Form FRA F 6180.a FRA F 6180.a Sample Car Inspection Checklist for S-2044 Appendix A-1:

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Inspector(s):
Builder:
ITEM
Hand Brake

Location

Sample Car Inspection Checklist For: S-2044 Appendix A-1
Safety Appliances for Box Cars and Other House Cars without Roof Hatches

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 an AAR-approved vertical-wheel hand brake that complies with MSRP
Appendix A1, 2.1.1
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 verticalwheel 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 A1, 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
shaft. 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.

Appendix A1, 2.1.3

The hand brake shall be located so that it can be safely operated from the horizontal end
platform while the car is in motion. The center of the hand brake shaft shall be located on the
B end of the car to the left of, and not less than 17 in. nor more than 22 in. from, the centerline
of the car and shall be not less than 28 in. nor more than 40 in. above the platform-support
surface of the end-platform mounting brackets. The hand brakes on cars equipped with more
than one hand brake shall be located as specified in paragraph 9.0 of the base standard.

Appendix A1, 2.2.1

Clearance around the rim of the hand brake wheel shall be not less than 4 in. Clearance
between the grip portion of the release lever, if used, throughout its full range of travel and
any part of the car shall be not less than 2 ½ in.

Appendix A1, 2.2.2

The outside edge of the hand brake wheel shall not extend more than 8 in. beyond the
striker or end of the center sill, whichever extends farther, and not more than 8 in. beyond
the outboard edge of the end platform. The outside edge of the hand brake wheel shall be not
less than 1 in. and not more than 18 in. outboard of the inside surface of the horizontal endplatform handhold.

Appendix A1, 2.2.3

FRA 6180.161a 12/15

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

Region:
Builder Job No.

Notes

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix A-1
Safety Appliances for Boxcars and Other House Cars without Roof Hatches

Number - Dimensions - Location - Manner of Application

Appendix Reference

If the hand brake application is such that the requirements of paragraph 2.2.2 can be met
2.2.2 can be met only 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”.

Appendix A1, 2.2.4

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

Appendix A1, 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 A1, 2.3.2

Hand brake rods shall be not less than ¾ in. diameter.

Appendix A1, 2.3.3

Sill Steps
Number

There shall be four sill steps.

Appendix A1, 3.1

Dimensions

Sill steps shall conform to the requirements of Standard S-2042. Minimum usable length of
tread shall be not less than 12 in.

Appendix A1, 3.2.1

Sill steps shall be of steel not less than ½ in. thick and not less than 2 in. wide.

Appendix A1, 3.2.2

Sill steps shall have sufficient treads such that the top tread is not more than 21 in. below
the lowest adjacent side handhold. Sill step treads shall be spaced not more than 21 in. apart.

Appendix A1, 3.2.3

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.

Appendix A1, 3.2.4

One sill step shall be applied near each end of each side of the car. The sill steps shall be located
in the longitudinal direction such that the inside face of the outboard vertical leg of the sill step
is not more than 2 in. inboard of the outboard clearance point of any side handhold. The inside
face of the inboard vertical leg of the sill step shall be not less than 10 in. from the outboard
clearance point of any side handhold.

Appendix A1, 3.3.1

In the transverse direction, the outside edge of any sill step tread shall be not more than 6 in.
inboard or outboard of the inside surface of the lowest adjacent side handhold. In addition, the
outside edge of any sill step tread shall be not more than 4 in. inboard of any car structure
below the clear length of the lowest adjacent side handhold.

Appendix A1, 3.3.2

ITEM

Manner of
Application

Location

FRA 6180.161a 12/15

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

Notes

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix A-1
Safety Appliances for Boxcars and Other House Cars without Roof Hatches

Number - Dimensions - Location - Manner of Application

Appendix Reference

The lowest tread shall be not more than 24 in., preferably not more than 22 in., above the top
of rail.

Appendix A1, 3.3.3

Manner of
Application

Sill steps shall be securely fastened to the car.

Appendix A1, 3.4

Side Handholds
Number

There shall be 16 side handholds, 4 near each end on each side of the car.

