TOTAL PRODUCTION (UPTO JUNE 2011)

TOTAL LHB PRODUCTION (UPTO JUNE 2011)

LHB POPULATION (RAILWAY WISE)

SR CR NCR SCR SWR ECR SER ECoR ER WR NR TOTAL

14 16 18 22 26 41 44 49 182 171 505 1088

WARRANTY PERIOD OF MAJOR COMPONENTS 

WARRANTY PERIOD ITEMS

Service Life >=  30,00,000 KM

•CTRB  (Roller Bearing)

06 Years •Lateral Bump stop•Ball Joint Control Arm•Ball Joint Roll Link•Traction Center Elastic Joint•Rubber Spring

4 Years •Dampers (all types)•Secondary Rubber Pad

WARRANTY PERIOD OF MAJOR COMPONENTS WARRANTY PERIOD ITEMS

2 Years (IRS 

Conditions)

•Springs (all types)•Ball Joint Traction Lever•Axle mounted Disc brake system•Doors (all types)•Water Tanks (all types)•Fuel  Tank•UIC  Vestibule•CDTS (all types)•Seats & berths (all Types)•Secondary  Rubber Pad•High Tensile AAR “H”

Type Tight lock CBC•Lavatory Module.•FRP Ceiling Panels (All Types)•FRP Side Panels (All Types) •Sealed Windows (all Types)•Honey Comb Partition Frame (all types)•PU Paint•Flooring 

1  Years •Wheel Set

WARRANTY PERIOD OF MAJOR ELECTRICAL  COMPONENTS Item (Electrical) Warranty period

500KVA, 3 PHASE Diesel Driven Alternator set 5 YearBattery chargers 12 monthsRMPU 12 months50KVA, 3 PHASE Diesel Driven Alternator set

IRS Conditions

TransformersPre‐cooling transformers60 KVA transformersPA system for  1ACPA system for  BuffetPA system for  Power CarPA system for  EOG CoachesPA system PA system for  Chair CarBatteries

WARRANTY PERIOD OF MAJOR ELECTRICAL  COMPONENTS 

Item (Electrical) Warranty  period

Regulated Battery chargerIRS Conditions

Emergency Battery Charger

Switch Board Cabinet for BUFFET

Switch Board Cabinet for AC/SG

Switch Board Cabinet for EOG

Switch Board Cabinet for Power car

Pantry equipments

MAJOR WARRANTY FAILURES OF LHB COMPONENTS

FIRM WISE COMPLAINTS OF CDTS IN ALL TYPES OF COACHES

FIRM AIKON VIBHU AMIT DARSHAN Total2009‐10 53 62 4 8 1272010‐11 78 127 26 34 2652011‐12 43 7 33 ‐ 83Total 174 196 63 42 475

Pending 35 (TKPR, SRC) ‐ 33 (SRC) ‐ 68

YEAR WISE COMPLAINTS OF CDTS IN ALL TYPES OF COACHES

FIRM AIKON VIBHU AMIT DARSHAN Total

2009‐10 53 62 4 8 1272010‐11 78 127 26 34 2652011‐12 43 7 33 ‐ 83Total 174 196 63 42 475

