भारत सरकार - GOVERNMENT OF INDIA

रेल मंत्रालय - MINISTRY OF RAILWAYS

COACH DEFECT CODIFICATION SYSTEM

IRCAMTECH/GWL/MECH/CODIFICATION

DECEMBER – 2019

महाराजपुर, ग्वाललयर – 474005 (भारत) Maharajpur, Gwalior - 474 005 (INDIA)

: 0751 - 2470890 & Fax : 0751 – 2470841

E_mail_id : dirmech@gmail.com

Coach defect Codification System Annexure

CAMTECH Page 2 of 10

Coach defect Codification System: Coach Defect (En-route/Primary/Secondary) is Classified as per following Codification System:

A 99

First digit (alphabetic) describes group of assembly.

Second and third digit (numeric) describes nature of defect in component

Example :

J05 Cut off angle cock defective

K03 Bio tank defect L01 Air spring bellow leak

M08 Lavatory tiles broken N03 Head stock corroded

O12 Draft gear pad perished P05 Wheel Deep Flange

Q01 V Belt deficient or Nil Belts

R06 Inverter failure

S01 Less cooling due to more than one compressor failure

Coach defect Codification System Annexure

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Coach Defect (En-route/Primary/Secondary) Classification

Group Assembly Defect in Component of Assembly Code

J Air brake System Alarm chain defect 01

AR tank 02

Brake accelerator defective 03

Brake cylinder 04

Cut off angle cock defective 05

Drain cock 06

DV 07

DV relay valve defective 08

WSP Defective 09

Brake indicator 10

Brake Bindings 11

BP/FP Metallic pipe 12

Ferrule Joint 13

Hand Brake 14

Other than above 99

K Bio – Toilet System Ball valve 01

Bio tank clutch wire 02

Bio tank defect 03

Bio tank wire rope 04

Bio Toilet defect 05

Bio tank nut bolt loose 06

Bio Toilet safety wire rope broken 07

Clutch wire broken 08

J Bracket corroded 09

S trap work out 10

Bio toilet channel 11

Other than above 99

L Bogie Air spring bellow leak 01

Air spring bellow tilted 02

Air spring hose 03

Air spring rubber damaged 04

Air spring levelling valve 05

Anchor link 06

Anti roll bar 07

Anti roll bar gap 08

B clearance less 09

Bolster safety lug 10

Brake calliper 11

Brake disc 12

Brake gear defect 13

Car bolt broken 14

Coach defect Codification System Annexure

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Group Assembly Defect in Component of Assembly Code

Cattle run over 15

Centre pivot bolt loose 16

Connecting link rubbing to axle 17

Control arm 18

Control arm bracket 19

Control arm lug clearance 20

Control arm bush worn out 21

Control arm lower part missing 22

Control arm lug 23

Control arm stud 24

Control arm thread worn out 25

Crown bolt assembly 26

Dash pot protection tube 27

Dash pot spring 28

Earthing device 29

Earthing device oiler ring stud broken 30

Equalizing stay bracket 31

Guide rod broken 32

Lateral bump stop 33

Lateral bump stop clearance less 34

Lateral bump stop hitting to traction centre

35

Bump stop longitudinal broken 36

Low buffer height 37

Lower bolster plank broken 38

Phonic wheel nut deficient 39

Primary Inner Spring 40

Primary Outer Spring 41

Primary suspension rubber pad 42

Safety lug 43

Secondary Inner Spring 44

Secondary Outer Spring 45

Secondary spring rubber pad 46

Secondary spring shifted 47

Secondary suspension lower pad 48

Side bearer crack 49

Speed Sensor 50

Trolley corner broken 51

Trolley hitting to body 52

Vertical dumper damaged 53

Trolley sole plate crack 54

Traction lever work out 55

Vertical bump stop 56

Other than above 99

Coach defect Codification System Annexure

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Group Assembly Defect in Component of Assembly Code

M Interior Carpentry work 01

Communication door 02

Fall plate deficient 03

Flusher valve 04

Gas pipe line pantry 05

Interior work 06

Lavatory pan cracked 07

Lavatory tiles broken 08

Luggage sliding door 09

Main door pivot 10

Paint defect 11

Painting work 12

Pipe fitting 13

PVC floor 14

Rain water leaking /Roof leaking 15

Rolling shutter 16

Roof leaking 17

Seat 18

Side filling pipe 19

Trimming work 20

UIC Vestibule 21

Water tank rubber hose 22

Window glass 23

Disinfestations 24

Other than above 99

N Corrosion Cylindrical member corrosion repair 01

Turn under 02

Head stock corroded 03

Inner headstock member corrosion 04

Sole Bar 05

Other Than above 99

O CBC /Buffing Gear/Draft Gear

CBC defect 01

CBC draft gear nut missing 02

CBC spindle broken 03

CBC supporting device 04

Knuckle defect 05

Muff coupler CBC defective 06

CBC knuckle 07

Additional anti creep mechanism not function

08

Draft gear 09

Draft gear pad perished 10

Buffer case 11

Buffer dead 12

Buffer face plate 13

Coach defect Codification System Annexure

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Group Assembly Defect in Component of Assembly Code