Appendix A1, 4.1

Dimensions

Handholds 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. The lowest side handhold at each corner shall have a foot guard or upward
projection not less than 2 in. in height at its inboard end.

Appendix A1, 4.2

Location

The side handholds shall be oriented horizontally and spaced not more than 19 in. apart, with
the lowest handhold located not more than 21 in. above the top tread of the sill step. Spacing
between side handholds shall be uniform within a maximum variation of 2 in.

Appendix A1, 4.3.1

There shall be a side handhold aligned with each end handhold. Individual side handholds shall
coincide in height with corresponding end handholds within a maximum variation of 2 in.

Appendix A1, 4.3.2

The clearance points of the outboard end of the side handholds shall be not more than 10 in.
inboard of, and no farther outboard than, the inside surface of the end handholds.

Appendix A1, 4.3.3

Manner
of Application

Side handholds shall be securely fastened to the car.

Appendix A1, 4.4

End Handholds
Number

There shall be 16 end handholds, 4 near each side on each end of the car.

Appendix A1, 5.1

Dimensions

Handholds 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. The lowest end handhold at each corner shall have a foot guard or upward
projection not less than 2 in. in height at its inboard end.

Appendix A1, 5.2

Location

The end handholds shall be oriented horizontally and spaced not more than 19 in. apart, with
the lowest handhold located not more than 21 in. above the top tread of the sill step not more
than 45 in. above the top of rail. Spacing between end handholds shall be uniform within a
maximum variation of 2 in.

Appendix A1, 5.3.1

ITEM

FRA 6180.161a 12/15

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

Notes

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix A-1
Safety Appliances for Boxcars and Other House Cars without Roof Hatches

Number - Dimensions - Location - Manner of Application

Appendix Reference

There shall be an end handhold aligned with each side handhold. Individual end handholds shall
coincide in height with corresponding side handholds within a maximum variation of 2 in.

Appendix A1, 5.3.2

The clearance points of the outboard end of the end handholds shall be not more than 10 in.
from the inside surface of the side handholds.

Appendix A1, 5.3.3

Manner
of Application

End handholds shall be securely fastened to the car.

Appendix A1, 5.4

End Platforms
Number

There shall be two end platforms.

Appendix A1, 6.1

Dimensions

End platforms shall conform to the requirements of Standard S-226. The platform material shall Appendix A1, 6.2
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. The thickness from
the mounting surface to the top of tread shall be not less than 3/8 in. and not more than 2 in.
End platform width shall be not less than 8 in. The preferred length for end platforms is 60 in.
Platforms shall not be shorter than 60 in. but may be longer if a longer length is necessary to
comply with the requirements of paragraph 6.3.1.

Location

One end platform shall be applied on each end of the car between end handholds. The center of Appendix A1, 6.3.1
the outer mounting holes shall be not more than 7 ¾ in. from the clearance points of the nearest
end handholds. The end platform shall be centered between the end handholds and, where
practicable, at the center of the car end.

ITEM

Where conventional draft gears or cushioning devices having less than 6 in. longitudinal coupler
travel in buff are used, the outside edge of the end platforms shall extend no farther from the
end of the car than the striker or end of the center sill. Where draft gears or cushioning devices
having 6 in. or greater longitudinal coupler travel in buff are used, the outside edge of the end
platforms shall extend not more than 6 in. beyond the striker or end of the center sill with the
cushioning device (if used) at full buff.

Appendix A1, 6.3.2

The platform-support surface of the mounting brackets shall be not more than 3 in. above not
more than 4 3/8 in. below the top surface of the lowest end handhold.

Appendix A1, 6.3.3

Minimum vertical clearance above the end platform, measured from the end platform mounting Appendix A1, 6.3.4
brackets, shall be not less than 7 in., except for the hand brake rod, hand brake chain, bell crank,
and sheave wheel.

