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

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OMB No. 2130-0565

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US Department of Transportation
Federal Railroad Administration

Inspector(s):
Builder:
ITEM
Hand Brake

Location

FRA F 6180.161 K (09/20)

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 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 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.
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. × 1 1/2
in. cotter, or their equivalent.

Appendix G1, 2.1.3

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 brake shall be applied on the B end of the car at the left side. 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 G1, 2.2.1

The center of the hand brake shaft shall be located in the transverse direction not less than 12
in. nor more than 22 in. from the inboard 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.

Appendix G1, 2.2.2

The outside face of the hand brake wheel shall be no more than 36 in. in the longitudinal
direction from the outside 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.

Appendix G1, 2.2.3

OMB No. 2130-0565
FRA F6180.161 K

Region:
Builder Job No.

Notes

Expires 09/30/2022

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

Appendix Reference

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 range of travel and any
part of the car shall be not less than 2 1/2 in.

Appendix G1, 2.2.4

If the hand brake application is such that the requirements of paragraph 2.2.4 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 1/2 in. high letters “SHORT
(LONG) RELEASE LEVER BRAKE ONLY.”

Appendix G1, 2.2.5

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 G1, 2.3.1

The hand brake chain shall conform to the requirements of S-475, but in any event shall have a
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 3/4 in. diameter.

Appendix G1, 2.3.3

Sill Steps

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 shall be 14 in.

Appendix G1, 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 G1, 3.2.2

Sill steps shall have sufficient treads such that the top tread is not more than 21 in. below the
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 running board. Sill step treads shall
be spaced not more than 21 in. apart.

Appendix G1, 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 G1, 3.2.4

ITEM

Manner of Application

FRA F 6180.161 K (09/20)

OMB No. 2130-0565
FRA F6180.161 K

Notes

Expires 09/30/2022

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

ITEM
Location

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

Number - Dimensions - Location - Manner of Application

Appendix Reference

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.
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 the
rail shall extend farther than 6 in. outboard of the outboard edge of the lowest sill step tread.

Appendix G1, 3.3.2

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

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 3/4 in. diameter or pipe of 1 1/4 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 1/2 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

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.
When applied, elective vertical handholds adjacent to the outboard vertical side handholds
shall conform to the requirements of Standard S-224, shall be of steel not less than 3/4 in.
diameter, shall have clearance not less than 2 in., preferably 2 1/2 in., and shall have clear
length not less than 8 in.
Location

Two vertical handholds, one at either end of each sill step, shall be applied.
The inside surface of the outboard vertical handhold shall be not more than 14 in. from the
inside 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.

FRA F 6180.161 K (09/20)

Appendix G1, 4.2.3

Appendix G1, 4.2.4

Appendix G1, 4.3.1
Appendix G1, 4.3.2

OMB No. 2130-0565
FRA F6180.161 K

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 G-1
Safety Appliances for Coil Cars

Number - Dimensions - Location - Manner of Application

Appendix Reference

The clearance points of the bottom end of the vertical handholds shall be not more than 42 in.
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.

Appendix G1, 4.3.3

If the car is equipped with horizontal side handholds, spacing between horizontal side
handholds and from the highest horizontal side handhold to the walking surface of the end
platform shall be not more than 19 in.

Appendix G1, 4.3.4

If 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. The requirements of
this paragraph do not apply to cars built prior to January 1, 2017.

Appendix G1, 4.3.5

Manner of Application

Side handholds shall be securely fastened.

Appendix G1, 4.4

End Handholds

There shall be four end handholds.

Appendix G1, 5.1

Dimensions

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 G1, 5.2

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
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. The
requirement for guards around shock retarders does not apply to cars built prior to January 1,
2017.

Appendix G1, 5.3.3

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

FRA F 6180.161 K (09/20)

OMB No. 2130-0565
FRA F6180.161 K

Notes

Expires 09/30/2022

OMB No. 2130-0565

US Department of Transportation
Federal Railroad Administration

ITEM
Manner of Application

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

Number - Dimensions - Location - Manner of Application

Appendix Reference

End handholds shall be securely fastened.

Appendix G1, 5.4

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

Appendix G1, 6.1

Dimensions

Transverse running boards shall comply with the requirements of Standard S-226. The running
board material shall have uniform slip-resistant surfaces and shall be of construction to provide
sufficient clear opening to permit elimination of accumulated snow and ice. Transverse running
boards shall be not less than 18 in. wide.

Appendix G1, 6.2

Location

The gap between the transverse edges of transverse running boards 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 G1, 6.3.1

The ends of transverse running boards 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 running board ends.

Appendix G1, 6.3.2

Manner of Application

Transverse running boards 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,
except the hand brake wheel, hand brake shaft, bell crank, sheave wheel, end running board, 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.

Appendix G1, 7.0

Running Boards
at Sides of Cars

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

Appendix G1, 8.1

Running Boards
at Ends of Car

FRA F 6180.161 K (09/20)

OMB No. 2130-0565
FRA F6180.161 K

Notes

Expires 09/30/2022

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

Dimensions

Side running boards shall comply with the requirements of Standard S-226. The running board
material shall have uniform slip-resistant surfaces and shall be of construction to provide
sufficient clear opening to permit elimination of accumulated snow and ice. Side running boards
shall be not less than 10 in. wide.

Appendix G1, 8.2.1

Location
Manner of Application
Uncoupling Devices

FRA F 6180.161 K (09/20)

Side running boards 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

Side running boards shall extend from end walkway to end walkway.

Appendix G1, 8.3

Side running boards shall be securely fastened with not less than 3/8 in. diameter fasteners.

Appendix G1, 8.4

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

Appendix G1, 9.0

OMB No. 2130-0565
FRA F6180.161 K

Notes

Expires 09/30/2022

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 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. 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

Miscellaneous

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

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)

FRA F 6180.161 K (09/20)

OMB No. 2130-0565
FRA F6180.161 K

Notes