FRA F 6180.161k Sample Car Inspection Checklist for S-2044 Appendix G-1:

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Inspector(s):
Builder:
ITEM
Hand Brake

Sample Car Inspection Checklist For: S-2044 Appendix G-1
Safety Appliances for Coil Cars

Inspection Location:
Car Initial and Number:

Car Type:

Date:
No. of cars to be Built:

Number - Dimensions - Location - Manner of Application

Appendix Reference

Each car shall have at least one AAR-approved vertical-wheel hand brake that complies with
Appendix G1, 2.1.1
MSRP Section E, Standard S-475 and that operates in harmony with the power brake equipment
on the car. Total braking force applied to the brake shoes by the hand brake shall comply with the
requirements of MSRP Section E, Standard S-401, but in any event shall be not less than that
developed by 50 psi brake cylinder pressure. The hand brake wheel and chain drum of
vertical-wheel hand brakes shall be arranged so that both will revolve when applying and
gradually releasing the hand brake. The hand brake shall be provided with means to prevent
application of the brake by turning the brake wheel in a counterclockwise direction.
The hand brake wheel shall have a nominal diameter of 22 in. The brake wheel shall be of
shallow configuration and shall be of steel or other material of equivalent strength.

Appendix G1, 2.1.2

The hub of the hand brake wheel shall be 2 5/8 in. deep with a square tapered fit to the shaft.
Appendix G1, 2.1.3
The taper on the brake wheel hub and shaft shall be 1 in. in 12 in. on each side, or 2 in. in 12 in.
total, with the small end of the shaft opening 7/8 in. square. The brake wheel shall be secured to
the brake shaft with an American National Standard 7/8-9 heavy hex nut and 3/16 in. x 1 ½ in.
cotter, or their equivalent.
Location

The hand brake shall be located so that it can be safely operated from the car while the car is in Appendix G1, 2.2.1
motion and safely operated from the ground while the car is stationary. The hand brake on cars
equipped with one brake shall be applied on the B end of the car at the left side. The hand brakes
on car equipped with more than one hand brake shall be located as specified in paragraph 9.0 of
the base standard.
The center of the hand brake shaft shall be located in the transverse direction not less than 12 in., Appendix G1, 2.2.2
nor more than 22 in., from the inside surface of the nearest side handhold and shall be not less
than 26 in. above the lowest sill step tread nor more than 46 in. above the highest sill step tread.
In addition, the center of the hand brake shaft shall be not more than 65 in. above the top of rail.
The outside face of the hand brake wheel shall be no more than 36 in. in the longitudinal
direction from the inside surface of the inboard vertical side handhold. The outside face of the
hand brake wheel shall be no more than 16 in. in the longitudinal direction from the inside
surface of the outboard vertical leg of the sill step and shall not extend more than 8 in. beyond
the striker or end of the center sill, whichever extends farther.

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Appendix G1, 2.2.3

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Region:
Builder Job No.

Notes

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix G-1
Safety Appliances for Coil Cars

Number - Dimensions - Location - Manner of Application

ITEM

Appendix Reference

Clearance around the rim of the hand brake wheel shall be not less than 4 in. Clearance between Appendix G1, 2.2.4
the grip portion of the release lever, if used, throughout its range of travel and any part of the car
shall be not less than 2 ½ in.
If the hand brake application is such that the requirements of paragraph 2.2.4 can be met only
Appendix G1, 2.2.5
with hand brakes having short hand brake release levers or only with long release levers, but not
both, the car shall be marked adjacent to the hand brake in 1 ½ in. high letters “SHORT (LONG)
RELEASE LEVER BRAKE ONLY”.
Manner
of Application

The hand brake housing shall be securely fastened. The hand brake application, including bolt
hole pattern, shall conform to MSRP Section E, Standards S-475.

Appendix G1, 2.3.1

The hand brake chain shall conform to the requirements of S-475, but in any event shall have
minimum working load of 5,875 lb and minimum proof test of 11,750 lb.

Appendix G1, 2.3.2

Hand brake rods shall be of no less than ¾ in. diameter.

