File No.

RDSO-MW0BD(SB)/1/2020-O/o PED/SW/RDSO
Hkkjrljdkj&jsyea=ky; Government of India - Ministry of Railways
vuql/a kkuvfHkdYivkSjekudlaxBu Research Designs & Standards
y[kuÅ& 226011 OrganisationLucknow – 226011
EPBX (0522) 2451200 DID (0522) 2450115
FAX (0522) 2458500 DID (0522) 2465310

No. MW/PLNG/CSNB Dated: 25.04.2023

iz/kku eq[; ;kaf=d vfHk;Urk %

1- e/; jsyos] N=ifrf’kokthVfeZul] eqEcbZ& 400001-
2- iwoZjsyos] Qs;jyhIysl] dksydkrk& 700001-
3- mRrjjsyos] cM+kSnkgkml] ubZfnYyh& 110001-
4- nf{k.kjsyos] ikdZVkmu] psUubZ& 600 003-
5- nf{k.k e/; jsyos] jsyfuyk;e] fldUnjkckn& 500071-
6- nf{k.kiwoZjsyos] xkMZsujhp] dksydkrk& 700043-
7- iwoksZRrjjsyos] xksj[kiqj& 273012-
8- iwoksZRrjlhekUrjsyos] ekyhxkWoa ] xqokgkVh& 781011-
9- if’pejsyos] ppZxsV] eqEcbZ& 400020-
10- iwoZ e/; jsyos] gkthiqj& 844101-
11- iwoZrVh; jsyos] chMh, jsVa ydkyksuh] jsyosdkEiysDl] pUnz’ks[kjiqjk] Hkqous’oj]&751016-
12- mRrj e/; jsyos] gkfLVaxjksM ]bykgkckn& 211001-
13- mRrjif’pejsyos] t;iqj& 302006-
14- nf{k.kif’pejsyos] gqcyh& 580023-
15- if’pe e/; jsyos] tcyiqj& 482001-
16- nf{k.kiwoZ e/; jsyos] vkj0bZ0 dkEiysDl] fcykliqj&495004

Sub: Comprehensive guidelines for maintenance of Constant Contact Side Bearer.

Ref.: This office letterNo. MW/PLNG/CSNB dated 07.03.23.

Vide reference above, a draft comprehensive maintenance instructions for the maintenance of
different variant of CCSBs utilized on IR freight Stocks was prepared by this office and the
same was circulated to zonal railways for their comments.
Based on the comments/suggestions received from the zonal railway the technical pamphlet
on the maintenance of CCS has been finalized.
The technical pamphlet on ‘’Comprehensive Guidelines for Maintenance of Constant
Contact Side Bearer’’ with a nomenclature ‘’Technical Pamphlet G-115’’is being uploaded at
RDSO website.
Zonal railways are required to follow the same.

DA: As above.
(Abhishek Kumar Gautam)
JDSW/BD
For Director General/RDSO
Copy to:
1. EDME (Freight), Railway Board, New Delhi-110001- for kind information please.
2. All CCSB Vendors as per RDSO Vendor Directory–for kind information.
 Technical Pamphlet No. G-115

Hkkjr ljdkj & jsy ea=ky;

Government of India- Ministry of Railways

dsoy dk;kZy; mi;ksx ds fy,

For Official Use Only

INSTRUCTIONS
FOR
EXAMINATION & MAINTENANCE
OF
CONSTANT CONTACT SIDE BEARER ASSEMBLY

TECHNICAL PAMPHLET No. G-115

(Revision- First issue)
MARCH 2023

***********

ISSUED BY

WAGON DIRECTORATE

RESEARCH DESIGNS AND STANDARDS ORGANISATION

MINISTRY OF RAILWAYS

MANAK NAGAR, LUCKNOW-226011

Page 1 of 22
 Technical Pamphlet No. G-115

Contents
1.0 INTRODUCTION .................................................................................................................... 4

2.0 TECHNICAL TERMS .............................................................................................................. 4

3.0 TYPE OF CONSTANT CONTACT SIDE BEARERS ........................................................... 6

4.0 GENERAL CONDITION OF OPERATION OF CCSB IN FREIGHT WAGONS............ 7

5.0 CAR BODY WEAR PLATE..................................................................................................... 7

6.0 SIDE BEARER ASSEMBLY FASTENING ............................................................................ 7

A. INSTRUCTIONS FOR EXAMINATION & MAINTENANCE OF CONSTANT

CONTACT SIDE BEARER ASSEMBLY TO SPEC.- WD-38- MISC-17, DRG. NO. AAL-021101
FOR CASNUB 22 HS BOGIES AND DRG. NO.AAL-021101/N FOR CASNAB 22 NLB BOGIES.
……………………………………………………………………………………………………………………………………………….8
1.0 OBJECTIVE ............................................................................................................................... 8
2.0 WARRANTY............................................................................................................................. 8

3.0 DESIGN DETAILS ................................................................................................................... 8

4.0 EXAMINATION OF PU SIDE BEARER PAD DURING ROH/POH/IN SICK

LINE/YARD .......................................................................................................................................... 9

5.0 RE-ASSEMBLY OF PU SBP ................................................................................................. 14

6.0 ACCEPTABLE FREE HEIGHT AFTER REASSEMBLY ................................................... 14

B. INSTRUCTIONS FOR EXAMINATION & MAINTENANCE OF CONSTANT

CONTACT SIDE BEARER ASSEMBLY TO SPECIFICATION WD-62-MISC-17 ..................... 15

a. Yard examination ................................................................................................................... 15

b. Maintenance of CCSB to WD-62-Misc-17during ROH/POH: .......................................... 16

