INSPECTION & TEST PLAN

CARBON BRUSH ASSEMBLY

FOR WHEEL SET EARTHING EQUIPMENT
(FOR LHB TYPE COACHES)

1. Specification/Drawing : RCF Drg. No. LW71239 Alt.-Nil & IS:13466/1992

2. Date of Inspection :

3. Place of Inspection :

4. Size of Lot :

5. Size of Sample :

As per Annexure C of IS:13466/1992 (Table 16)

1st Sample 2nd Sample Acceptance 1st Rejection 2nd Rejection
Lot Size
Size Size Number No. No.
(1) (2) (3) (4) (5) (6)
Up to 100 5 - 0 1 -
100 – 300 8 8 0 2 2
301 – 1000 13 13 0 2 2
1001 – 3000 20 20 0 3 4
3001 – 10000 32 32 1 4 5
10001 & above 50 50 2 5 7
In any consignment all the carbon brushes of the same designation, manufactured from the same material
under similar conditions of production shall be grouped together to constitute a lot.

6. Document Verification: a) Internal/ External test certificate for raw material & Bought-Out items
(i.e. Brush Block, Terminals, etc., as applicable)
b) Dimensional check report
c) Calibration record of gauges, measuring instruments & test equipment

7. Tests/Checks (to be witnessed/conducted by inspector):-

SS.
Parameter Value Specified Observations Remarks
No.
The brushes shall be examined
Ref. Cl. No.16.4 of
with a magnifying glass of
IS:13466/1992
magnification factor 10X min.,
for the following:
(i) Cracking, chipping or
(a) Visual distortion.
(ii) Smoothness of surfaces.
(iii) Sound and proper jointing of
pigtail to carbon brush.
(iv) Appropriate marking.

Prepared by- Checked by- Forwarded by-

IE: RY Technical Cell: RAS CM: CAK
 INSPECTION & TEST PLAN
CARBON BRUSH ASSEMBLY
FOR WHEEL SET EARTHING EQUIPMENT
(FOR LHB TYPE COACHES)

S.
Parameter Value Specified Observations Remarks
No.

As per RCF Drg. No. LW71239

Alt.-Nil
& Dimensional Sheet
Ref. Cl. No.16.5 of IS:13466/92 attached
(i) The dimensions shall be Specially fabricated
measured with vernier callipers ‘go’ and ‘no-go’
(b) Dimensional
& screw gauges with their least gauges may be used
count not more than 0.01mm for checks of
dimensional accuracy
(ii) For measuring the curvatures on mass scale
& checking trueness of the flat production.
surfaces, dial gauge should be
used.

COMPONENTS
(c)
Ref. Material & Spec. as per RCF Drg. No. LW71239 Alt.-Nil

As per IS:13525/1992 Ref. Cl. No. 5.1 of

2 Nos. Copper Braded Cable IS:13466/92
Copper Braded Ø5x100 duly crimped with tongue
c.1
Cable type copper crimping sockets to OEM TC/Test
be embedded firmly in the Carbon Report may be
Brushes. reviewed/ verified

As per Cl. No.6.1 of IS:13466/92

Crimping Socket Crimping Socket Tongue Type OEM TC/Test
c.2 ETP Copper-99.9% purity & Silver Report may be
Tongue Type
plated, Coating thickness 5 reviewed/ verified
Micron or more.

Ref. Note- 4 of RCF

As per Cl. No. 4 of IS:13466/92
Drg. No. LW71239
The Brush Material (Metal- Alt.-Nil
Graphite-SKM9) used for
manufacture of carbon brushes Manufacturer’s T.C
shall be one of the grades :- may also be verified/
Metal Graphite reviewed.
c.3 BE-14/Z1 M/s Elka Carbon or
(Carbon Block) Mersen India or
BM-51 of M/s ACPL or any other
RDSO approved make.

The Brush material used shall

conforms to the requirements
given in IS:13584/1993

Prepared by- Checked by- Forwarded by-

IE: RY Technical Cell: RAS CM: CAK
 INSPECTION & TEST PLAN
CARBON BRUSH ASSEMBLY
FOR WHEEL SET EARTHING EQUIPMENT
(FOR LHB TYPE COACHES)

S.
Parameter Value Specified Observations Remarks
No.
As per Note-5 of RCF Drg. No.
LW71239 Alt.-Nil
Manufacturer’s insignia shall be
legibly embossed on the Brush
Block above the worn out limit.
(d) Marking
As per Cl. 14.1 of IS:13466/92
Batch No. & Year of manufacture
may also be legibly & indelibly
marked on carbon brush.

As per Cl. 15.1 of IS:13466/92

Carbon brush shall be suitably
(e) Packing protected & packed so as to avoid
any damage to flexible, terminals
& carbons.

Name & Signature of IE

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IE: RY Technical Cell: RAS CM: CAK
 INSPECTION & TEST PLAN
CARBON BRUSH ASSEMBLY
FOR WHEEL SET EARTHING EQUIPMENT
(FOR LHB TYPE COACHES)

S. Parameter Specified Observation Remarks

No. Dimension (for guidance
with tolerance only)
1 2 3 4 5 6 7 8 9 10 11 12 13
Length of carbon block
1 52/45 ± 0.8*
(with bevel top)
2 Width of carbon block 40 -0.15/-0.05*
3 Thickness 20 -0.13/-0.04*
Dia. of pigtail (copper
4 Ø5 ± 0.3**
braided cable) (2 Nos.)
5 Pigtail’s centre spacing 28 ± 0.5**
2 x 45°
6 Chamfer (bottom edges)
(±0.4/±1o)**
Worn-out limit Mark
7 8 ± 0.5**
from bottom
Side edge chamfer 1 x 45°
8
(3 edges) (±0.4/±1o)**
Side edge chamfer 4 x 45°
9
(1 edge) (±1/±1o)**
Terminal (Socket) length-
10 As per Table-10
(A)Tongue type
Terminal (Socket) width- of IS:13466/92
11 or PO
(B)Tongue type
requirement
12 Terminal slot hole Dia. (d)
(may be
Terminal slot centre clarified).
13
position (x)
*Tolerance as per IS:13466/92
**For untoleranced dimension, tolerance to be as per IS:2102(Part-1) Coarse.
Note- Specially fabricated ‘go’ and ‘no-go’ gauges may be used for checks of dimensional accuracy on mass scale production.

Name & Signature of IE

Prepared by- Checked by- Forwarded by-

IE: RY Technical Cell: RAS CM: CAK