Appendix G1, 2.3.3

Sill Steps
Number

There shall be four sill steps.

Appendix G1, 3.1

Dimensions

Sill steps shall conform to the requirements of Standard S-2042. Minimum usable length of tread Appendix G1, 3.2.1
shall be 14 in.
Sill steps shall be of steel not less than ½ in. thick, shall be not less than 4 in. wide, and shall be
provided with an antiskid surface.

Appendix G1, 3.2.2

Sill steps shall have sufficient treads such that the top tread is not more than 21 in. below the
Appendix G1, 3.2.3
lowest adjacent horizontal side handhold, if the car is so equipped, or, if there are no horizontal
side handholds, below the walking surface of the end walkway. Sill step treads shall be spaced not
more than 21 in. apart.
The clear depth above the entire usable length of all sill step treads shall be not less than 8 in.
and the clear width of the lowest sill step tread shall be not less than 6 in. for both loaded and
empty conditions with the trucks rotated to simulate the maximum curvature specified for the
uncoupled car.

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Appendix G1, 3.2.4

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Notes

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix G-1
Safety Appliances for Coil Cars

ITEM

Number - Dimensions - Location - Manner of Application

Appendix Reference

Location

One sill step shall be applied near each end of each side of the car. The sill steps shall be located Appendix G1, 3.3.1
in the longitudinal direction such that the inside face of neither vertical leg of the sill step extends
more than 2 in. into the space between the vertical side handholds or the space between the
vertical handhold supports, whichever space is smaller.
In the transverse direction, the outside edge of any sill step tread shall be not more than 6 in.
Appendix G1, 3.3.2
inboard or outboard of the inside surface of the adjacent side handholds. In addition, the outside
edge of any sill step tread shall be not more than 4 in. inboard of any car structure below the
adjacent side handholds in the area between the side handholds. With the exception of the side
handholds and their supports, no part of the car below 66 in. above the top of rail shall extend
farther than 6 in. outboard of the outboard edge of the lowest sill step tread.
The lowest tread shall be not more than 20 in. above the top of rail.

Appendix G1, 3.3.3

Manner
of Application

Sill steps shall be Securely Fastened.

Appendix G1, 3.4

Side Handholds
Number

There shall be not less than eight side handholds, two at each corner.

Appendix G1, 4.1

Dimensions

Handholds shall be of steel not less than ¾ in. diameter or pipe of 1 ¼ in. nominal pipe size with
Schedule 40 minimum wall thickness. Handhold material shall conform to the requirements of
Standard S-224. Minimum clear length shall be 16 in. Minimum clearance shall be 2 in.,
preferably 2 ½ in.

Appendix G1, 4.2.1

Side handholds shall have an uninterrupted span between the upper and lower clearance points. Appendix G1, 4.2.2

Location

Horizontal side handholds below the end platform, if the car is so equipped, shall have foot
guards or upward projections not less than 2 in. in height at both ends.

Appendix G1, 4.2.3

Two vertical handholds, one at either end of each sill step, shall be applied.

Appendix G1, 4.3.1

The inside surface of the outboard vertical handhold shall be not more than 14 in. from the inside Appendix G1, 4.3.2
surface of the nearest end handhold. At corners of the car where a hand brake is located, the
14 in. limit shall be measured to the end handhold at the opposite side of the car from the
hand brake. The clear opening between the surfaces of the vertical handholds and their supports
shall be not less than 18 in. The width over the outside surfaces of the vertical handholds shall be
not more than 30 in.

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OMB No. 2130-0565
F6180.161k 12/15

Notes

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix G-1
Safety Appliances for Coil Cars

Number - Dimensions - Location - Manner of Application

ITEM

Appendix Reference

The clearance points of the bottom end of the vertical handholds shall be not more than 42 in.
Appendix G1, 4.3.3
above the top of rail and the clearance points of the top end shall be not less than 33 in. above the
walking surface of the end platform.
If the car is equipped with horizontal side handholds, spacing between horizontal side handholds, Appendix G1, 4.3.4
and from the highest horizontal side handhold to the walking surface of the end platform shall be
not more than 19 in.
If car is equipped with horizontal side handholds, the outboard clearance points of the handholds Appendix G1, 4.3.5
shall be not more than 2 in. inboard of the inside surface of the outboard vertical leg of the sill
step, and the inboard clearance points of the handholds shall be not more than 2 in. outboard of
the inside surface of the inboard vertical leg of the sill step.
Manner

Side handholds shall be securely fastened.