C. INSTRUCTIONS FOR EXAMINATION & MAINTENANCE OF CONSTANT

CONTACT SIDE BEARER ASSEMBLY TO CONTR-01-MISC-07(MS-25) ................................ 18

1.0 Examination of CCSB to CONTR-01-Misc-07(MS-25) ...................................................... 18

2.0 Part List.................................................................................................................................... 20

Figure 1 : Constant Contact Side Bearer (CCSB).............................................................................. 4

Figure 2: Setup Height......................................................................................................................... 5
Figure 3 : Center Pivot & Side Bearer (CP-SB) Arrangement ........................................................ 5
Figure 4 : PU CCSB in assembled condition .................................................................................. 10
Figure 5: Set up height measurement of PU CCSB in assembled condition............................. 10
Figure 6: Excessive Gap between PU CCSB in assembled condition ......................................... 10
Figure 7: WD-62-Misc-17 CCSB in assembled condition............................................................. 17
Figure 8: Setup height measurement of WD-62-Misc-17 CCSB in assembled condition ........ 17
Page 2 of 22
 Technical Pamphlet No. G-115

Figure 9 : CONTR-02-Misc-07CCSB in assembled condition ..................................................... 18

Figure 10 : Setup height measurement of CONTR-02-Misc-07 CCSB in assembled condition...
.............................................................................................................................................................. 19
Annexure 1: …………………………………………………………………………………………………………………………………….21

Page 3 of 22
 Technical Pamphlet No. G-115

1.0 INTRODUCTION

Constant Contact Side Bearer (CCSB) as name indicates is designed with no

clearance between the Wagon body and CCSB itself. The compression in the
side bearer springs (Figure-1) are achieved by placing them in the envelop size
known as setup height lesser than the free height of the side bearer. The
envelop size is a geometrical configuration which is maintained as per the CP-
SB arrangement of the Wagon depending upon the load sharing criteria of the
wagon in empty condition.

The maintenance of Constant Contact Side Bearer are governed by the OEM
maintenance instructions, RDSO specification and their respective drawings. In
the present maintenance guideline, it has been attempted to consolidate all the
present instructions and guidelines. These instructions should be strictly
complied during yard examination, ROH and POH. In case of any clarification
and further updating, OEMS maintenance instructions shall be referred.

Figure-1 : Constant Contact Side Bearer (CCSB)

2.0 TECHNICAL TERMS

Following are the technical terms related to constant contact side bearers-
(i) Set up height
Set up height as shown in figure-2 is the nominal installed height of side
bearer in the wagon on leveled track. Set-Up Height- in static condition

Page 4 of 22
 Technical Pamphlet No. G-115

is fixed whether car is empty or loaded. To ensure the proper pre-load it

is important that the setup height is properly maintained as per the CP-
SB arrangement of the wagon as shown in figure 3. Accurate set up
height measurement is critical for optimal performance. The set up
height should be measured using inside calipers and a steel rule. Center
pivot height is to be ensured first before checking up of Setup height of
the wagon. Center Pivot Height and Setup height are geometrical
configuration of the wagon. Setup height shall be maintained and
ensured during ROH/POH of the Wagon. To maintain the setup height
as per the CP-SB arrangement, appropriate size/numbers of shim/s shall
be used. The details of setup height of wagons are placed at Annexure I.
This procedure must be performed with an empty wagon located on
level track.

Figure-2: Setup Height

Figure 3 : Center Pivot & Side Bearer (CP-SB) Arrangement

Page 5 of 22
 Technical Pamphlet No. G-115

(ii) Pre load

Pre load is the vertical load taken by the side bearer at set up height.
(iii) Side bearer travel
Side bearer travel is the compression of side bearer from nominal set up
height to solid height.
(iv) Solid Height
Solid height is compressed height of CCSB at non yielding arrangement.
It is nominal set up height minus travel of the CCSB.
3.0 TYPE OF CONSTANT CONTACT SIDE BEARERS
Freight wagons are fitted with three types of Constant Contact Side Bearers
(CCSB).
i) PU CCSB to RDSO specification WD-38-Misc-04
a) Drg. No. AAL-021101 for CASNUB 22 HS Bogies.
b) Drg. No. AAL-021101/N for CASNUB 22 NLB Bogies.
ii) CCSB to RDSO specification WD-62-Misc-17.Drawing numbers for these
variants of CCSB are-
a) Variant ‘A’: Drawing No.–WD-17025-S/1or equivalent firm’s
design.
b) Variant ‘B’: Drawing No.–WD-12008-S/1 or equivalent firm’s
design.
c) Variant ‘C’: Drawing No.–WD-12007-S/1 or equivalent firm’s
design.
iii) CCSB to RDSO specification CONTR-01-Misc-07.

Table 1 : Types of Constant Contact Side Bearer and their dimensions:

Sl. Type Free Condemning Set up Height

No Height Height (in mm)
. (in mm) (in mm)
1 WD-38 MISC 2004 142.5±1. 137 As per CP-SB
(Design-A) 6 arrangement Drg. of
wagon
WD-38 MISC 2004 134±1.5 128.5 As per CP-SB arrangement
(Design-B) Drg. of wagon
2 WD-62-MISC-17 Drg. 164±1.5 146 128.5±1
No. WD-17025/S-1
Drg. No. WD-12008/S-1 163±1.5 146 128.5±1
Drg. No. WD-12007/S-1 167±1.5 148 128.5±1
3 MS 25 Side Bearer to 153±3 As per firm’s As per CP-SB arrangement
DRG. No. 40704 Approved Drg. of BLCAM/BM and
Drawing
BOXNHL wagon.

