peNN CEN1RAL TRANSPORTATION COMPANY

RAILRQAD FREIGHT CAR SAFETY STANDARDS

May ie. 1976

MP28 (New 5-75)

NOTICE

The purpose of this book is to provide supervisors, inspectors and carmen with proper information which will allow them to comply with the current Federal Railroad Administration Freight car Safety Standards.

The instructions set-forth herein govern the inspection and repair of Ineight cars on the property ·of the Peru) Central Transportation Company. They must be observed by all employees whose duties are in any way affected thereby.

They supersede all rules and instructions issued in the past which may be in direc conflict therewith.

Issued by:

JMbr

Chief Mechanical Officer

Approved:

iii

Section

215.1 215.3 215.5 215.'7 215.9

215.11 215.15 215.17 215.19

RAILROAD FREIGH.T CAR SAFETY STANDARDS

1974

Subpart A - Gen.eral

Page No.

Scope of Part. . . . . 8

Application , 8

Definitions. . . . . . . . . . . . , 8

Responsibility for Defective Cars. 10 Movement of Defective Cars

for Repair. . . . . . . . . . . . . .. 11 Stenciling. . . . . . . . . . . . . . . .. 13 Designation of Qualified Persons. 17

Waivers. . . . . . . . . . . . . . 17

Civil Penalty . . . . . . . . . . 18

Subpart B - Ins}J{Iction

215.21 Scope . . . . . . . . . . . . . 18 215.23 Safety Inspection Requil'ed ..... 18 215.25 Periodic Inspection Required. . •. 19 215.27 Periodic Inspection: Suspension

and Draft Systems. . . . . . 20

215.29 Approval Procedures. . . . . 21

215.31 Amendment Procedures. . 21

Subpart C - Wheels

215,41 Scope . . . . . . . . . . . . . . . 23

215.43 Defective Wheels. . . . . . . . 23

215.45 Defective Wheel Sets 27

iv

Subpart D - AJdes

Section

Page No.

215.51 Scope................... 28 215.53 Defective Axles . . .. . . . . .. 28 215.55 Defective Plain Bearing Journals 28

Subpart E - Journal Bearings

215.81 Scope. . . . . . . . . . . 30 215.83 Defective Plain Bearing Boxes.. 31 215.85 Defective Journal Lubricating

System. . . . . . . . . . . .. .,. 31

215.87 Plain Bearings and Wedges

Required 31

215.89 Defective Plain Bearings. . . .. 32 215.91 Defective Plain Bearing Wedges. 34 2i5.93 Defective Roller Bearings. . 34 215.95 Defecti va Roller Bearing

Adapters.. 36

Journal Bearing Lubrication

215.97 Plain Bearing Boxes. 38

215.99 Roller Bearings. . . . . 39

Subpart F - Other Truck Component

215.121 Scope. . . . . . . . . . . . . . . 40

215.123 Defective Car Trucks. . . . . . 41

Subpart G - Car Bodies

215.151 Scope. . . . . . . . . . . . . . . . 42

215.153 Defective Car Bodies: Loaded

or E rnpty . . . . . . . . . . . . . . . 42

v

Subpart H - Couplers

Section

Page No.

215.171 Scope 43

215.173 Defecti ve Couplers; Generally. 43

215.175 Defective Knu.ckles 46

215.177 Defective Uncoupling Levers 48

215.179 DeIecti ve Inte r'locktng Features

on Couplers .. , .. , . . . . . 48

Stlbpart. I - Draft Systems

215.191 Scope. . . . . . . . • . . . . . • . S4 215.193 Defective Draft Arrangement .. 54 215.197 Defective Cushioning Davtcea , . 54

Subpart J - Prohibited &. Restricted Equipment

215.221 Scope , SS

215.22-3 Prohibited Cars. . . . . . 5S

215.22-5 Restricted Cars 55

Appendix A - Defect Detection Gages .... <;7

Appendix B - Railroad Freight Car Components . . . . . . . . . 66

Appendix C - Stenciling Examples. . . . . 70

vi

FIGURES AND GAGES

Page No.