FAILURES OF CDTS IN ALL TYPES OF COACHESDefects AIKON VIBHU DARSHAN AMIT Total

Speed sensor 35 26 12 12 85

Dislodging of lav. Pan 10 47 8 - 65

Power supply /DC-DC converter 28 17 2 1 48

Slide / cylinder 37 6 - 43

Switches defective 16 11 14 - 41

Slide valve problem 5 24 1 1 31

Flapper/ valve 1 9 - 19 29

Solenoid valve 13 3 1 5 22

Retention Tank - 5 - 16 21

PLC defective 5 13 1 - 19

Lower slide paddle/ gasket - 15 - - 15

Pressurizer control NRV/ rubber 1 11 1 6 15

Air filter problem 4 - 2 3 9

Air pipe/ isolating cock 5 2 - 5

Flush cover - 4 - - 4

Water supply 4 - - - 4

Flush valve 4 - - - 4

Water filter 3 - - - 3

Flapper cylinder bkt. - 3 - - 3

Leakage 3 - - - 3

Total 174 196 42 63 469

DAMPER  POPULATION UPTO JUNE’11Firm name KONI SACH GEREP MEDITTER ESCORT ABROL TOTAL

PRIMARY 8 0 0 0 0 0 8

SECONDARY 4 0 0 0 0 0 4

YAW 2165 2031 900 75 15 0 5186

secondary V/GS 73 123 12 0 0 0 208

LATERAL 756 1582 400 44 5 0 2787

PRIMARY 1948 5870 2366 139 19 0 10342

SECONDARY 997 2806 1201 80 10 48 4805

TOTAL Population

5951 12412 4879 338 49 48 22340

Major defects: leaky, fixing arrangement failure, silent bush perishing, breakage & corrosion on protecting tube casing.

DAMPER  FAILURE UPTO JUNE’11

Firm name KONI SACH GEREP MEDITTER ESCORT ABROL TOTALTOTAL

Population5951 12412 4879 338 49 48 22340

FAILURES 82 587 84 0 0 0 753

% age Failure 1.37 4.8 1.7 0 0 0 3.37

2008-09 - 306 - 306

2009-10 0 142 0 0 0 0 1422010-11 81 139 84 0 0 0 304

2011-12 1 0 0 0 0 7

TOTAL 82 587 84 0 0 0 753PENDING 

COMPLAINTS 01 103 05 0 0 0 109

ER –

32, SR ‐22, NR ‐21, SER ‐13, WR‐7, NCR‐7, SCR‐7Major defects: leaky, fixing arrangement failure, silent bush perishing,

breakage & corrosion on protecting tube casing.

FIRMS WISE FAILURE DATA OF DAMPERSYear Name of firm Primary Secondary Yaw Railways

2008‐09 Sach (M.G.World wide) 15 ‐ ‐ ECR

Sach (M.G.World wide) 88 44 9 ER

Sach (M.G.World wide) 150 ‐ ‐ WR

TOTAL 253 44 9

2009‐10 Sach (M.G.World wide) 53 29 9 ERSach (M.G.World wide) 12 7 32 NR

TOTAL 65 36 412010‐11 Sach (M.G.World wide) 62 15 6 ER

Sach (M.G.World wide) 22 ‐ ‐ SRSach (M.G.World wide) 15 4 2 SERSach (M.G.World wide) 6 1 ‐ WR

Sach (M.G.World wide) 3 ‐ ‐ NCR

Sach (M.G.World wide) 2 ‐ ‐ SCR

TOTAL 110 20 8

FIRMS WISE FAILURE DATA OF DAMPERSYear Name of firm Primary Secondary Yaw Railways

