FRA F 6180.161e Sample Car Inspection Checklist for S-2044 Appendix D-3:

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 D-3
Safety Appliances for Cars of Well or Spine Construction
with End-Mounted Hand Brakes

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 or lever hand brake that complies Appendix D3, 2.1.1
with 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 counter-clockwise direction.
The brake wheel of vertical-wheel hand brakes shall have a nominal diameter of 22 in. The brake Appendix D3, 2.1.2
wheel shall be of shallow configuration and shall be of steel or other material of equivalent
strength.
The hub of the hand brake wheel shall be 2 5/8 in. deep with a square tapered fit to the shaft.
Appendix D3, 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
motion and safely operated from the ground while the car is stationary. The hand brake on cars
equipped with one hand brake shall be applied on the left side of the car at the B end. 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 D3, 2.2.1

The center of the hand brake shaft shall be located in the transverse direction not less than 12 in., Appendix D3, 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.

FRA 6180.161e 12/15

Appendix D3, 2.2.3

OMB No. 2130-0565
F6180.161e 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 D-3
Safety Appliances for Cars of Well or Spine Construction
with End-Mounted Hand Brakes

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 D3, 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 D3, 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 D3, 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 D3, 2.3.2

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

Appendix D3, 2.3.3

Sill Steps
Number

There shall be four sill steps.

Appendix D3, 3.1

Dimensions

Sill steps shall conform to the requirements of Standard S-2042. Minimum usable length of tread Appendix D3, 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 D3, 3.2.2

Sill steps shall have sufficient treads such that the top tread is not more than 21 in. below the
Appendix D3, 3.2.3
lowest adjacent horizontal side handhold, if the car is so equipped. If there are no horizontal side
handholds, sill steps shall have sufficient treads such that the top tread is not more than 21 in.
below the walking surface of the adjacent walkway, if the car is equipped with an adjacent
walkway, and not more than 21 in. below the deck of the car. 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.

FRA 6180.161e 12/15

Appendix D3, 3.2.4

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

Notes

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix D-3
Safety Appliances for Cars of Well or Spine Construction
with End-Mounted Hand Brakes

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 D3, 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.
inboard or outboard of the inside surface of the adjacent side handholds. With the exception of
the side handholds and their supports, no part of the car below 66 in. above the top of the rail
shall extend farther than 6 in. outboard of the outboard edge of the lowest sill step tread. 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 and their supports in the area between the side
handholds. With the exception of the side handholds, 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.

Appendix D3, 3.3.2

The lowest tread shall be not more than 20 in. above the top of rail.

Appendix D3, 3.3.3

When applied, sill steps adjacent to articulated connectors or drawbar connections of multi-unit Appendix D3, 3.3.4
cars shall conform to the requirements of paragraphs 3.2.1, 3.2.3, and 3.2.4. These sill steps shall
be of steel not less than ½ in. thick and shall be not less than 2 in. wide. The sill steps shall be
located 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. Sill steps adjacent to hand
brakes shall also comply with the requirements of paragraph 3.2.2
Manner
of Application

Sill steps shall be securely fastened.

Appendix D3, 3.4

Side Handholds at
Ends of Car
Number

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

Appendix D3, 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 D3, 4.2.1

FRA 6180.161e 12/15

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

Notes

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix D-3
Safety Appliances for Cars of Well or Spine Construction
with End-Mounted Hand Brakes

Number - Dimensions - Location - Manner of Application

ITEM

Appendix Reference

Vertical side handholds shall have an uninterrupted span between the upper and lower clearance Appendix D3, 4.2.2
points.

Location

Horizontal side handholds below the car deck or adjacent walkway, if applied, shall have foot
guards or upward projections not less than 2 in. in height at both ends.

Appendix D3, 4.2.3

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

Appendix D3, 4.3.1

The inside surface of the outboard vertical handhold shall be not more than 14 in. from the inside Appendix D3, 4.3.2
surface of the nearest end handhold. The clear opening between the inside 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.
The clearance points of the bottom end of the vertical handholds shall be not more than 42 in.
above the top of rail. The clearance points of the top end shall be not less than 33 in. above the
adjacent walking surface of the walkway, if so equipped. If not equipped with an adjacent
walkway, the clearance points of the top end shall be not less than 33 in. above the car deck.