Page 6 of 22
 Technical Pamphlet No. G-115

4.0 GENERAL CONDITION OF OPERATION OF CCSB IN FREIGHT

WAGONS

CCSB is to be maintained at their set up heights as per the drawings of ‚Centre

Pivot and Side bearer arrangement‛ of respective wagon. In any case, there
shall not be any gap between the CCSB and side bearer top liner. Wagon may
be called for urgent attention in the event of any of the following.

• Housing crack, breakage, deformation.

• Gap between under frame Side Bearer plate and CCSB Top. (However, if
gap is found between under frame Side Bearer plate and CCSB Top then all
relevant parameters that would be contributing the gap to be investigated. The
measurement of CCSB height shall preferably be taken on level track.)
• No gap between Top & Bottom Housings

5.0 WAGON BODY WEAR PLATE

The car body wear plate must conform to IS: 3885 Part.1 Gr.IV. The car body
side bearing wear plate must be smooth. Any weld spatter, heavy rust or
surface projections must be removed by grinding. Fastener heads must be
smooth and flush below wear plate surface, and the fasteners securely
tightened.

6.0 SIDE BEARER ASSEMBLY FASTENING

The side bearer base must be secured to the pad using fasteners as specified in
their respective drawings. Lock bolting may also be used as an alternate
method of fastening.

Page 7 of 22
 Technical Pamphlet No. G-115

A. INSTRUCTIONS FOR EXAMINATION & MAINTENANCE OF

CONSTANT CONTACT SIDE BEARER ASSEMBLY TO SPEC.- WD-38-
MISC-17, DRG. NO. AAL-021101 FOR CASNUB 22 HS BOGIES AND DRG.
NO.AAL-021101/N FOR CASNAB 22 NLB BOGIES.

Constant Contact (PU) Side Bearer was introduced in April 2004 to the Casnub
22 HS bogies and subsequently in the Casnub 22NLB Bogies. The active
element is made of PU (Polymer) and it is not metal bonded.
These maintenance guidelines for the maintenance PU type side bearer is based
on the OEMs maintenance instructions. Therefore for any clarifications OEMs
may be contacted.

1.0 OBJECTIVE
Objective of the present write up is to lay down a guideline for
examination/maintenance/replacement/rejection of the PU side bearer assembly
during the ROH/POH of 22 HS & 22 NLB bogies and also in the yard and sick
line examination.

2.0 WARRANTY
The PU Side Bearer is warranted for 30 months from Month & Year of
manufacturing for its performance. Replacement for any premature failure
shall be claimed from the firm.

3.0 DESIGN DETAILS

3.1 PU Side Bearer Pad for CASNUB 22 HS Bogies to drg. No. AAL-21101/Alt.8
Consists of :
(i) PU Rings (donuts) with circular and flattened top& bottom cross section -
3 Nos.
(ii) Steel (lS: 2062 Fe410WA) Spacer plate with contract guide and stopper
spring molded with TPU 2 Nos.
(iii) Polymer (TPU) Lining/Sleeve in the top and bottom housing. Sleeves are
provided with central stopper spring cum locator/guide at the bottom for
locating the donuts-2nos.
(iv) Bottom Housing made of forged steel to IS: 1875 Cl. IV, EN9/EN8, which
can be riveted to the existing drilled holes in the bolster. This has been
made stronger than the Bottom Housing of the Alt.6 version. Please see
the Drg. For verifying the dimensions.
(v) Top housing made of forged steel to IS: 1875 Cl. IV, EN9/EN8.

Page 8 of 22
 Technical Pamphlet No. G-115

3.2 PU Side Bearer Pad for CASNUB 22 NLB Bogies to drg. No. AAL-21101/N
Consists of :
(i) PU rings (donuts) with circular and flattened top & bottom cross section -
2 Nos.
(ii) Steel (lS:2062 Fe410WA) Spacer Plate with Central guide and stopper
spring molded with TPU - I No.
(iii) Polymer (TPU) Lining/Sleeve in the top and bottom housing. Sleeves are
provided with central stopper spring cum locator/guide at the bottom for
locating the donuts-2nos.
(iv) Bottom Housing made of forged steel to IS: 1875 Cl. IV, EN9/EN8, which
can be riveted to the existing drilled holes in the bolster. This has been
made stronger than the Bottom Housing of the Alt.6 version. Please see
the Drg. For verifying the dimensions.
(v) Top housing made of forged steel to IS: 1875 Cl. IV, EN9/EN8. A central
stopper cum-guide integral to the roof of the top housing has been
provided to locate the donut in place.
(vi) One steel plate (IS:2062 Fe4l0 WA) as a packing under the bottom sleeve.

4.0 EXAMINATION OF PU SIDE BEARER PAD DURING ROH/POH/IN SICK

LINE/YARD

4.1 Yard Examination

Wagon may be called for urgent attention in Sick line if the following visual
check faults are detected:
• Visual examination of Housing crack, breakage, deformation.
• Gap between under frame Side Bearer plate and PU CCSB Top. However,
wagon may be checked for uneven loading.
• No gap between Top & Bottom Housings.
• The CCSB assembly and gap between top linear is explained in Fig’s 4-6.

4.2 Sick line Attention:

Bogie should be run out after lifting the Wagon body and the detailed
examination must be done for rejection and replacement of items as detailed in
4.4 below.

Page 9 of 22
 Technical Pamphlet No. G-115

Figure 4 : PU CCSB in assembled condition

Figure 5: Set up height measurement of PU CCSB in assembled

condition

Figure 6: Excessive Gap between PU CCSB in assembled

condition

Page 10 of 22
 Technical Pamphlet No. G-115

4.3 ROH & POH

At the POH and every alternate ROH complete kit replacement is to be made
for the PUSBP. In all other ROH if there is a permanent set up to 4mm then the
free height of the CCSB should be adjusted with a PU packing Washer of size
105ø x 57ø x 3mm (thick), Provided all internal elements are in good /healthy
condition.

