RDSO CCSB Letter

File No.
RDSO-MW0BD(SB)/1/2020-O/o PED/SW/RDSO
Hkkjr ljdkj &jsy ea=ky; Government of India - Ministry of Railways
vuqla/kku vfHkdYi vkSj ekud laxBu Research Designs & Standards Organisation
y[kuÅ & 226011 Lucknow – 226011
Fax : 91-0522-2452494 DID (0522)2450115
Tele/Fax: 0522- 2465773 DID(0522)2465310
No. MW/PLNG/CSNB Dated: 07.03.2023
iz/kku eq[; ;kaf=d vfHk;Urk %

1- e/; jsyos] N=ifr f’kokth VfeZul] eqEcbZ& 400 001-
2- iwoZ jsyos] Qs;jyh Iysl] dksydkrk & 700 001-
3- mRrj jsyos] cM+kSnk gkml] ubZ fnYyh & 110 001-k
4- nf{k.k jsyos] ikdZ Vkmu] psUubZ & 600 003-
5- nf{k.k e/; jsyos] jsy fuyk;e] fldUnjkckn & 500 071-
6- nf{k.k iwoZ jsyos] xkMZsu jhp] dksydkrk & 700 043-
7- iwoksZRrj jsyos] xksj[kiqj & 273 012-
8- iwoksZRrj lhekUr jsyos] ekyhxkWao] xqokgkVh & 781 011-
9- if’pe jsyos] ppZxVs ] eqEcbZ & 400 020-
10- iwoZ e/; jsyos] gkthiqj & 844 101-
11- iwoZ rVh; jsyos] chMh, jsVa y dkyksuh] jsyos dkEiysDl] pUnz’ks[kjiqjk] Hkqous’oj]&751 016-
12- mRrj e/; jsyos] gkfLVax jksM ]bykgkckn & 211 001-
13- mRrj if’pe jsyos] t;iqj & 302 006-
14- nf{k.k if’pe jsyos] gqcyh & 580 023-
15- if’pe e/; jsyos] tcyiqj & 482 001-
16- nf{k.k iwoZ e/; jsyos] vkj0bZ0 dkEiysDl] fcykliqj&495004
Sub: Comprehensive guidelines for maintenance of Constant Contact Side Bearer.

Ref: Webex meeting of all CRSEs on 22.02.2023.
1. Presently the Maintenance of Constant Contact Side Bearers to RDSO specification No WD-
38, WD-62 and CONTR-01 are governed by OEM’s maintenance manual, respective
drawings of CCSBs and RDSO specifications.
2. In reference to Webex meeting as above, Railway Board has directed RDSO for drafting
comprehensive maintenance instruction for the maintenance of Constant Contact Side
Bearer used on IR freight Stocks and same may be circulated to all Zonal Railways for their
comments before finalization.
3. Accordingly, a comprehensive maintenance instruction for the maintenance of Constant

Contact Side Bearer used on IR freight Stocks have been prepared and enclosed with this
letter.
4. All Zonal Railways are requested to examine the maintenance manual and provide their
comments by 18.03.2023 on email abhishek.gautam84@gov.in for further necessary action.
Railways are also requested to provide their feedback on the provision of using lock-bolting
as an alternate method for fastening of bottom housing with bogie bolster.
DA: As above.
(A.K. Gautam)
JDSW/BD
for Director General/RDSO
File No.RDSO-MW0BD(SB)/1/2020-O/o PED/SW/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 and feedback
please.
File No.RDSO-MW0BD(SB)/1/2020-O/o PED/SW/RDSO 207
1756980/2023/O/o ED/SW/RDSO
INSTRUCTIONS
FOR
EXAMINATION & MAINTENANCE
OF
CONSTANT CONTACT SIDE BEARER ASSEMBLY
***********
ISSUED BY
WAGON DIRECTORATE
RESEARCH DESIGNS AND STANDARDS ORGANISATION
MINISTRY OF RAILWAYS
MANAK NAGAR, LUCKNOW-226011
(March-2023)
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Contents
1.0 INTRODUCTION .................................................................................................................... 4
2.0 TECHNICAL TERMS .............................................................................................................. 5
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 BOLT DOWN AND ASSEMBLY ........................................................................................... 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 ASSEMBLYTO SPECIFICATION WD-62-MISC-17 ...................... 16
a. Yard examination ....................................................................................................................... 16
b. Maintenance of CCSB to WD-62-Misc-17during ROH/POH: .............................................. 17
C. INSTRUCTIONS FOR EXAMINATION & MAINTENANCE OF CONSTANT

CONTACT SIDE BEARER ASSEMBLY TO CONTR-01-MISC-07(MS-25) ................................ 19
1.0 Examination of CCSB to CONTR-01-Misc-07(MS-25) ...................................................... 19