Appendix D3, 4.3.3

Spacing between horizontal side handholds, if applied, shall be not more than 19 in. Spacing from Appendix D3, 4.3.4
the highest horizontal side handhold to the adjacent walking surface of the walkway, if so
equipped, shall be not more than 19 in. If not equipped with an adjacent walkway, spacing from
the highest horizontal side handhold to the car deck shall be not more than 19 in.
If car is equipped with horizontal side handholds, the outboard clearance points of the handholds Appendix D3, 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 be 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 D3, 4.4

Side Handholds
Adjacent to the
Articulated
Connectors or
Drawbar Connections
of Multi-Unit Cars

When side handholds are applied adjacent to articulated connectors or drawbar connections of
multi-unit cars, sufficient vertical and horizontal handholds shall be applied to provide access
from the ground to the deck or adjacent walkways.

Appendix D3, 5.1

FRA 6180.161e 12/15

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

Notes

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix D-3
Safety Appliances for Cars of Well or Spine Construction
with End-Mounted Hand Brakes

ITEM

Number - Dimensions - Location - Manner of Application

Appendix Reference

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 D3, 5.2.1

Vertical side handholds shall have an uninterrupted span between the upper and lower clearance Appendix D3, 5.2.2
points.

Location

Horizontal side handholds below the car deck or adjacent walkway, if applied, shall have foot
guards or upward projections not less than 2 in. in height at both ends.

Appendix D3, 5.2.3

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

Appendix D3, 5.3.1

The clear opening between the surfaces of the vertical handholds and their supports shall be not Appendix D3, 5.3.2
less than 18 in. The width over the outside surfaces of the vertical handholds shall be not more
than 30 in.
The clearance points of the bottom ends of vertical handholds shall be not more than 16 in.
Appendix D3, 5.3.3
above the highest horizontal side handhold. If there are no horizontal handholds, the clearance
points shall be not more than 16 in. above the highest sill step tread. The clearance points at the
top ends shall be not less than 33 in. above the walking surface of the adjacent walkway.
Spacing between horizontal side handholds, if applied, shall be not more than 19 in. Spacing from Appendix D3, 5.3.4
the highest horizontal side handhold to the adjacent walking surface of the walkway, if so
equipped, shall be not more than 19 in. If not equipped with an adjacent walkway, spacing from
the highest horizontal side handhold to the car deck shall be not more than 19 in.
If the car is equipped with horizontal side handholds, the outboard clearance points of the
handholds 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.

Appendix D3, 5.3.5

Handholds adjacent to articulated connectors of cars equipped to carry both highway trailers and Appendix D3, 5.3.6
double-stacked intermodal containers need not extend higher than the top of the adjacent
walkways.
Manner
of Application

Side handholds shall be securely fastened.

FRA 6180.161e 12/15

Appendix D3, 5.4

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

Notes

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix D-3
Safety Appliances for Cars of Well or Spine Construction
with End-Mounted Hand Brakes

ITEM

Number - Dimensions - Location - Manner of Application

Appendix Reference

End Handholds
Number

There shall be four end handholds.

Appendix D3, 6.1

Dimensions

Handholds shall be of steel not less than ¾ in. diameter and shall conform to the requirements of Appendix D3, 6.2
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 D3, 6.3.1

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 D3, 6.3.2

Unless protected by a guard around the chain, handholds shall have not less than 5 in. clearance Appendix D3, 6.3.3
from the hand brake chain throughout the entire range of chain travel. Guards shall be provided
around hand brake shock retarders, if used, that are closer to the handhold than 5 in.
End handholds shall not extend more than 8 in. beyond the striker or end of the center sill.

Appendix D3, 6.3.4

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

Appendix D3, 6.3.5

Manner
of Application

End handholds shall be securely fastened.