4.3.1 Replacement kit for CASNUB 22 HS (Drg. No. AAL-021101 Alt.8)

Item Item Name Quantity

No.
5 PU Rings (donuts) 3 Nos
3&6 Spacers 1 No
4 Sleeve 2 Nos.

The solid steel plate of the rejected PUSBP can be reused.

4.3.2 Replacement kit for CASNUB 22 NLB (Drg. No. AAL-021101/N)

Item No.
Item Item Name Quantity
No.
5 PU Rings (donuts) 2 Nos
3&6 Spacers 1 No
4 Sleeve 2 Nos.

The solid steel plate of the rejected PUCCSB can be reused.

4.4 Examination During ROH

After the bogie has been run out from under the wagon, the side bearers are
free of any load. The side bearer assembly should be visually examined for any
damage, deformation and fracture to the housings. If nothing abnormal is
observed then -
 For CASNUB 22 HS Wagon -Measure the free height of the Assembly.
The free height, in new condition is l42.5±l.6 mm. The free height
measured should not be less than l37mm considering the 4mm in service
permanent set permitted.
 For CASNUB 22 NLB - Measure the free height of the Assembly. The
free height in new condition is 134 ±1.5mm. The free height measured
should not be less than 128.5mm. Considering the 4mm in-service
permanent set permitted.

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 Technical Pamphlet No. G-115

 In case of permanent set exceeding 4mm, a kit replacement is

recommended in both HS and NLB bogies. In no case a single item or
single PU ring (donut) be replaced.
 Next remove the components one by one i.e. Top housing, PU Rings
(Donuts) Spacer Plates from the assembly.
 Top Housing (Item NO. 1 of Drg. No. AAL-021101/N)

The top housing ID, OD, Ht. condemning dimensions are given in the
Table-2 below.

TABLE 2- CONDEMNING LIMITS/CONDITIONS

Sl. Name of Bogie/Drg. (Alt.) Location New Condemning Limits

No Component Dimension
.
1 Top Housing CASNUB 22 HS Ht. 87.5 + 0.8 85.5 + 0.8
AAL- ID 136+ 0.8 No wear due to sleeve
21101/Alt.8
CASNUB 22 NLB Ht. 87.5 + 0.8 85.5 + 0.8
AAL-021101/N ID 136+ 0.8 No wear due to sleeve
2 Bottom CASNUB 22 HS Ht. 90.0 + 0.8 88.0 + 0.8
Housing AAL- ID 130+ 0.8 Less than 128.5
21101/Alt.8
CASNUB 22 NLB Ht. 90.0 + 0.8 88.0 + 0.8
AAL-021101/N ID 130+ 0.8 Less than 128.5
3 CCSB CASNUB 22HS AAL- 142.5+1.6 Less than 137.0
Assembly 21101/Alt.8
(Free Ht.)) CASNUB 22 NLB AAL- 134.0+ 1.5 Less than 128.5
021101/N
4 PU Ring For all types Thickness 33 + 0.7 31.5

i) If the top housing is in any way deformed, broken, fractured then scrap
it.
ii) If there is no visible damage/deformation, then measure the height of top
Housing at least at 4 different circumferential locations (preferably two
diagonally opposite pairs of points).
If the minimum height measured has reached the condemning limit as
given in Table-2 then the top housing must be replaced with fresh top
housing of respective design.
iii) If the wear of the top surface of top housing is less than 2mm, it should
be smoothened and leveled by filing/grinding and reused for assembly.
iv) Side bearer top Liner to be replaced with new one.

Page 12 of 22
 Technical Pamphlet No. G-115

 PU Rings (donuts) (ItemNo.5 of Drg. No. AAL-021101 or AAL-

021101/N)
Examine each donut visually. If there is any crack, plastic deformation or
crashing sign in any of the donuts, scrap it. If no damage is visible,
measure the OD, ID and particularly the thickness of the ring. In case of
permanent set more than the specified limit (see table-2). The donuts
must be replaced.

Old good donuts along with new ones must not be mixed and used for
reassembly of a PU SBP, In case out of one Assembly if all the Donuts
are good then reuse, but do not mix part quantity with other reused
ones. In case a PUSB is assembled with old good donuts then the free
height should be adjusted with a polymer packing washer, if necessary.

 Spacer Plate (Item No. 3 Drg. No. AAL-021101 or AAL-021101.N)

If the spacer plate is not deformed or damaged in any form either in the
metallic or in the central PU stopper spring part it can be reused in the
respective assembly. Any deformed, bent, twisted, broken spacer plate
must be scrapped.
 PU Lining (sleeve): Item No.4 of drg. No. AAL-021101 or AAl-
021101/N)
There are 2 Nos. of PU Sleeves one each in the inner surface of the top &
bottom housings. It is occasionally found in crumbled, heat deformed,
crushed condition. It must be scrapped in such a condition and a new
one fitted in place.
In the event of any damage, heat deformation, crushing and crumbling
in the cylindrical wall or in the stopper spring the sleeve must be
scrapped and replaced with new ones.
 Bottom Housing (Item No.7 of Drs. No. AAL-021101 or AAL-021101/N
Bottom Housing may be damaged by shear breakage at the root of the
wall, cracking or breaking the wall or any deformation. In such cases the
Bottom housing is to be removed by cutting the rivets. A fresh Bottom
Housing is to be refitted by riveting.
 Solid Steel Plate (Item Ng. 7 of Drs. No. AAL-021101/N
This item is exclusive for the PUSBP used for BOXN (NLB) bogies. Since
this is a solid steel plate placed at the bottom of the PUSBP used as a
packing to fill up the void left by the absent third donut and the spacer
plate, there is very little chance of its getting damaged. It can almost
always be reused.