Fi"gure 1. . . . . . . . . . . . . . . . . 24

Figure 2. . . . . . . . . . . . . . . . . . . . .. 24 Figure 3. . . . . . . . . . . . . . . . . . . . .. 2S Fig\ll"e 4 . . . . . . . . . . . . . . . . • . . . .. 26 Figul"e 5. .. . . . . . . . . . . . .. .. .. . .• 29

Figure 6. . . . . . . . . . . . . . . . . . . . .. 33

Figure 7. . . . . . . . . . . . . . . . . . . . .. 35

Figure 8 , " 37

Figure 9. . . . . . . , . . . . . . . . . . . . " 37

Figul'e 10 , . . . . . .. 44

Figure 11 , " 4S

Figure 12 , • . . . . . . . . .. 4S

Figure 13 . . . . . . . . . . . . . . . . . . . •. 47

Figure 14 , ' , ,. 47

Figure 1.5 . . . . . . ,. . . . , . . . . . . . . .. 49

Figure 16 , " 50

Figure 17 . . . . . . . . . . . . . . . . . . . " S1

Figure 18 , . . . . . .. 52

Figure 19 " 53

Gage No.1. . . . . . . . . . , . . . . . . . " 58

Gage No.2 - " S9

Gage No.3. . . . . . . . . . . . . . . . . . .. 60 Gag-e No.4. . . . . . . . . . . . . . . . . . .. 61

qage No .. 5 , , .. " 62

Gage No.6 " 63

Gage No. 7A . . . . . . . . . . . . . . . . . .. 64 Gage No. 7B . . . . . . . . . . . . . . . . . .. 64

Gage No.8 " 65

vii

SUBPART A - GENERAL

Section

215.1 Scope of Part

This part prescribes minimum Federal safety requirements for railroad freight cars.

215.3 AppLication

(a) Except as provided in paragraphs (b) and (c) of this section, this part applies to any railroad freight car operating on standard gage track which is part of the general railroad system of transportation.

(b) Sections 215,11 (b), (cJ and (d), 215.25 and 215.27 do not apply to allY car owned by a Canadian or Mexican railroad with Canadian or Mexican reporting mark and COIl' number.

(c) This part does not apply to railroad freight cars which are operated->-

(1) Solely OIl track inside an installation which is not part of the general railroad system of transportation; or

(2) Exclusively in dedicated service as defined in § 215.5(f).

215.5 Definitions

As used in this part-

(a) "Break" means a fracture 01' 5 paratlon resulting in a IOS8 of structural integrity so

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that the component involved can no longer perform the function for w hicb it was designed.

(b) "Cracked" means broken or fractured without complete separation into parts. Castings with shrinkage cracks or hot tears that do not significantly diminish the strength of the member are not considered to be "cracked."

(c) "Railroad freight car" means a car designed to carry fr'eight or railroad personnel by rail, and includes a;

(1) Boxear

(2) Refrigerator Car (3) Ventilator Car (4) Stock Car

(5) Gondola Car

(6) Hopper ar

(7) Flatcar

(8) Special Cal' (9) Caboose Car

(10) Tank Car (11) Yard Car

(d) "Reconditioned" means that aU railroad freight car components subject to requirements of thls part have been rebuilt or restored by repair or replacement to:

(1) Their original condition - or ~

(2) A functional condition which is equivalent to or better than their original condition.

(e) "Cushioning device" means a draft arrangement with more than five inches travel in either direction between coupler and body.

(f) "Dedicated Service" me-ans exclusive assignment to the transportation of freight between speci£led points under the following conditions:

(1 The cars are operated primarily on track which is inside an installation

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that-Is no'[ part of the general railro-ad system of transportation and occasionally over track that is part of the general railroad system of transportation,

(2) Tbe cars are not operated at speeds in excess of 15 miles per hour and the distance the cars travel does not exceed 30 miles whiJe operating over track that is part of the general railroad system;

(3) The cars are not freely Interchanged for movement in the general railroad system or transportation;

(4) The cars are stenciled or otherwise display in clearly legible letters the words "Dedicated Service" on each side of the car body;

(5) The cars have been examined by a qualified person and found safe to operate in this service; and

(6) The FRA must be notified in writing that these cars are to be operated in dedicated service, The notice must identify the railroads affected the number and type of cars involved. and commodities being carried, and the territorial and speed limits within which these cars are operated. This notice must be filed at least thirty days before the cars commence to operate in dedicated service.

21S.7 Responsibility for Defective Cars

(a) Any railroad that knows, has notice, or should have .known that a railroad freight car

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that it operates has any component which is described as defective in this part is responsible for compliance with this section. Subject to § 215.9. each railroad freight CaJ: which bas a component described as defective in this part must be--

(1) Repaired; or

(2) Removed from service.

(b) For purposes of paragraph (a) of this section, a railroad is deemed to know

or have notice that a. freight car it operates has a defecti.ve component if a card described in § 215.9(a) (3) is attached to the car.