Appendix D3, 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 D3, 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 car deck or walking surface of the end walkway,
if the car is so equipped, other than the exceptions herein noted, shall extend beyond the outer
face of the striker or end of the center sill.

Walkways
Number

Cars not having full-width flooring at ends of the car adjacent to a coupler shall be equipped with Appendix D3, 8.1.1.
transverse walkways at those locations.
Cars having full-width metal flooring and no transverse walkways adjacent to the couplers shall
be provided with an antiskid surface on the flooring.

FRA 6180.161e 12/15

Appendix D3, 8.1.2

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

Notes

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix D-3
Safety Appliances for Cars of Well or Spine Construction
with End-Mounted Hand Brakes

ITEM

Number - Dimensions - Location - Manner of Application

Appendix Reference

Dimensions

Walkways used for access to interbox connectors at the sides of double-stack wells shall comply
with the requirements of Standard S-226 or S-227. All other walkways shall comply with the
requirements of Standard S-226. Walkways shall be considered running boards under Standard
S-226 and shall conform to the design, manufacturing, and testing requirements of Standard
S-226 applicable to running boards.

Appendix D3, 8.2.1

All walkways shall be not less than 18 in. wide, except longitudinal walkways at the sides of
double-stack wells used for access to interbox connectors shall be not less than 10 in. wide.
The 10 in. minimum width does not include side guards, if applied. Top edges of side guards
shall be not more than ¼ in. above the walking surface of the walkway.

Appendix D3, 8.2.2

The gap between the transverse edges of transverse walkways at vertical side handholds and
the 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.

Appendix D3, 8.3.1

The outboard edge of the antiskid surface shall be no more than 4 in. from the facing surface of
the outboard vertical handhold or its support, whichever is farther from the end of the car.
The inboard edge shall be no more than 4 in. from the facing surface of the inboard vertical
handhold or its support, whichever is closer to the end of the car, for the entire width of the
flooring.

Appendix D3, 8.3.2

Location

The ends of transverse walkways at locations where access to the ground is provided shall not be Appendix D3, 8.3.3
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.
When intermodal containers or highway trailers of sizes for which the car is designed are loaded Appendix D3, 8.3.4
on the car, there shall be not less than 18 in. unobstructed width over transverse walkways at
ends of the car adjacent to a coupler. This requirement does not apply to refrigeration units,
heater units, or generators mounted on and extending beyond the end of the container or trailer
body.
When walkways are provided to permit passage from one carbody to another of multi-unit cars,
the separation between the walkways of adjacent units shall be no more than 20 in.
Manner
of Application

Appendix D3, 8.3.5

Walkways shall be securely fastened to the car with not less than 3/8 in. diameter fasteners,
Appendix D3, 8.4
except that walkway supports may be welded to closed tube or box sections of car structure.
Walkways conforming to the requirements of Standard S-227 and their supports used for access
to interbox connectors at the sides of double-stack wells may be welded to the car structure.

FRA 6180.161e 12/15

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

Notes

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix D-3
Safety Appliances for Cars of Well or Spine Construction
with End-Mounted Hand Brakes

ITEM

Number - Dimensions - Location - Manner of Application

Appendix Reference

Ground Access

Transverse walkways at ends of the car adjacent to a coupler shall provide access to the ground
at both sides of the car. When transverse walkways are applied to the carbodies at both ends of
articulated or drawbar connections, access to the ground shall be provided on both sides of the
car from the left of the connection as viewed from the side of the car.

Appendix D3, 8.5

Uncoupling Devices

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

Appendix D3, 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.
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

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

FRA 6180.161e 12/15

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

Notes

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix D-3
Safety Appliances for Cars of Well or Spine Construction
with End-Mounted Hand Brakes

Number - Dimensions - Location - Manner of Application

ITEM

Appendix Reference

OMB No. 2130-0565
F6180.161e 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 ~ 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 D3 or CFR Parts (e.g. 215, 224 & 232)

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FRA 6180.161e 12/15