Page 13 of 22
 Technical Pamphlet No. G-115

5.0 RE-ASSEMBLY OF PU SBP

 If the old Bottom housing has been scrapped, a fresh Bottom housing is
to be fitted by riveting/lock bolting it on the bolster. Precaution should
be adopted to avoid any direct contact of heat to the polymer sleeve
during riveting operation because polymer loses its properties after
coming in direct contact of heat and gets damaged in a short time.
 If all inner items are good, reassemble, but do not change part and mix
New Parts with old ones (used Ones) and replace full kit of all 6 or 7
parts as per AAL-021101, Alt.-8 for BOXNHS and as per AAL-021101/N
for BOXN (NLB).
 Choose good healthy old PU rings (donuts) of respective design. These
can be reused but old and new donuts must not be mixed up for
reassembling a side bearer.
 In case of PU-CCSB for CASNUB 22 HS, put 3 (donuts) PU rings and
two spacer plates alternately in the bottom housing, after putting the
sleeve into it.
 In case of PU-CCSB for CASNUB 22 NLB, first put the solid steel plate.
Next put the sleeve in the bottom housing and then put the two donuts
and a spacer plate alternately in it.
 Finally close the pad with the top housing and measure the free height.

6.0 ACCEPTABLE FREE HEIGHT AFTER REASSEMBLY

For CASNUB 22 HS (Drg No. AAL-021101)

Free height with new kit = 142.5+ 1.6mm with all new Kit.
Free height with 2mm wears of
top housing = 140.5+l.6mm
Free height with old healthy donuts
considering 4mm maximum permanent set = 137mm

For CASNUB 22 NLB (Drg. No. AAL-021101/N)

Free Height with new kit = 134.0+l.5mm
Free Height with 2mmwear of
top housing = 132.0 +l.5mm
Free Height with old healthy donuts
considering 4mm maximum permanent set = 128.5mm
Note: It is recommended to use a 3 mm polymer packing washer to maintain the free
height of the reassembled PUSBP using old PU rings (donuts). Drawing No.
ARL/PPW/0506 is attached.

Page 14 of 22
 Technical Pamphlet No. G-115

B. INSTRUCTIONS FOR EXAMINATION & MAINTENANCE OF

CONSTANT CONTACT SIDE BEARER ASSEMBLY TO SPECIFICATION
WD-62-MISC-17

Constant contact Side Bearer to RDSO specification has been developed by

RDSO as per the requirements of AAR specification M-948 and long travel.
There are three variants of constant of constant contact side bearer to suit all the
BG wagon fleet of Indian Railways. Each variants has RDSO design (Spring
Element is metallic) and Firms Own Design ((Spring Element is generally
nonmetallic).

a)Variant ‘A’ Drawing No. – WD-17025- Pre load (Kg) -

S/1 or equivalent firm’s (Generally applicable for wagons
design having empty body weight up to
9.4t)
b) Variant ‘B’ Drawing No. – WD-12008- Pre load (Kg) -
S/1 or equivalent firm’s (Generally applicable for wagons
design having empty body weight
between 9.4t to12.7t)
c)Variant ‘C’ Drawing No. – WD-12007- Pre load (Kg) -
S/1 or equivalent firm’s (Generally applicable for wagons
design having empty body weight over
12.7t)

WARRANTY
The CCSBs to the specification WD-62-Misc-17 are warranted for 60 months
from Month & Year of manufacturing for its performance. Replacement for any
premature failure shall be claimed from the firm.

Maintenance of CCSB to specification WD-62-Misc-17 shall be done as follows:

1. Yard examination
Wagons having check for following defects during yard examination:
(a) Visual examination of Housing crack, breakage, deformation.
(b) Gap between under frame Side Bearer plate and CCSB Top. However, wagon
may be checked for uneven loading.

The wagon if found with above defects wagon may be called for urgent
attention in Sick line and maintained as per the instructions given for
ROH/POH.

The CCSB assembly in assembled condition and measurement of set up height

is shown in Fig’s 7-8.
Page 15 of 22
 Technical Pamphlet No. G-115

2. Maintenance of CCSB to WD-62-Misc-17 during ROH/POH:

CCSBs as per the RDSO Drawing shall be examined and maintained as follows:
(i) Top and Bottom Housing shall be examined and maintained as follow:

Top/Bottom Housing shall be replaced if found with any of the following

defects:
 Crack/ breakage in top/bottom housing.
 Wear of 3 mm or more in top face of top housing and increase/decrease
more than 3 mm in diameter of bottom/top housing measured from
nominal values.

(ii) Spring Element shall be examined and maintained as follow:

Spring Element shall be replaced if found with any of the following defects:

• Crushing, tears, breakage or crack in any suspension element. However

minor surface crack which do not affect properties may be ignored.
• A permanent set in spring elements observed equal or more than half of
the difference between nominal free height of CCSB and nominal set up
height for the wagon. For example, if nominal free height of CCSB is
163.0 mm, then half of deflection (163.0-128.5)/2 = 17.25 mm say 17 mm.
Then the CCSB to be renewed with new springs/housing.

Condemning heights of CCSB springs shall be as follows:

S.No. CCSB Variant Free height of Condemning

springs in New height (mm)
Condition (mm)
1. Variant ‘A’ WD-17025-S/1 144+ 1 126
2. Variant ‘B’ WD-12008-S/1 143+ 1 125
3. Variant ‘C’ WD-12007-S/1 147.5+ 1 128
CCSBs as per the Firms Drawing shall be examined and maintained as per the
Firms maintenance instructions. The same may be referred.

