FRA F 6180.161F Sample Car Inspection Checklist for S-2044 Appendix D-4:

Expires 09/30/2022

OMB No. 2130-0565

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US Department of Transportation
Federal Railroad Administration

Inspector(s):
Builder:
ITEM

Sample Car Inspection Checklist For: S-2044 Appendix D-4
Safety Appliances for Flatcars Constructed for Chain Tie-Down Service

Inspection Location:
Car Initial and Number:

Car Type:

Date:
No. of cars to be Built:

Number - Dimensions - Location - Manner of Application

Appendix Reference

Hand Brake

Each car shall have at least one AAR-approved lever hand brake that complies with MSRP
Appendix D4, 2.1
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.

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 D4, 2.2.1

When the tip of the operating lever is swung through its arc of travel, the closest point of that
Appendix D4, 2.2.2
arc shall be located in the longitudinal direction not less than 4 in. nor more than 6 in. inboard of
the inside surface of the inboard vertical leg of the sill step. In addition, the closest point of the
arc of travel shall be not more than 11 in. inboard of the inboard clearance point of the highest
side handhold. When in the released position, the tip of the lever shall be not less than 4 in.
above the lowest sill step tread nor more than 48 in. above the top of rail. On cars built prior to
January 1, 2017, the tip of the lever shall be not more than 56 in. above the top of rail when in
the released position.
Clearance around the grip portion of the hand brake operating lever throughout its full range of Appendix D4, 2.2.3
travel 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 1/2 in.
Manner of Application

FRA F 6180.161 F (09/20)

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

Appendix D4, 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 D4, 2.3.2

Hand brake rods shall be not less than 3/4 in. diameter.

Appendix D4, 2.3.3

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FRA F6180.161 F

Region:
Builder Job No.

Notes

Expires 09/30/2022

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

ITEM

Sample Car Inspection Checklist For: S-2044 Appendix D-4
Safety Appliances for Flatcars Constructed for Chain Tie-Down Service

Number - Dimensions - Location - Manner of Application

Appendix Reference

Sill Steps

There shall be four sill steps.

Dimensions

Sill steps shall conform to the requirements of Standard S-2042. Minimum usable length of tread
shall be 14 in.

Appendix D4, 3.2.1

Sill steps shall be of steel not less than 1/2 in. thick, shall be not less than 4 in. wide, and shall be
provided with a slip-resistant surface.

Appendix D4, 3.2.2

Sill steps shall have sufficient treads such that the top tread is not more than 21 in. below a side
Appendix D4, 3.2.3
handhold having foot guards at both ends. If there is no side handhold having foot guards at both
ends above the sill step, the top sill step tread shall be 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.
Location

Appendix D4, 3.2.4

One sill step shall be applied near each end of each side of the car. The sill steps shall be located Appendix D4, 3.3.1
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 16 in. from the outboard clearance
point of any horizontal side handhold.
Appendix D4, 3.3.2
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.

Manner of Application

Side Handholds

FRA F 6180.161 F (09/20)

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

Appendix D4, 3.3.3

Sill steps shall be securely fastened.

Appendix D4, 3.4

There shall be not less than six side handholds, two at each corner of the car at which a hand
brake is located, two at the diagonally opposite corner, and one at each of the other corners.

Appendix D4, 4.1

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Notes

Expires 09/30/2022

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

ITEM

Sample Car Inspection Checklist For: S-2044 Appendix D-4
Safety Appliances for Flatcars Constructed for Chain Tie-Down Service

Number - Dimensions - Location - Manner of Application

Appendix Reference

Dimension

Handholds shall be of steel not less than 3/4 in. diameter and shall conform to the requirements Appendix D4, 4.2
of Standard S-224. Minimum clear length shall be 16 in. Minimum clearance shall be 2 in.,
preferably 2 1/2 in.The side handholds shall be oriented horizontally, one near each end on each
side of the car.

Location

One handhold shall be located at each corner of the car not more than 48 in. above the top of
Appendix D4, 4.3.1
rail and shall not extend above the deck of the car. This handhold shall be not less than 18 in.
above the lowest sill step tread and not more than 21 in. above the highest sill step tread. If the
highest sill step tread is more than 21 in. below the deck of the car, the first side handhold shall
have foot guards not less than 2 in. high at both ends and shall be not more than 19 in. below
the deck of the car. A second side handhold shall be located at each corner of the car at which a
hand brake is located and at the diagonally opposite corner located not less than 42 in. nor more
than 50 in. above the lowest sill step tread. The second handhold shall be mounted on the car
body separately from the first handhold such that temporary removal of the second handhold
will not necessitate removal of the first.
The clearance points of the outboard end of the side handholds shall be not more than 12 in.
from the inside surface of the nearest end handhold.