Buffer plunger 14

Other then above 99

P Wheel/Axle/Axle Box

Wheel axle box bolt 01

Wheel axle box cover 02

Wheel axle box grease oozing out 03

Wheel axle box wing 04

Wheel Deep Flange 05

Wheel dia low 06

Wheel flange cut mark 07

Wheel gauge excess 08

Wheel grazing 09

Wheel groove 10

Wheel hollow tyre 11

Wheel radius too small 12

Wheel roller bearing defect 13

Wheel rubbing to under-frame channel 14

Wheel sharp flange 15

Wheel shattered rim 16

Wheel shelled tread 17

Wheel skidded 18

Wheel spread rim 19

Wheel thermal crack 20

Wheel thin flange 21

Wheel touching to under-frame 22

Wheel warm box 23

Wild case/OMRS 24

Other than above 99

Q Alternator V Belt deficient or Nil Belts 01

V belt smoked 02

Alternator winding defects 03

Alternator pulley worn out/Damaged 04

Alternator pulley loose 05

Axle pulley worn out/Damaged 06

Axle pulley loose 07

Axle pulley shifted 08

Bogie bracket worn out 09

Bogie bushes worn out 10

Both alternator no generation 11

Tensioning Rod defect 12

Other than above 99

Coach defect Codification System Annexure

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Group Assembly Defect in Component of Assembly Code

R RRU/ ERRU/ Inverter

Less generation 01

Over Generation 02

No generation 03

Load Sharing problem 04

Physical damages to under-slung mounted 25 kVA Inverters

05

Inverter failure 06

Other than above 99

S Air Conditioner Unit (RMPU)

Less cooling due to more than one compressor failure

01

Less cooling due to choking in the system 02

Less cooling due to ducting canvass torn out

03

Refrigerant leaks (in refrigerant pipe lines condenser coil/ evaporator coil)

04

Harting connector defects 05

Drip tray leakage 06

Air filters choked 07

Microprocessor defect 08

Heaters defect 09

Condenser fan defect 10

Condenser fan motor defect 11

Blower defects 12

Blower motor defect 13

Compressor defect 14

HP/ LP/ OHP cut-out switch defect 15

NTC sensor defect 16

Expansion valve/ capillary tubes defect 17

Evaporator coil defect 18

Condenser coil defect 19

RMPU doors defect 20

Vent relay defective 21

Other than above 99

Coach defect Codification System Annexure

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Group Assembly Defect in Component of Assembly Code

T Battery and Battery Box

Battery box damages (welding failures/ corrosion)

01

Battery defects 02

Defective Battery charger 03

Regulated Battery Charger failure 04

Emergency Battery Charger failure 05

Other than above 99

U Transformer &

IV/ ZS Couplers

60 /50 kVA transformer failure 01

60 kVA/ 50 kVA transformer suspension defect

02

15/9 kVA transformer failure 03

Inter vehicle coupler / Z-S coupler defects / damages

04

Feeder cable defect 05

Damage to Feeder junction box 06

Entry of rain water into feeder junction

box 07

Other than above 99

V Power panels / Switch board

cabinet & Wiring

Rain water leak over Power panel / Switch board cabinet

01

Wiring Insulation failures 02

Overheating of cables 03

Shorting of 750 Volts circuit cables /

fuses 04

Rotary switch defects 05

Lighting transformer 1kVA defect 06

Wiring earth fault 07

Door lock and hinges defect 08

MCB defects 09

Earthing device defect 10

DC-DC converter defect 11

MMR defect 12

Contactors defect 13

Fuses defect 14

Coach Supply not getting ‘ON’ 15

Control transformer 400 VA defective 16

Other than above 99

Coach defect Codification System Annexure

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Group Assembly Defect in Component of Assembly Code

W Pantry Equipment

Geyser defect 01

Soup boiler defect 02

Hot case defect 03

Deep freezer defect 04

Thermostat defect 05

Hot plate defective 06

Electric chimney defect 07

Chimney filter defect 08

Water boiler defect 09

Bottle cooler defect 10

Refrigerator defect 11

Other than above 99

X Lights, Fans and Sockets

Lights defect 01

Fan defect 02

Emergency light defect 03

Mobile charging socket defect 04

Exhaust fan defect 05

Other than above 99

Y Water Supply System

Mono-block pump defect 01

Pump controller defect 02

Other than above 99

Z Power Cars Fuel leak in fuel tank / fuel pipe line 01

Failure of 60 kVA transformer 02

Failure of radiator motor 03

Failure of vent motor 04

Radiator water leak 05

Rain water leak from roof above Switch Board Cabinet

06

Inter vehicle coupler / Z-S coupler defects / damages

07

Wiring Insulation failures 08

Damage to Feeder junction box due to external reasons

09

HOG panel wiring failures 10

Shorting of 750 Volts circuit cables / fuses in SBC

11

Starter Battery failures 12

Diesel Generator failures 13

Self starter defect

Feeder contactor 630 amps defects 14

Bus coupler defect 15

Air Circuit Breaker (ACB) defect 16

Other than above 99