Appendix G1, 4.4

End Handholds
Number

There shall be four end handholds.

Appendix G1, 5.1

Dimensions

Handholds shall be of steel not less than ¾ in. diameter and shall conform to the requirements of Appendix G1, 5.2
Standard S-224. Minimum clear length shall be 16 in. Minimum clearance shall be 2 in.,
preferably 2 ½ in.

Location

The end handholds shall be oriented horizontally, one near each side of each end of the car on
the face of the end sill.

Appendix G1, 5.3.1

The clearance points of the outer end of the end handholds shall be not more than 16 in. from
the inside surface of the nearest side handhold.

Appendix G1, 5.3.2

Unless protected by a guard around the chain, handholds shall have not less than 5 in. clearance Appendix G1, 5.3.3
from the hand brake chain throughout the entire range of chain travel. Guards shall be provided
around hand brake chain shock retarders, if used, that are closer to the handhold than 5 in.

FRA 6180.161k

End handholds shall not extend more than 8 in. beyond the striker or end of the center sill.

Appendix G1, 5.3.4

The end handholds shall be not more than 45 in. above the top of rail.

Appendix G1, 5.3.5

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OMB No. 2130-0565
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Notes

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix G-1
Safety Appliances for Coil Cars

ITEM

Number - Dimensions - Location - Manner of Application

Appendix Reference

Manner
Application

End handholds shall be securely fastened.

Appendix G1, 5.4

Walkways at End
of Car
Number

There shall be two transverse walkways, one at each end of the car.

Appendix G1, 6.1

Dimensions

Transverse walkways shall comply with the requirements of Standard S-226. Walkways shall be Appendix G1, 6.2
considered running boards under Standard S-226 and shall conform to design, manufacturing,
and test requirements of Standard S-226 applicable to running boards. The walkway material
shall have uniform antiskid surfaces and shall be of construction to provide at least 50% clear
opening in a representative area to permit elimination of accumulated snow and ice. Transverse
walkways shall be not less than 18 in. wide.

Location

The gap between the transverse edges of transverse walkways at vertical side handholds and the Appendix G1, 6.3.1
nearest surfaces of the vertical handholds or their supports, whichever limits the clear opening
between the vertical handholds or their supports, shall not exceed 4 in.
The ends of transverse walkways shall not be outboard of, and shall be not more than 2 in.
inboard from, the outside surface of the sides of the car directly below the walkway ends.

Appendix G1, 6.3.2

Manner
of Application

Transverse walkways shall be securely fastened with not less than 3/8 in. diameter fasteners.

Appendix G1, 6.4

Clearance at
End of Car

No part of the car above the end sill more than 30 in. from the longitudinal centerline of the car, Appendix G1, 7.0
except the hand brake wheel, hand brake shaft, bell crank, sheave wheel, end platform, or
horizontal end handholds, shall extend beyond the striker or end of the center sill with the draft
gear or cushioning device (if used) at full buff. No other part of the car end or fixtures on the end
above the end sill and less than 84 in. above the walking surface of the end platform, other than
the exceptions herein noted, shall extend beyond the outer face of the striker or end of the
center sill.

Walkways at
Sides of Cars
Number

When walkways are applied to the sides of the car, they shall be applied to both sides.

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Appendix G1, 8.1

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Notes

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix G-1
Safety Appliances for Coil Cars

Number - Dimensions - Location - Manner of Application

ITEM
Dimensions

Appendix Reference

Side walkways shall comply with the requirements of Standard S-226. The walkway shall be
Appendix G1, 8.2.1
Considered running boards under Standard S-226 and shall conform to the design, manufacturing,
and test requirements of Standard S-226 applicable to running boards. The walkway material
shall have uniform antiskid surfaces and shall be of construction to provide at least 50% clear
opening in a representative area to permit elimination of accumulated snow and ice. Side
walkways shall be not less than 10 in. wide.
Side walkways shall be continuous and shall not be cut at any point, except that the length may
be made up of several sections secured to mounting brackets.