Appendix D4, 4.3.2

Transverse handholds may be applied in place of the second side handholds of paragraph 4.3.1.
The transverse handholds shall be located with the inside surface of the horizontal portion not
more than 30 in. in the longitudinal direction from the tip of the hand brake operating lever
when the lever is located as in paragraph 2.2.2 and not more than 2 in. from the inside face of
the outboard leg of the sill step. The handhold shall be of solid steel not less than 1 in. diameter
with the length between the vertical legs not less than 18 in. The inside surface of the outboard
vertical leg shall be not less than 4 in. nor more than 7 in. in the transverse direction from the
inside surface of the side handhold, and the top of the horizontal portion shall be not less than
40 in. nor more than 50 in. above the lowest sill step tread.

Appendix D4, 4.3.3

When applied, side handholds adjacent to articulated connectors or drawbar connections of
multi-unit cars shall conform to the requirements of paragraph 4.2.

Appendix D4, 4.3.4

Manner of Application

Side handholds and transverse handholds shall be securely fastened.

Appendix D4, 4.4

End Handholds

There shall be four end handholds.

Appendix D4, 5.1

Dimensons

Handholds shall be of steel not less than 3/4 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 1/2 in.

Appendix D4, 5.2

FRA F 6180.161 F (09/20)

OMB No. 2130-0565
FRA F6180.161 F

Notes

Expires 09/30/2022

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

Sample Car Inspection Checklist For: S-2044 Appendix D-4
Safety Appliances for Flatcars Constructed for Chain Tie-Down Service

Number - Dimensions - Location - Manner of Application

Appendix Reference

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 D4, 5.3.1

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

Appendix D4, 5.3.2

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

Appendix D4, 5.3.3

Manner of Application

End handholds shall be securely fastened

Appendix D4, 5.4

Deck Slots

Four pair of deck slots shall be applied, one pair at each corner of the car.

Appendix D4, 6.1

Dimensions

Deck slots shall be not less than 2 1/2 in. nor more than 3 in. wide. Each pair of slots shall consist Appendix D4, 6.2.1
of two slots in line longitudinally, each slot having straight edges not less than 6 in. long. The
longitudinal distance between the ends of the two slots shall be not less than 6 in. and not more
than 16 in., measured between the ends of the straight edges. The corners of all edges of the
slots shall be rounded, and the slots shall have corner radii not less than 1/2 in.

ITEM
Location

The thickness of the deck at the straight edge of the deck slots closest to the side of the car shall Appendix D4, 6.2.2
be not less than 3/4 in. but not greater than 1 5/8 in. The 3/4 in. minimum thickness shall extend
not less than 1 in. beyond the straight portion of the edge of each slot in each direction.
The space under the deck within 4 in. from the outboard longitudinal edge of the slot shall have Appendix D4, 6.2.3
not less than 2 1/2 in. vertical clearance for the entire length of the slot. This clearance shall
exist for all conditions, including wear, spring deflection from empty car to loaded car, and truck
rotation for the tightest horizontal and vertical curves for which the car is constructed to
negotiate when coupled to another car.
Location

Uncoupling Devices

FRA F 6180.161 F (09/20)

The long direction of the deck slots shall be parallel to the side of the car.

Appendix D4, 6.3.1

In the transverse direction, the edge of the deck slot closest to the side of the car shall be not
less than 8 in. nor more than 25 in. from the widest part of the car above the adjacent sill step.

Appendix D4, 6.3.2

In the longitudinal direction, the end of the deck slot closest to the end of the car shall be not
more than 2 in. inboard of the inside face of the outboard leg of the adjacent sill step.

Appendix D4, 6.3.3

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

Appendix D4, 7.0

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Notes

Expires 09/30/2022

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

ITEM

Sample Car Inspection Checklist For: S-2044 Appendix D-4
Safety Appliances for Flatcars Constructed for Chain Tie-Down Service

Number - Dimensions - Location - Manner of Application

Appendix Reference

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

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

FRA F 6180.161 F (09/20)

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

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Notes

Expires 09/30/2022

Miscellaneous

OMB No. 2130-0565

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 D4 or CFR Parts (e.g. 215, 224 & 232)

FRA F 6180.161 F (09/20)