, M max, and the minimum total vehicle mass, M min, and dividing the
result by two.

That is,

E = 0.5(M max − M min)

The average total vehicle mass, Ma referred to in 8.1, 8.2.2, and 8.2.3 shall be calculated
using all the total vehicle masses, as determined above for each of the four weighings.

That is,

Ma = 0.25[(M1) + (M 2) + (M 3) + (M 4)]

For the vehicle weighed in the tare and fully loaded condition and in running order, the
average total vehicle mass, Ma, minus the weighing uncertainty E, shall not exceed the
maximum specified mass.

Ma – E ≤ Maximum specified mass

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Static vehicle weigh test EPR 0026

8.2 Individual wheels

8.2.1 Wheel load P

For each wheel in turn the average wheel load shall be determine using that wheel’s
individual load from each of the four weighings. For further reference in this procedure,
this individual average wheel load shall be referred to as ‘wheel load P’.

That is,

P = 0.25[P(1) + P(2 ) + P(3) + P(4)]

8.2.2 Driving axles – axle to axle load

The following is recommended for vehicles with driving axles:

The sum of the two wheel loads P at each driving axle in turn, shall not deviate by more
than ± 2% from the average axle load, (determined by dividing the average total vehicle
mass, Ma by the number of axles), for driving axles intended to exert the same tractive
effort.

In summary, for each driving axle in turn,

1.02
(P1 + P2) max = (Ma + E)
A
0.98
(P1 + P2) min = (Ma − E)
A
Where,

P1, P2 = wheel loads on the same driving axle.

Ma = average total vehicle mass.

A = total number of axles on vehicle being weighed.

E = weighing uncertainty.

(P1 + P2)max shall not exceed the maximum axle load.

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Static vehicle weigh test EPR 0026

8.2.3 Non driving axles- axle to axle load

For vehicles with non driving axles:

The sum of the two wheel loads P at each non-driving axle in turn, shall not deviate by
more than ± 6% from the average axle load, (determined by dividing the average total
vehicle mass, Ma by the number of axles).

In summary, for each non driving axle in turn,

1.06
(P3 + P4) max = (Ma + E)
A
0.94
(P3 + P4) min = (Ma − E)
A
Where,

P3, P4 = wheel loads on the same non driving axle.

Ma = average total vehicle mass.

A = total number of axles on vehicle being weighed.

E = weighing uncertainty.

(P3 + P4) max shall not exceed the maximum allowable axle load.

8.2.4 Wheel load across an axle

For a given axle, the measured wheel load P must not deviate by more than ± 4% from
the average load per wheel of this axle.

In summary for each axle in turn:

 E


P max = 0.52 P1 + P 2 + 
 A

 E
P min = 0.48 P1 + P 2 − 
 A

Where,

P max, P min = Maximum and minimum allowable wheel loads P,

respectively.

P1, P2 = The two wheel loads associated with each axle in turn.

E = Weighing uncertainty.

A = Total number of axles on vehicle being weighed.

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Static vehicle weigh test EPR 0026

8.2.5 Vehicle mass side to side

Notwithstanding Clause 8.2.4, the sum of measured wheel loads P along one side of the
vehicle must not deviate by more than ± 2% from the average of the sum of all wheel
loads P on both sides of the vehicle.

In summary:

R max = L max =
1.02
(L + R + E )
2
R min = L min =
0.98
(L + R − E )
2
Where,

R max, L max = Maximum permissible sum of ‘wheel loads, P’ on right

and left hand side of vehicle respectively.

R min, L min = Minimum permissible sum of ‘wheel loads, P’ on right and

left hand side of vehicle respectively.

R, L = Sum of ‘wheel loads, P’ on right and left hand sides of

vehicle respectively.

E = Weighing uncertainty.

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Static vehicle weigh test EPR 0026

9 Static vehicle weigh test recording form

Below is a suggested table to record all relevant data acquired from a static vehicle weigh test. Analysis of the measured results will have to be carried
out (refer to Section 8).

Weighbridge Location: Number of Axles (A):

Weighbridge: Bogie No. 1 S/N:
Date: Bogie No. 2 S/N:
Vehicle Type: Fuel in Tank:
Vehicle Number:
Vehicle Weighing Record Axle No. 1 Axle No. 2 Axle No. 3 Axle No. 4 Axle No. 5 Axle No. 6 Total Vehicle
Left Right Left Right Left Right Left Right Left Right Left Right Mass (M)
Weigh (1) - Direction A M1=
Weigh (2) - Direction B M2=
Weigh (3) - Direction A M3=
Weigh (4) - Direction B M4=
Average Wheel Load (P)
Axle Load

Axle to Axle Load (Non Driving Axles) Axle to Axle Load (Driving Axles)
Maximum Total Vehicle Mass 1.06 1.02
( P1 + P 2) max = ( Ma + E ) = ( P1 + P 2) max = ( Ma + E ) =
Minimum Total Vehicle Mass A A
0.94 0.98
( P1 + P 2) min = ( Ma − E ) = ( P1 + P 2) min = ( Ma − E ) =
A A
Weighing Uncertainty (E)
E=0.5(M max - M min)=

Average Total Vehicle Mass

Ma=0.25(M1+M2+M3+M4)=

Wheel Load Across an Axle Axle No. 1 Axle No. 2 Axle No. 3 Axle No. 4 Axle No. 5 Axle No. 6
P max = 0.52(P1+P2+(E/A))=
P min = 0.48(P1+P2-(E/A))=

Vehicle Mass Side to Side

Vehicle Mass Side to Side (Sum of all average wheel load P on corresponding side) Left Right
R max = L max =0.51(L+R+E)= Measured
R min = L min =0.49(L+R-E)=

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