Appendix G1, 8.2.2

Location

Side walkways shall extend from end walkway to end walkway.

Appendix G1, 8.3

Manner
of Application

Side walkways shall be securely fastened to the car with not less than 3/8 in. diameter fasteners. Appendix G1, 8.4

Uncoupling Devices

There shall be a minimum of two uncoupling devices that conform to the requirements of the
base standard.

Appendix G1, 9.0

Uncoupling devices and their application shall conform to MSRP Section S, Part III, Standard
S-129, S-131, S-133, or S-134; or Specification M-961.

S-2044 6.1 (Base Standard)

One uncoupling device shall be applied at the left side of the B end of the car (BL corner) and
one at the right side of the A end of the car (AR corner).

S-2044 6.2

Under all operating conditions, the outside surface of the uncoupling device handles shall be not S-2044 6.3
more than 12 in. closer to the car center than the inside surface of the adjacent side handholds.

FRA 6180.161k

There shall be not less than 2 in. clearance, preferably 2 ½ in., around the uncoupling device
handles for a length not less than the lowest 4 in. of straight handles and not less than 4 in. in
the grip portion of handles having clearly defined grip portions. The lower ends of the handles
shall be not less than 12 in. nor more than 15 in. below the top surface of the uncoupling
device at the device support and not less than 15 in. above the top of rail.

S-2044 6.4

Uncoupling device mounting brackets shall be securely fastened to the car with fasteners not
less than 5/8 in. diameter.

S-2044 6.5

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Notes

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix G-1
Safety Appliances for Coil Cars

ITEM

Number - Dimensions - Location - Manner of Application

Appendix Reference

Handholds on
Removable Coil
Cover

When handholds are applied to removable covers, they shall be of steel not less than ¾ in.
diameter and shall conform to the requirements of Standard S-224. Minimum clear length shall
be 16 in. Minimum clearance shall be 2 in., preferably 2 ½ in. Handholds shall be securely
fastened to the covers.

Appendix G1, 10.0

Stenciling

Car initial, numbers and built date stenciled on the car.

49 CFR Part 215.301

Reflectorization.

Reflectorization must meet all requirements. Attached Drawing

49 CFR Part 224

Coupler Height

Verify coupler height 31½ inch minimum, 34½ inch maximum.

49 CFR Part 231.31(a)(1)

Power Brakes

Except for cars equipped with nominal 12-inch stroke (8 ½ and 10-inch diameters)
brake cylinders, all cars shall have a legible decal, stencil, or sticker affixed to the car
or shall be equipped with a badge plate displaying the permissible brake cylinder
piston travel range for the car at Class I brake tests and the length at which the piston
travel renders the brake ineffective, if different from Class I brake test limits. The
decal, stencil, sticker, or badge plate shall be located so that it may be easily read and
understood by a person positioned safely beside the car.

49 CFR Part 232. 103

All equipment ordered on or after August 1, 2002, or placed in service for the first time
on or after April 1, 2004, shall have train brake systems designed so that an inspector
can observe from a safe position either the piston travel, an accurate indicator which
shows piston travel, or any other means by which the brake system is actuated.
The design shall not require the inspector to place himself or herself on, under, or
between components of the equipment to observe brake actuation or release.
SCT

A single car air brake test shall be performed on each new car prior to placing or using
the car in revenue service.

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49 CFR Part 232.305

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Notes

OMB No. 2130-0565

Miscellaneous

Check for any sharp or protruding objects or areas on the equipment that may create a safety concern or personal injury.
Check for potential pinch points at all safety appliance arrangements.

Digital Photos

General Arrangement Photo Sheet ~ No Deviations Noted (six photos minimum, A & B ends, each corner at 45 degree angle)
Deviation Photo Sheet ~ As many photos as necessary to fully depict, document and illustrate deviations
of S-2044 Appendix G1 or CFR Parts(e.g. 215, 224 & 232)

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