(iii) Side bearer top Liner to be replaced with new one.

Page 16 of 22
 Technical Pamphlet No. G-115

Figure 7: WD-62-Misc-17 CCSB in assembled condition

Figure 8: Setup height measurement of WD-62-Misc-17 CCSB in

assembled condition

Page 17 of 22
 Technical Pamphlet No. G-115

C. NSTRUCTIONS FOR EXAMINATION & MAINTENANCE OF CONSTANT

CONTACT SIDE BEARER ASSEMBLY TO CONTR-01-MISC-07(MS-25)

This maintenance guideline for the maintenance MS-25 side bearer is based on
the OEMs drawing and maintenance instructions. Therefore for any
clarifications OEMs drawing/guidelines may be referred.

WARRANTY
The CCSBs to the specification CONTR-01-Misc-2007 are warranted for 60
months from Month & Year of manufacturing for its performance. Replacement
for any premature failure shall be claimed from the firm.

1.0 Examination of CCSB to CONTR-01-Misc-07 (MS-25)

Maintenance of CCSB to specification CONTR-01-Misc-07 (MS-25) CCSBs shall
be examined and maintained as follows:

a) Yard eamination
The wagon may be called for urgent attention in Sick line examination if found
with following defects and its maintenance shall be done as per the
maintenance manual of OEM and respective drawings.
• Visual examination of Housing crack, breakage, deformation.
• Gap between under frame Side Bearer plate and PU CCSB Top.
However, wagon may be checked for uneven loading.
• The CCSB assembly in assembled condition and measurement of set up
height is shown in Fig’s 9-10.

Figure 9 : CONTR-02-Misc-07CCSB in assembled condition

Page 18 of 22
 Technical Pamphlet No. G-115

Figure 10 : Setup height measurement of CONTR-02-Misc-07 CCSB in

assembled condition

b) Maintenance of CCSB to CONTR-01-Misc-07(MS-25) during ROH/POH:

(i) CCSB Top and Bottom shall be examined and replaced by new if found
with following defects:
a) Any crack/ breakage in top/bottom housing.
b) Wear of more than 1.5mm measured from nominal values in
top/bottom housing.

(ii) CCSB Spring Element shall be examined and replaced by new if found
with following defects:
a) Crushing, tears, breakage or crack in any spring elements. However
minor surface crack which do not affect properties may be ignored.
b) A permanent set in spring elements observed equal or more than half
of the difference between nominal free height of CCSB and nominal
set up height for the wagon.

(iii) To determine if the MS-25 casting need to replaced. Measure the gap
between the two parts. Follow the following steps:
a) Remove the pad from assembly.
b) Place the top cap back inside the housing.
c) Push the top cap tone side until it is in contact with the housing.
d) Measure the gap between top Cap and the housing.
e) For optimal performance the gap should be less than 5mm.
f) If the gap is larger than this, install a new top cap and repeat step 2-
5.If this brings the gap below 3.5mm the assembly is acceptable.
g) If the new top cap does not reduce the gap to below 3.5mm, replace
the housing and use a new housing and new top cap.

(iv) Side bearer top Liner to be replaced with new one.

Page 19 of 22
 Technical Pamphlet No. G-115

2.0 Part List

Sr. No. Quantity Part Name Part Number

1 01 Housing (Bottom Housing) 40705
2 01 Top Cap (Top Housing) 40706
3 01 Tecspak -------

 To determine if the Tecspak elastomer pad has sufficient preload,

measure the free height of the pad.

Follow the below steps:

(i) Remove pad from assembly.
(ii) Allow two hours at or above 20° C for the pad to stabilize.
(iii) Measure the height of pad as per drawing.
(iv) Condemning height of the Tecspak shall be as per OEMs approved
drawing.
(v) Set up height- The set up height should be measured before the wagon is
lifted off the center pivot. Consult the wagon specifications for
condemning limits, adjust if needed.