2.0 Part List.................................................................................................................................... 21
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 ......................................... 11
Figure 7: WD-62-Misc-17 CCSB in assembled condition............................................................. 18
Figure 8: Setup height measurement of WD-62-Misc-17 CCSB in assembled condition ........ 18
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Figure 9 : CONTR-02-Misc-07CCSB in assembled condition ..................................................... 19

Figure 10 : Setup height measurement of CONTR-02-Misc-07 CCSB in assembled condition
.............................................................................................................................................................. 20
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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)
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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 fig 2 is the nominal installed height of side
bearer in the wagon on leveled track. Set-Up Height- in static condition
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 II.
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

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(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 Height Condemning Set up Height

No. (in mm) Height (in mm)
(in mm)
1 WD-38 MISC 2004 142.5±1.6 137 As per CP-SB
(Design-A) arrangement Drg.
of wagon
WD-38 MISC 2004 134±1.5 128.5 As per CP-SB
(Design-B) arrangement Drg.
of wagon
2 WD-62-MISC-17 Drg. 164±1.5 146.25 128.5
No. WD-17025/S-1
Drg. No. WD-12008/S-1 163±1.5 145.75 128.5
Drg. No. WD-12007/S-1 167±1.5 147.75 128.5
3 MS 25 Side Bearer to 153±3 142 As per CP-SB
DRG. No. 40704 arrangement Drg.
of BLCAM/BM
and BOXNHL
wagon.
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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
shall always be withdrawn from the service in the event of any of the
following.
• Housing crack, breakage, deformation.
• Gap between under frame Side Bearer plate and CCSB Top. However,
wagon may be checked for uneven loading.
• 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 BOLT DOWN AND ASSEMBLY
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.
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• 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 with copies to DG Wagon.
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.
3.2 PU Side Bearer Pad for CASNUB 22 NLB Bogies to drg. No. AAL-21101/N
Consists of :
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(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:2062Fe4l0 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

Mark the Wagon for Sick line Examination 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,
• 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.
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Figure 4 : PU CCSB in assembled condition
Figure 5: Set up height measurement of PU CCSB in

assembled condition
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Figure 6: Excessive Gap between PU CCSB in assembled

condition
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 upto 4mm then the
free height of the SBP 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.
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4.3.1 Replacement kit for CASNUB 22 HS (Drg. No. AAL-021101 Alt.8)

Item No.
5 PU Rings (donuts) = 3 Nos.
3&6 Spacers = 2 Nos.
4 Sleeve = 2 Nos.
4.3.2 Replacement kit for CASNUB 22 NLB (Drg. No. AAL-021101/N)

Item No.
5 PU Rings (donuts) = 2 Nos.
3&6 Spacers = 1 Nos.
4 Sleeve = 2 Nos.
The solid steel plate of the rejected PUSBP 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 - 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.
 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
chart in Annexure -1.
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 Annexure-I then the top housing must be
replaced with fresh top housing of respective design.
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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.
 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 (see annexure I) 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
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spacer plate, there is very little chance of its getting damaged. It can
almost always be reused.
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 it on the bolster. During riveting TPU sleeve
must be covered suitably to save it from direct contact of heat in case of
Alt.5. Even in case of Alt. 6 and Alt. I 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
Wear of top housing = I40.5+l.6mm
Free height with old healthy donuts
considering 4mm maximum permanent set: 137-0mm
For CASNUB 22 NLB (Drg. No. AAL-021101/N)

Free Height with new kit = 134.0+l.5mm
Free Height with 2mm
Wear of top housing: 132.0 +l.5mm
Free Height with old healthy donuts
Considering 4mm maximum permanent set = 128.5mm
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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). Drg. No.
ARL/PPW/0506 is attached.
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A. INSTRUCTIONS FOR EXAMINATION & MAINTENANCE OF

CONSTANT CONTACT SIDE BEARER ASSEMBLYTO 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-S/1 or Pre load (Kg) - 1750± 0200
equivalent firm’s design (Generally applicable for
wagons having empty body
weight up to 9.4t)
b) Variant ‘B’ : Drawing No. – WD-12008-S/1 or Pre load (Kg) - 2000± 0250
weight between 9.4t to12.7t)
c) Variant ‘C’ : Drawing No. – WD-12007-S/1 or Pre load (Kg) - 2700± 0300
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 with copies to DG
Wagon.
Maintenance of CCSB to specification WD-62-Misc-17 shall be done as follows:

a. Yard examination
Wagons having following defects will not be allowed for operation.
i) Visual examination of Housing crack, breakage, deformation.
ii) Gap between under frame Side Bearer plate and CCSB Top. However,
The wagon if found with above defects shall be sick marked and to be examined an
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.
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b. Maintenance of CCSB to WD-62-Misc-17during ROH/POH:

CCSBs as per the RDSO Drawing shall be examined and maintained as
follows:
1. Top and Bottom Housing shall be examined and maintained as follow.
1.1. Top/Bottom Housing shall be replaced if found with any of the

following defects
1.1.1. Crack/ breakage in top/bottom housing.
1.1.2. Wear of 3mm or more in top face of top housing and
increase/decrease more than 03mm in diameter of bottom/top
housing measured from nominal values.
2. Spring Element shall be examined and maintained as follow
2.1. Spring Element shall be replaced if found with any of the following
defects
2.2. Crushing, tears, breakage or crack in any suspension element.
However minor surface crack which do not affect properties may
be ignored.
2.3. 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 163.0mm, then half of deflection (163.0-128.5)/2 =
17.25mm. Then the CCSB to be renewed with new springs/housing.
Condemning heights of CCSB springs shall be as follows:

S. CCSB Variant Free height of Condemning
No. 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 refered.
3. Side bearer top Liner to be replaced with new one.
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Figure 7: WD-62-Misc-17 CCSB in assembled condition
Figure 8: Setup height measurement of WD-62-Misc-17 CCSB in

assembled condition
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B. INSTRUCTIONS 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 with
copies to DG Wagon.
1.0 Examination of CCSB to CONTR-01-Misc-07(MS-25)

Maintenance of CCSB to specificationCONTR-01-Misc-07 (MS-25 ) CCSBs
shall be examined and maintained as follows:
a) Yard eamination
Wagons having following defects will not be allowed for operation, 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 19 of 24
1756980/2023/O/o ED/SW/RDSO
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.
Page 20 of 24
1756980/2023/O/o ED/SW/RDSO
c) 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.
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
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 21 of 24
1756980/2023/O/o ED/SW/RDSO
Annexure-I
TABLE SHOWING CONDEMNING LIMITS/CONDITIONS
Sl. Name of Bogie/Drg. Location New Condemning Limits

No. Component (Alt.) Dimension
1 Top Housing Alt.8 Ht. 87.5 + 0.8 85.5 + 0.8
ID 136+ 0.8 No wear due to
sleeve
NLB Ht. 87.5 + 0.8 85.5 + 0.8
ID 136+ 0.8 No wear due to
sleeve
2 Bottom NLB/Alt.8 Ht. 90.0 + 0.8 88.0 + 0.8
Housing ID 130+ 0.8 Less than 128.5
3 SB (Assembly) NLB/Alt.8 (Free Ht.) 134.0+ 1.5 Less than 128.5
4 PU Ring For all types Thickness 33 + 0.7 31.5
Page 22 of 24
1756980/2023/O/o ED/SW/RDSO
Annexure-II
DETAILS OF WAGONS SETUP HEIGHT
Sl. Wagon Component Setup Height (mm) CPSB Drawing No.

1 BOXNS CCSB 128.5 WD-14014-S-7
2 BOST/BOSTHS CCSB 128.5 WD-20024-S-4
3 BOXNLW CCSB 128 WD-01085-S-01
4 BOXN/BOXNM CCSB 124 WD-85079-S-01
5 BOXNHS/BOXNHSM CCSB 123 WD-04038-S-3
WD-04078-S-2
6 BOXNR CCSB 128.5 WD-20024-S-02
7 BOXNRHS CCSB 128.5 WD-20024-S-02
8 BOXNHL CCSB 126.5 WD-09034-S-08
9 BOXNHAM CCSB 124 WD-98015-S-11
10 BOXNHA CCSB 124 WD-98015-S-11
11 BCN/BCNM CCSB 123 WD-84014-S-7A
12 BCNHS/BCNHSM CCSB 123 WD-01011-S-52
WD-17029-S-18
13 BCNA/BCNAM CCSB 124 WD-90030-S-68
14 BCNAHS/BCNAHSM CCSB 123 WD-01011-S-52
15 BCNHL CCSB 127 WD-06076-S-19
126 WD-11054-S-27
16 BOBR(20.32T) CCSB 127 WD-86013-S-56
17 BOBR(22.32T) CCSB 127 85076/S-1
18 BOBRM1(22.32T) CCSB 127 85076/S-1
19 BOBRN CCSB 126 85076/S-7
20 BOBRNM1 CCSB 126 85676/S-1
21 BOBRNHS CCSB 121 WD-05016-S-56
22 BOBRNHSM1 CCSB 121 WD-15042-S56
23 BOBYN CCSB 124 S.K-77538
24 BOBYN22.9/BOBYNHS CCSB 119.5 WD-02020-S-01
25 BOBSNS CCSB 128.5 WD-18076-S-26
26 BRNA CCSB 124 WD-92004-S-09
27 BRN CCSB 124 WD-84013-S-14
28 BRNAHS CCSB 124 WD-02-009-S-01
29 BRN 22.9 CCSB 124 WD-09053-S-16
30 BFNS 22.9 CCSB 117 WD-00052-S-06
31 BFNSM CCSB 128 WD-14035-S17
32 BRHNEHS CCSB 123.5 WD-04004-S-57
33 BTFLN CCSB 125 RSD-6315-007
34 BTALNM CCSB 125 WD-14002-S-56
35 BTPN CCSB 124 WD-86081-S-55
36 BTPGLN CCSB 124 WD-93047-S-61
37 BCFCM CCSB 128.5 WD-15014-S-23
38 BTFC CCSB 128.5 WD-19050-S-14
39 BLC CCSB 131 CONTR-9404-S-8
Page 23 of 24
1756980/2023/O/o ED/SW/RDSO
40 BLCM CCSB 131 CONTR-9404-S-8