2010‐11 Koni (Pan India) 22 28 4 ER

Koni (Pan India) 3 ‐ 5 NCR

Koni (Pan India) 3 ‐ ‐ SR

Koni (Pan India) 2 ‐ ‐ SCR

Koni (Pan India) 1 ‐ ‐ SER

TOTAL 31 28 9GEREP (SFT Engg.) 21 47 2 ER

GEREP (SFT Engg.) 9 ‐ ‐ SER

GEREP (SFT Engg.) 5 ‐ ‐ SCR

TOTAL 35 47 2

2011‐12 Koni (Pan India) ‐ 1 ‐ SER

TOTAL ‐ 1 ‐

Year Wise Complaints of Dampers

Firm Wise Complaints of Dampers

RAILWAY WISE FAILURE DATA OF DAMPERSYear  Type of 

damperSER ER WR NCR NR SR ECR SCR TOTA

L

2008‐

09PRIMARY ‐ 88 150 ‐ ‐ ‐ 15 ‐ 253

SECONDARY ‐ 44 ‐ ‐ ‐ ‐ ‐ ‐ 44

YAW ‐ 9 ‐ ‐ ‐ ‐ ‐ 9

2009‐

10PRIMARY ‐ 53 ‐ ‐ 12 ‐ ‐ ‐ 65

SECONDARY ‐ 29 ‐ ‐‐ 7 ‐ ‐ ‐ 36

YAW ‐ 9 ‐ ‐ 32 ‐ ‐ ‐ 41

2010‐

11PRIMARY 25 105 6 6 ‐ 25 ‐ 9 176

SECONDARY 4 90 1 ‐ ‐ ‐ ‐ ‐ 95

YAW 2 12 ‐ 5 ‐ ‐ ‐ ‐ 19

2011‐

12PRIMARY ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐

SECONDARY 1 ‐ ‐ ‐ ‐ ‐ ‐ ‐ 1

YAW ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐

TOTAL 32 439 157 11 51 25 15 9 739

Railway Wise Complaints of Dampers

Firm Type of coach LWRRM LWACCN LWACC W

LFA C

TOTA L

LPDN

PRIMARY INNER - 2 - - 2

SECONDARYINNER 1 3 - - 4

OUTER 5 - - - 5

GRUEBER PRIMARY OUTER 1 5 3 3 12

TOTAL 07 10 3 3 23

BREAKAGE PRIMARYINNER 1 5 3 3 12

OUTER 1 5 - 06LIP

DEFORMATIONSECONDARY OUTER 1 - - - 01

BUFFER HEIGHT

SECONDARY OUTER 4 - - - 04

TOTAL 07 10 3 3 23

Data of Spring Failure 2008‐09 TO 2011‐12

LHB SPRING DETAILSTYPE OF COACH OUTER SPRING INNER SPRING

DRG. NO. PL NO. DRG. NO. PL NO.

PRIMARY PRIMARYChair Car, Ex. CC, 2 Tier, Hot 

Buffet, First Class

1267411 33503035 1267412 33503047

3 Tier 1267411 33503035 1277143 33500356

Power Car (Guard & Gen) 1277142 33500368 1277143 33500356

SECONDARY SECONDARYChair Car, Ex. CC, 2 Tier, Hot 

Buffet, First Class

1269514 33503060 1269513 33503059

3 Tier 1268836 33500400 1269513 33503059

Power Car (Guard) 1277146 33500381 1277145 33500370

Power Car (gen) 1268836 33500400 1268837 33500393

Data of Spring Failure

Data of Spring Failure

WHEEL SET EARTHING EQUIPMENT

DEFECTS IN CBCFirm name Faiveley Escort ASF Key 

StoneTOTAL 

Knuckle pin replaced ‐ 52 ‐ 52Supporting Compression spring 

replaced08 ‐ ‐ 08

Supporting bolt shear ‐ ‐ 08 08CBC knuckle changed ‐ 06 ‐ 06CBC  tell tale recess unclear 06 ‐ ‐ 06

Defective spring  cartridge 

assembly  of back lash 

compensating device 

01 ‐ ‐ 01

Unclamping device not working 1 ‐ ‐ 01Total 16 58 08 82

YEAR WISE FAILURES OF CBCFirm name Faiveley Escorts ASF Key Stone TOTAL 

2008‐09 02 ‐ 08 102009‐10 06 ‐ ‐ 062010‐11 08 58 ‐ 66

Total  16 58 08 82

FIRM WISE FAILURES OF CBCFirm name Faiveley Escorts ASF Key Stone TOTAL 2008‐09 02 ‐ 08 102009‐10 06 ‐ ‐ 062010‐11 08 58 ‐ 66Total  16 58 08 82

FIRM WISE FAILURE OF CBC IN 08‐09, 09‐10, 10‐11 

Firm name Faiveley Escorts ASF Key Stone TOTAL 

2008‐09 02 ‐ 08 102009‐10 06 ‐ ‐ 062010‐11 08 58 ‐ 66

Total  16 58 08 82

ENROUTE COACH DETACHMENT (BEARING FAILURES)

ENROUTE COACH DETACHMENT (BEARING FAILURES) 2008‐09DATE 20/09/2008 22/10/2008

TRAIN NO. (SDAH‐

Rajdhani) 2423 (Rajdhani Exp.)