Page 20 of 22
 Technical Pamphlet No. G-115

Annexure-1
DETAILS OF WAGON SETUP HEIGHT
Sl. Wagon Component Setup Height CPSB Drawing No.
(mm)
1 BOXNS Variant B to WD-62-Misc-17 128.5 WD-14014-S-7
2 BOXN/BOXNM1 PUCCSB WD-85079-S-01
3 BOXNM2 Variant B to WD-62-Misc-17 128.5 WD-20024-S-02
4 BOXNHS/ BOXNHSM1 PUCCSB WD-04038-S-03
WD-04078-S-02
5 BOXNHSM2 Variant B to WD-62-Misc-17 128.5 WD-20024-S-02
6 BOXNHL PUCCSB, MS-25& Variant B to WD-05086-S-08
WD-62-Misc-17 WD-08008-S-08
WD-09034-S-08
WD-14021-S-08
WD-14014-S-07
7 BOXNHAM Variant C to WD-62-Misc-17 128.5±1 WD-20024-S-04
8 BOXNHA Variant C to WD-62-Misc-17 128.5±1 WD-20024-S-04
9 BOXNR Variant B to WD-62-Misc-17 128.5±1 WD-20024-S-02
10 BOXNRM1 Variant B to WD-62-Misc-17 128.5±1 WD-20024-S-02
11 BOXNRM2 Variant B to WD-62-Misc-17 128.5±1 WD-20024-S-02
12 BOXNRHS Variant B to WD-62-Misc-17 128.5±1 WD-20024-S-02
13 BOXNRHSM1 Variant B to WD-62-Misc-17 128.5±1 WD-20024-S-02
14 BOXNLWM1 Variant B to WD-62-Misc-17 128.5±1 WD-20024-S-02
15 BOXNLWM2 Variant B to WD-62-Misc-17 128.5±1 WD-20024-S-02
16 BOST PUCCSB WD-00012-S-20
17 BOSTHS PUCCSB WD-04017-S-08
18 BOSTHSM2 Variant C to WD-62-Misc-17 128.5±1 WD-20024-S-04
19 BOSTHSM3 Variant C to WD-62-Misc-17 128.5±1 WD-20024-S-04
20 BOXNEL Variant B to WD-62-Misc-17 128.5±1 WD-20024-S-02
21 BOYEL Metal Bonded WD-81074-S-07
22 BCN/BCNM1 PUCCSB WD-84014-S-7A
23 BCNM2 Variant C to WD-62-Misc-17 128.5 WD-20024-S-04
24 BCNHS/BCNHSM1 PUCCSB WD-84014-S-7A
WD-17029-S18
25 BCNA/BCNAM1 PUCCSB WD-90030-S-68
26 BCNAM2 Variant C to WD-62-Misc-17 128.5 WD-20024-S-04
27 BCNAHS/BCNAHSM1 PUCCSB WD-01011-S-52
WD-17029-S-18
28 BCNHL PUCCSB WD-11012-S-14
WD-10068-S-27
WD-11054-S-27
WD-15003S-21
29 BCNHLM1 Variant-B to WD-62-Misc-17 128.5 WD-20024-S-02
30 BCPVN PUCCSB/ Variant C to WD-62- /128.5 WD-13037-S-23/
Misc-17 WD-20024-S-04
31 BCFC PUCCSB WD-07054-S-23
WD-13001-S-23
WD-14030-S-23
32 BCFCM PUCCSB WD-15014-S-23
33 BCFCM1 Variant-B to WD-62-Misc-17 128.5 WD-20024-S-02
34 BOBR(20.32T) PUCCSB 127.0 WD-86013-S-56

Page 21 of 22
 Technical Pamphlet No. G-115

35 BOBR(22.32T) PUCCSB 127.0 WD-85076/S-1

36 BOBRM1(22.32T) Variant C to WD-62-Misc-17 128.5 WD-20024-S-04
37 BOBRN PUCCSB WD-91071-S-56
38 BOBRNM1 PUCCSB WD-91071-S-56/S-57
39 BOBRNM2 Variant C to WD-62-Misc-17 128.5 WD-20024-S-02
40 BOBRNEL Variant B to WD-62-Misc-17 128.5 WD-20024-S-02
41 BOBRNHS / PUCCSB WD-05016-S-56
BOBRNHSM1
42 BOBRNHSM2 Variant B to WD-62-Misc-17 128.5 WD-20024-S-02
43 BOBRNELHSM1 Variant B to WD-62-Misc-17 128.5 WD-20024-S-02
44 BOBYN PUCCSB WD-02020-S-1
45 BOBYNM1 Variant C to WD-62-Misc-17 128.5 WD-20024-S-01
46 BOBYN22.9/BOBYNHS PUCCSB WD-02020-S-1
47 BOBYNHSM1 Variant C to WD-62-Misc-17 128.5 WD-20024-S-01
48 BOBSA/BOBSN Variant C to WD-62-Misc-17 128.5 WD-20024-S-04
49 BOBSNS Variant C to WD-62-Misc-17 128.5 WD-20024-S-04
50 BOBSNM1 Variant C to WD-62-Misc-17 128.5 WD-20024-S-04
51 BRN PUCCSB WD-84013-S-14
52 BRNM1 Variant C to WD-62-Misc-17 128.5 WD-20024-S-04
53 BRN22.9 PUCCSB WD-09053-S-16
54 BRN22.9M1 Variant B to WD-62-Misc-17 128.5 WD-20024-S-05
55 BRNA PUCCSB WD-02009-S-01
56 BRNAM1 Variant C to WD-62-Misc-17 128.5 WD-20024-S-04
57 BRNAHS PUCCSB WD-02009-S-01
58 BFNS PUCCSB WD-00052-S-1
59 BFNS 22.9 PUCCSB WD-14035-S17
60 BFNSM 1 Variant B to WD-62-Misc-17 128.5 WD-20024-S-5
61 BRHNEHS PUCCSB WD-04004-S-57
62 BRHNEHSM1 Variant B to WD-62-Misc-17 128.5 WD-20024-S-02
63 BFNV Variant B to WD-62-Misc-17 128.5 WD-20044-S-17
64 BTPN PUCCSB WD-86081-S-55
65 BTPNM1 Variant C to WD-62-Misc-17 128.5 WD-20024-S-04
66 BTAPM1 PUCCSB WD-82056-S-62
67 BTPGLN PUCCSB WD-93047-S-61
68 BTALNM PUCCSB 125 WD-14002-S-56
69 BTALNM1 Variant C to WD-62-Misc-17 128.5 WD-21004-S-56
70 BTCS Metal Bonded WD-80114-S-56
71 BTFLN PUCCSB/ Variant B to WD-62- 125 /128.5 RSD-6315-007/ WD-
Misc-17 20024-S-02
72 BLC Contr-9404-S-15 CONTR-9404-S-8
73 BLCM Variant A to WD-62-Misc-17 128.5 CONTR-9404-S-8
74 BLCA/BLCB Contr-9404-S-15 CONTR-9405-S-7/8
75 BLCAM/BLCBM MS-25/Variant A to WD-62- CONTR-9405-S-7/8
Misc-17
76 BLLAM/BLLBM MS-25/Variant A to WD-62- CONTR-9404-S-8
Misc-17
77 BLCS- (A/B Car) Variant A to WD-62-Misc-17 125 WD-20021-S-01
78 BLSS Variant A to WD-62-Misc-17 128.5 WD-22061-S-23
79 BCACBM (Double Variant C to WD-62-Misc-17 WD-11013-S-25
Decker)