FRA 6180.161a 12/15

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

Notes

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix A-1
Safety Appliances for Boxcars and Other House Cars without Roof Hatches

Number - Dimensions - Location - Manner of Application

ITEM

Appendix Reference

No part of the car end or fixture on the car end above the end-platform and
less than 84 in. above the end platform mounting brackets, other than the hand brake,
hand brake rod, hand brake chain, bell crank, sheave wheel, horizontal end-platform handhold,
and end platform handhold support, shall extend closer to the outside edge of the end platforms
than 8 in. When car construction does not permit 8 in. clearance to be provided, not less than
5 in. clearance shall be provided.
Manner
of Application

Each end platform shall be supported by four mounting brackets. The mounting brackets shall be Appendix A1, 6.4
of steel not less than 3/8 in. thick nor less than 2 in. wide and shall conform to Standard S-226.
The mounting brackets shall be securely fastened to the car body. The end platforms shall be
securely fastened with two fasteners at each mounting bracket.

Horizontal End
Platform Handholds
Number

There shall be two horizontal end-platform handholds.

Appendix A1, 7.1

Dimensions

Handholds shall be of steel not less than ¾ in. diameter and shall conform to the requirements
of Standard S-224. Handholds with unsupported length greater than 36 in. shall be not less than
1 in. diameter. The unsupported length of 1 in. diameter handholds shall not be greater than
72 in. It is preferred that the clear length of the end-platform handholds be not less than 60 in.
Minimum clearance shall be 2 in., preferably 2 ½ in.

Appendix A1, 7.2

Location

One horizontal end-platform handhold shall be applied on each end of the car above the end
platform and between end handholds. The transverse distance between the clearance points at
the ends of the end-platform handholds and the clearance points at the inboard ends of the
corresponding end handholds shall not exceed 6 in.

Appendix A1, 7.3.1

Horizontal end-platform handholds shall preferably coincide in height with the top end
handholds, but shall be within a maximum variation of 2 in. Height from the top of the endplatform handhold to the platform-support surface of the end-platform mounting brackets shall
be not less than 50 in. nor more than 60 in.

Appendix A1, 7.3.2

Horizontal end-platform handholds shall be located no farther than 6 in. in the longitudinal
Appendix A1, 7.3.3
direction from the corresponding end handholds, measuring from inside surface to inside surface.
This requirement applies to the entire length of end-platform handholds and end handholds.
Manner
of Application

Horizontal end-platform handholds shall be securely fastened to the car.

FRA 6180.161a 12/15

Appendix A1, 7.4

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

Notes

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix A-1
Safety Appliances for Boxcars and Other House Cars without Roof Hatches

ITEM

Number - Dimensions - Location - Manner of Application

Appendix Reference

Clearance at the
End of the Car

No part of the car above the end sill more than 30 in. from the longitudinal centerline of the car, Appendix A1, 8.0
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 end-platform mounting brackets, other than the
exceptions herein noted, shall extend beyond the outer face of the striker or end of the center sill.

Uncoupling Devices

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

Appendix A1, 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.

Painting
and Markings

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

Cars with roofs 16 ft. 10 in. or more above the top of rail shall be marked as follows:

Appendix A1, 10.0

That portion of each end of the car that is more than 15 ft. above the top of rail shall be white to Appendix A1, 10.1
contrast with the remainder of the end and shall bear the words “EXCESS HEIGHT CAR” in letters
not less than 3 in. high. Cars whose ends are white below 15 ft. above the top of rail shall be
yellow above 15 ft.
On each side sill, or as close to the side sill as practicable, near each lower end corner there shall Appendix A1, 10.2
be painted or otherwise displayed a yellow rectangular area with a ¾ in. border containing the
words “THIS CAR EXCESS HEIGHT” in lettering not less than 1 ½ in. high. The border shall be of a
color that contrasts with the yellow area and with the surrounding car side.

FRA 6180.161a 12/15

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

Notes

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix A-1
Safety Appliances for Boxcars and Other House Cars without Roof Hatches

ITEM

Number - Dimensions - Location - Manner of Application

Appendix Reference

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

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

Notes

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.

49 CFR Part 232.305

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, (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 A1 or CFR Parts (e.g. 215, 224, & 232)

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FRA 6180.161a 12/15