PRIMARY SDAH NDLS

STATION Bela Koba (KIR Division)

COACH DETAILS ER 06116  LWACCNB/ DATE:      R/DATE : IOH : 08/11/2007

NR06854  LWLRRMB/DATE:  02/2007(RCF)R/DATE : 02/2010IOH : 

BEARING DETAILS TIMKEN TIMKEN

PERIOD BEFORE FAILURE 20 Months   

VISUAL INSPECTION 

Cage broken.

Sealing Ring damaged.

Cage broken

Rollers damaged.

ENROUTE COACH DETACHMENT (BEARING FAILURES) 2008‐09

DATE 23/01/2009TRAIN NO. 2310  (NDLS‐RNCC)PRIMARY RNCC

STATION Somna (GHZ‐TDL section)COACH DETAILS EC 07851 LWLRRM

B/ DATE:  04/2007 (RCF)R/DATE : 04/2010IOH : 

BEARING DETAILS TIMKEN

PERIOD BEFORE FAILURE 20 Months   VISUAL INSPECTION 

Cage broken.

Grease burnt.

Outer race broken. 

Rollers seized.CAUSES

Cage broken

ENROUTE COACH DETACHMENT (BEARING FAILURES) 2010‐11

DATE 02/05/2010TRAIN NO. 2444 (BBS‐NDLS  RAJDHANI)PRIMARY NEW  DELHISTATION DHANMANDALCOACH DETAILS NR‐LACCN 10106

B/DATE : 02/2010 (RCF)R/DATE : 04/2012IOH  : ‐‐‐

BEARING DETAILS TIMKENPERIOD BEFORE FAILURE 2 MonthsVISUAL INSPECTION 

LTTR

Outer race melted.

Cage melted 

Inner race partially melted.

Locking plate meltedCAUSES

Over  heating , melting  and breakage of outer race.

CORRECTIVE MEASURES

RWF  to  ensure thread length as 35 mm.

Axle end  cap screw is standardized  to  60 mm.

Locking plate to be modified to ensure proper locking of 

screw head.

IMPROPER LOCKING PLATE  

Though locking plates are received as  per the drawing but  it 

is 

observed 

that    locking   tabs   are   not 

in 

a 

position 

to 

lock the  hex head screw  from three faces.

Suggestion:Position of locking tabs should be at 120º . 

ENROUTE COACH DETACHMENT (BEARING FAILURES) 2010‐11DATE 5/9/10 25/10/2010TRAIN NO. 2421 (BBS‐NDLS) Rajdhani Patna‐NDLS RajdhaniPRIMARY New DelhiSTATION Hijli near KGP Mugal SaraiCOACH DETAILS NR 07122 LWACCN

B/Date : 09/2007R/Date : 11/2010IOH: 02/05/2009 (JUDW)

NR 9057 LACCWB/Date : 03/2010R/Date:  03 /2013

BEARING DETAILS TIMKEN TIMKENPERIOD BEFORE 

FAILURE

23 Months 7 Months

VISUAL INSPECTION 

Journal badly scoured

Partially melted  and  elongated

Axle box front cover &rollers 

were missing

Inner & outer recess had also 

melted.

Earthing equipment missing

Earthing housing found broken.

Rubbing mark on bearing seal.

01 no. Axle end screw worked out.

CAUSES

Could not be ascertained due to 

complete rollers falling down.  