Page 22 of 22
cOR
POLYMER PACKING WASHER
PU SIDE BEARER TO DRG, NO.
8 DRG. NO. AAL- AAL- 021101
021101/N

R1.5 3.0
12411
-57
-0105
SECTION A-A

AVADH RUBBER LIMITED

Drg. No. :- ARL/PPW/0506
 *** ******
924

* L
2 3 (TECSPAK)
IDENTIFICATION MARKING
INSTALLED HEIGHT
105
SEE
IABLE 1
IR
SECTON A-A TABLE1
2 1 6 REF -
TOP CAP
271 REF
TABLE 1 VALUES AT SPECIFIC SETUP HEIGHTS
FREE HEIGHT OFASSEMBLY=153 +/-3 MM
o 158 R
WEIGHT OF ASSEMBLY= 9.5 KG[APPROXIMATE)
ONI NE
SETUP HEIGHT MM
1630 KG
O
PRELOAD RANGE
-200 KG
M
B. MINIMUM TRAVEL 21 MM NIW
FREE HEIGHT
EE
709122/2021/O/o ED/QAM/RDSO/MUMBAI

TABLE 1
HOUSING
SUJAN
YYYY
40704
Provisionally Approved (Font size-Height: 6mm)
® NOTE
Voad wp 2 Sep 201 u
1. Gray paint application for rust prevention.
2. Part identification for Tecspak- laser printed with 6mm of engrave
letter height & non erasable
3. Tecspak - Imported from Miner Enterprises, U.S.A.
TECSPAK
Dated o6lFor DG (WaRDSO
PART LIST VASAI (Tvetl
SR.NO. QUANTITY PART NAME PART NUMBER REV. NO.
B.5
CONTROLLED COPY
01 HOUSING (BOTTOM HOUSING) 40705
40706 B.5
SUSHIL K.TRIPATHIin Pua ci
CONSIANECONIACSIDE BEANING
D1 TOPCAP (TOP HOUSING) Re a A/S. Section Engineer (1&) DESIGN 01
cONFIDENTIAL SUJAN INQUSTRIES 31.AI,v., RDSO ACA Mnistry 0f Ralway NINAD V
T Mumbal-400 020 abo
B,5 22/10/2018
iON MARKING ADDED. 40704
2.FOR SETUP HEIGHT-131 MM NTS
TO1630KG 0/-200KG
A N G E FROM 23 AIM TO21 M
Sujan Industr 40704
APART UST ADDED.
sDROJECT :CC
CUSTOMER:1NDIAN RKALLWA ERZA
oRAWINGTO ANOTHER PARTSOOUr EOREIS
AWTNGISA DROPERr Or SUJAN INDUSTRIESA
ANIL ATLL
 * * * *
925

- -
46-
A
ol44.25t0.3
6.5
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-HARDNESS CHECK
OUNDRMARK AND
THIS SURFACE
2
T
PART NUBERAND
REVISION LEVEL
A
709122/2021/O/o ED/QAM/RDSO/MUMBAI

SECTIONA-A Provisionally Approved

Ne. m.g cesapu.au
V
Datod nsnltyFor DT (Wagea) 3 0
NOTE
engrave with 8mm
929 - -
1. Part identification for Top cap
letter height.
2 8 20u
VASAI SUSHIL K.TRIPATHI m b.frrt
ao a arveam (ALS. Section Engineer (1 CONTROLLEDCOPY WEIGHI: 3.9 KG
..M, RDs0 HI AMinistry Of Railwly TOP CAP (TOP HOUSING)
H Mumbai- 400 020 sD ENGIEER RAANASER R D SECTION HEAD
cONFIDENTIAL - SUJAN INDUSTRIES DESIG ED BY: ANILP.
DATE:210 /2018
aseNLY MAT NUSER
</10/2018
40704
1. ECIED AARNNGS
NTS
ACENEAG
AL
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LA
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TNOJA RI RAII WAY: PROJEC E AY SUAR TALUSTAIts
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926

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16
3N W
-446-
SECTION A-A
216 NOIEE
Part identification for Housing engrave
1
with 8mm letter height.
709122/2021/O/o ED/QAM/RDSO/MUMBAI

HARDNESS CHECK
Provisionally Approved
Valud npo 3 ap 19 8
105
22-
FOUNDRY MARK-
DATE CODE Datsdo6tra For DG {agG*
VASAI
sUSHIL K.TRIPATHI s.fri CONTROLLED COPY wEGHT: 4.8 KG
afe as ata AMS Section Engineer(tá
HOUSING |BOTTOM HOUSING)
aMM. RDS0 t aea Ministry 0f Rait.
Mumbal-400 020 DESIGNED BY: ANILP. R&D ENGIEER RAD MANAGER
CONFIDENTIAL SUJAN INDUSTRIES
-
DATE 2204010+
B. 4/40/200
40704
COnEDNARAIFIGS
A1
40705
San tral Wath
8.51/1
o y g Hagar,Vasa (tat, olst Palghardo120xo JECT:CCSB
STOMER : INDIAN RAILWVAY
ORAWING TO ANOER PARY SHOULDBt AUTHORIo r suAN INDUSTATES
THIS D'EAWNG ISA DEODERY OF SU1AN TNDUSTRIESA HAY NO o d
ANL PA
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