Engineering Standard
Rolling Stock
Engineering Standard
ESR 0531
OVERHAUL OF FREIGHT AXLES
Version 1.0
Issued June 2010
Owner: Chief Engineer Rolling Stock
Approved Stephen White, Authorised Michael Uhlig,
by: Technical Specialist Rolling by: Manager,
Stock Performance Standards, Rolling Stock Access Integrity
Rolling Stock Access Integrity
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UNCONTROLLED WHEN PRINTED Page 1 of 6
RailCorp Engineering Standard — Rolling Stock
Overhaul of freight axles ESR 0531
Document control
Revision Date Summary of change
(RSS 0531) 1.0 August 2007 Based on TRS 1551
(RSS 0531) 1.1 Mar 2008 References to some RSS standards amended
(ESR 0531 1.0 June 2010 Reformatted and renumbered ESR 0531
Summary of changes from previous version
Summary of change Section
NOTE – If the final document is small enough for the ‘Contents’ and ‘Document control’
to fit on one page remove the page break between the existing pages 2 and 3.
HOWEVER if the ‘Document control’ page carries over to a second page separate
pages must be used for ‘Contents’ and ‘Document control’
© Rail Corporation Page 2 of 6
Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1.0
RailCorp Engineering Standard — Rolling Stock
Overhaul of freight axles ESR 0531
Contents
1 Scope..................................................................................................................................................4
2 Terminology .......................................................................................................................................4
3 Non destructive testing ....................................................................................................................4
4 Visual inspection...............................................................................................................................4
5 Machining...........................................................................................................................................4
6 Wheelseat...........................................................................................................................................5
7 Bearing journals ................................................................................................................................5
8 Threaded holes ..................................................................................................................................5
8.1 Repair........................................................................................................................................5
9 Axle limits on reconditioning ...........................................................................................................6
10 Referenced documents.....................................................................................................................6
10.1 RailCorp standards ...................................................................................................................6
© Rail Corporation Page 3 of 6
Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1.0
RailCorp Engineering Standard — Rolling Stock
Overhaul of freight axles ESR 0531
1 Scope
This standard details the requirements for the overhaul of freight axles.
2 Terminology
The axle is described using terms as shown in Figure 1 and Table 1.
Figure 1
Stepped end or tapered end A
Bearing journal B
Dust guard seat C
Axle Barrel D
Wheelseat E
Table 1
3 Non destructive testing
The axle shall be non destructive tested according to specification ESR 0333.
4 Visual inspection
The axle barrel shall be inspected for damage according to ESR 0331.
Welding of axles or any other method not specified in this specification, is not permitted
under any circumstances and any axle showing welding or cutting torch damage is to be
scrapped.
5 Machining
All axles shall be machined and finished in accordance with the relevant drawings unless
detailed otherwise in this specification.
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Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1.0
RailCorp Engineering Standard — Rolling Stock
Overhaul of freight axles ESR 0531
6 Wheelseat
All axles shall be closely examined to identify any surface defects. Any axle with a
wheelseat defect that cannot be removed either by machining within the prescribed
tolerance (i.e. not below the condemning diameter of the axle at the point where the
defect was detected) or by precision grinding out all sharp edges and surface
discontinuities without reducing the minimum surface contact between the axle wheelseat
and wheel bore below 95%, then the axle shall be scrapped. Axles that are to be
machined must be segregated with respect to the axles awaiting wheelset assembly.
Wheelseats shall not be reclaimed when beyond their condemning diameter, as
discussed in Section 9 of this Specification.
Depression, circumferential score or damage or injury to the surface metal of the
wheelseat must be removed. Such defects if allowed to remain may result in a broken
axle. Any longitudinal channel-way or crack in the wheelseat must also be removed. If a
circumferential check or crack is found in the wheelseat the axle must be scrapped
unless the checks or cracks can be machined by turning or grinding without going below
the axle's serviceable limit.
Each axle wheelseat must be checked in not less than three points equispaced along its
length and on two different diameters at each of these points to ensure that it is
cylindrical. The variation for any two of these measurements must not exceed 0.05mm
(0.002"). Where taper exists within allowable limits (ie: 0.05mm) the small diameter must
be on the journal end of the wheelseat.
Wheelseats may be hand polished with a light abrasive material for rust removal and
minor surface defect removal. It is preferable that a machine cut, ground or rolled surface
be provided to give satisfactory results.
A taper must be turned on the journal end of the wheelseat extending to a maximum of
12 mm (0.5") towards the centre of the axle. This taper shall be started at 0.8 mm
(0.032") less than the wheelseat diameter and is intended to ensure true entry of the axle
into the wheel bore.
7 Bearing journals
Bearing journals are to be requalified according to ESR 0032.
8 Threaded holes
Capscrew holes shall be checked with a 2B go no-go thread checking gauge and
retapped if necessary.
8.1 Repair
Defective capscrew holes may be repaired by drilling and retapping the holes 60 degrees
from their original position provided that this repair has not been done previously.
Plug the old capscrew holes with a capscrew that is of sufficient length for it to bottom in
the hole. The capscrew should be torqued to 100 foot/lbs over the maximum specified
see ESR 0032.
Retap the new holes to the tolerances specified on the drawing for a new axle.
© Rail Corporation Page 5 of 6
Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1.0
RailCorp Engineering Standard — Rolling Stock
Overhaul of freight axles ESR 0531
9 Axle limits on reconditioning
Figure 2
Axle item number Minimum wheelseat Minimum axle barrel
diameter I mm diameter K mm
A118 189.85 150
A136 180.30 138
A143 206 157
A144 189.85 148
A153 189.85 150
A166 206 157
A201, A203 213 172
Table 2
10 Referenced documents
10.1 RailCorp standards
ESR 0032 Axle bearing reference manual
ESR 0331 Wheel & Axle reference manual
ESR 0333 Non destructive testing of axles
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Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1.0