Due to breakage of wheel set earthing 

equipment.

CORRECTIVE MEASURES

Look out glass has been incorporated on the 

housing.

Inspection of wheel set earthing equipment is to 

be incorporated in the maintenance schedule.

36

IMPROVEMENTS  IN RCF BUILT  COACHES

Improper grinding of sole bar & sidewall joints of LHB & Hybrid type coaches.

Grinding of welding joints between sole bar and sidewall ensured.

SOLE BAR WELDING

DEFECTS IN MAGAZINE BAG 

38

EARLIER NOW 

39

EARLIER NOW 

DROPPING OF MIRRORS 

Undulations on Lavatory floor 

40EARLIER NOW 

Undulations on Lavatory floor (Front Part)

Heavy undulations Undulations eliminated

Ribs provided

Complaints 

from 

various 

railways 

were received regarding stagnation 

of 

water 

on 

lavatory 

floors. 

Undulations 

in 

front 

part 

have 

been 

eliminated 

by 

providing 

supporting 

ribs.    This 

is 

to 

be incorporated in the drawing.

Complaints 

regarding 

water 

logging 

near 

doorways 

and  working 

out 

of 

water 

discharge 

pipe 

has 

been 

reported 

by many railways.

3 Joints

Water Discharge Pipe 

EARLIER NOW

Lavatory Pan dislodging problem 

ProblemComplaints of Lavatory  Pans  getting loosened and dislodged  from the 

FRP base were reported from various railways.Solution

• Studs are welded on the backside of lavatory pan so as to hold the pan firmly with the FRP floor. This has completely eliminated the problem. Sikaflex 221 has been standardized for adhesion & sealing.

Studs

Attachment Wall Locking Mechanism 

EARLIER NOW

Breakage of Snack table were reported due to failure of adhesive at the joints .Corrective Actions :

•Single piece injection moulded polycarbonate snack table has been developed which can accommodate six water bottles.

Breakage of Polycarbonate Snack Table 

Earlier Now

Brakage/theft of earthing unit

• Cases of breakage of Earthing Cable 

• Breakage of Al. earthing box cover 

Wash Basins getting Defaced

47

FRP  Wash  Basin SS  Wash Basin

Water tank level gauge

•Complaints of defective gauge has received from Zonal Rlys. 

•Tank manufactures refuse to replace these defective gauges as RCF 

has recommended BAYHAM make only.

VINYL WRAPPING DEFECTS 

49

Wrinkles around the Window

QUALITY CONTROL ON APPLICATION OF VINYL  WRAPPING

1.

Surface 

preparation 

is 

ensured 

by 

way 

of 

roughening 

and 

removal of uneven paint marks for better adhesion.2.

Overlapping of vinyl sheets  between two joints on sidewall. 2.

Edge sealing started immedietly & simultaneously after fixing of

vinyl sheets.3.

Shower test ing is done prior to Vinyl wrapping.4.

No Vinyl wrapping on door‐way corners.5.

Overlapping of vinyl wrapping  to endwalls .6.

No vinyl wrapping on turn‐under.7.

No vinyl wrapping  on power car grills.8.

20 mm gap below rain water gutter. 9.

10 mm gap around non  ac windows.10.

No vinyl wrapping on window rubber sealings.11.

Vinyl wrapping application done in covered shed

CBC Knuckle pin jamming reported by SER: Garnets were found adjoining knuckle pin housing. Thorough masking of CBC during garnet blasting is ensured.

High incidence of corrosion and pitting in FIAT Bogies within 3years of service.

Breakage of Allen bolts of upper berth guide - SER

Bump stop clearance problems – SER

Corrosion of dampers and its cover. – ER

Berth reading lights defective. – NCR

Soap dispenser rusty. – NCR

Air entrapment in water tank circulation.

Upper berth nylon sleeve breakages.

Working out of loading door.

Breakage of disc brake and its cooling fins.