41 BLL CCSB 131 CONTR-9404-S-8
42 BLCS CCSB 125 WD-20021-S-01
Page 24 of 24
1756980/2023/O/o ED/SW/RDSO
1756980/2023/O/o ED/SW/RDSO
1756980/2023/O/o ED/SW/RDSO
1756980/2023/O/o ED/SW/RDSO
1756980/2023/O/o ED/SW/RDSO
*** ******
924
236
* L
2 3 (TECSPAK)
IDENTIFICATION MARKING
INSTALLED HEIGHT
SEE
105 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
ED/SW/RDSO
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
1756980/2023/O/o
(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
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REVISION LEVEL
A
1756980/2023/O/oED/QAM/RDSO/MUMBAI
SECTIONA-A Provisionally Approved

Ne. m.g cesapu.au
V
ED/SW/RDSO
Datod nsnltyFor DT (Wagea) 3 0

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engrave with 8mm
929 - -
1. Part identification for Top cap
letter height.
2 8 20u
VASAI
709122/2021/O/o
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)
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cONFIDENTIAL - SUJAN INDUSTRIES DESIG ED BY: ANILP.
DATE:210 /2018
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40704
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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
ED/SW/RDSO
105
22-
FOUNDRY MARK-
DATE CODE Datsdo6tra For DG {agG*
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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
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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
L TA

RDSO CCSB Letter

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RDSO CCSB Letter

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File No.

No. MW/PLNG/CSNB Dated: 07.03.2023

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

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

3. Accordingly, a comprehensive maintenance instruction for the maintenance of Constant

EXAMINATION & MAINTENANCE

CONSTANT CONTACT SIDE BEARER ASSEMBLY

RESEARCH DESIGNS AND STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW-226011

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

A. INSTRUCTIONS FOR EXAMINATION & MAINTENANCE OF CONSTANT

1.0 OBJECTIVE ............................................................................................................................... 8

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

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

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

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

B. INSTRUCTIONS FOR EXAMINATION & MAINTENANCE OF CONSTANT

a. Yard examination ....................................................................................................................... 16

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

C. INSTRUCTIONS FOR EXAMINATION & MAINTENANCE OF CONSTANT

1.0 Examination of CCSB to CONTR-01-Misc-07(MS-25) ...................................................... 19

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

Figure 9 : CONTR-02-Misc-07CCSB in assembled condition ..................................................... 19

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

Figure 1 : Constant Contact Side Bearer (CCSB)

2.0 TECHNICAL TERMS

Figure 2: Setup Height

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

(ii) Pre load

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

Sl. Type Free Height Condemning Set up Height

4.0 GENERAL CONDITION OF OPERATION OF CCSB IN FREIGHT

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

5.0 WAGON BODY WEAR PLATE

6.0 BOLT DOWN AND ASSEMBLY

• INSTRUCTIONS FOR EXAMINATION & MAINTENANCE OF

3.0 DESIGN DETAILS

4.1 Yard Examination

4.2 Sick line Attention:

Figure 4 : PU CCSB in assembled condition

Figure 5: Set up height measurement of PU CCSB in

Figure 6: Excessive Gap between PU CCSB in assembled

4.3 ROH & POH

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

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

4.4 Examination During ROH

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

5.0 RE-ASSEMBLY OF PU SBP

6.0 ACCEPTABLE FREE HEIGHT AFTER REASSEMBLY

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

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

Note: It is recommended to use a 3 mm polymer packing washer to maintain the free

A. INSTRUCTIONS FOR EXAMINATION & MAINTENANCE OF

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

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

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

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

2. Spring Element shall be examined and maintained as follow

Condemning heights of CCSB springs shall be as follows:

3. Side bearer top Liner to be replaced with new one.

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