215.9 Movement of Defective Cars for Repair

(a) EXcept as provided In paragraph (b) of this section, a railroad freight car which has any component described as defective in this part may be moved to another location jor repair only after:

(.1) A person designated under § 215.15 determines-

(i) Tha it is safe to move the car; and (li) The maximum s-peed and other restrictions necessary for safely conducting the movement;

(2) The person in charge of the train in which the car is to be moved is notified in writing and informs all other crew members of the presence of the defective car and the maximum speed andether restrictions determined under paragraph (a) (1) (iO of this section. A copy of the tag or card described in subparagraph (3) may be used to provide written notification; and

(3) A tag or card bearing the w-ords "bad order" or "home- shop for repairs" and containing the following information, is securely attached to each side of the cat-

(i) Reporting mark and car number; (ii) Name of inspecting railroad;

(iii) Inspection location and date;

(iv) Nature of defect and movement

reatrietions:

(v) Destination for shopping or repair; and

(vi) Signature of aperson designated under § 215.1S.

This tag or card may only b removed from the car by a person dealgnated under

§ 215.15. A record or copy of each card attached to or removedlrom a car must be retained for 90 days and, upon request, made available for inspection by FRA inspectors. Each card removed from a car must contain a notation stating the date, location, reason for its removal and the signature of the person who removed It from the car. These

record keeping requirements have been approved by the Office of MaJ1agement and Budget in accordance with the Federal Reports Act of 1942.

(b) For purposes of paragraph (a) of this section, when a railroad freight car is discovered to have. any component described as defective in this part at a location where a person designated under 215.15 is Dot on duty. but the car is inspect-ed by available personnel and found to be safe to move, the car may be moved to the next locatiou.enroute where a person designated under 215.15 is on duty.

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215.11 Stenciling

(a) The railroad or private car owner reporting mark and the car number must be stenciled or otherwlsedisplayed in clearly legible letters and numbers at least 7 inches high on each side of each railroad freight car body. On tank cars the reporting mark and car number may appear on the car in any location that is visible to a person walking at track level alongside the car.

(b) Atter December 31, 1974, each railroad freight car described in 215.225(a) which has received its initial periodic inspection under 215.25 or which the railroad knows, or has notice, that it is described under 215.225, and after D cember 3l 1976, every car described in 215.225(a), must be stenciled or otherwise display in clearly legible letters on each side as fnllnws:

(l) Immediately below or to the right of the car number, in the same color as the reporting mark, tbe symbol "R" which must be the same size as the reporting mark.

(2) Following the symbol "R", in letters at least ODe inch high, as many of the following terms as are needed to completely indicate the basis for the restricted operation of the car under 215.225:

(i) Age

(il) Coupler (ill) Draft (iv) Bearings

(v) (vi) (vii) (viii)

Truck Underf'rame Wheels Yoke

(c) Except as provided in paragraph (d) of this section, the following must be stenciled or

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otherwise displayed In a tabular form in clearly legible letters and numbers at least 1 incb high near either end on each side of each railroad freigbt car body when the car receives its initial inspection under 215.25:

(1) The symbol "BLT" followed by the month and year the cal' was or-iginally constructed and, on cars originally constructed after July 31, 1974, the reporting mark of the railroad that initially operated the car.

(2) If the car bas been reconditioned, the symbol "ReD" followed by -

(1) the month and year it was last reconditioned;

(ti) the reporting mark of the railroad that initially operated the car after it was last reconditioned; and

(iii) letters or abbreviated words which identify the entity that last reconditioned the car.

(3~ IT the car is equipped with plain bearing boxes, tbe symbol 'RPKD" followed by a hyphen and the number of months (24 or 30) within Which the boxes must be lubricated under 215.97.

(4) If the car Is equipped with roller bearings which by desjgn must be periodically lubricated. the symbol "LUB" followed by a hyPhen and the number of months (12, 18, or 48) within which the bearings must be lubricated under 215.99.

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(5) Except for a car originally constructed or reconditioned within the period required by 215.97 or 215.99 [or lubrication of its journal bearings. following the marks stenciled Or otherwise displayed in accordance with paragraphs (c) (3) or (4) of this section;

(i) the month and year all journal bearings were last lubrtcated as required by 215.97 or 215.99.

(li) the .repor ting mark of the railroad that initially operated the car after that lubrication; and

(iii) letters or abbreviated words which identify the entity that performed the lubrication.

(6) In the case of a "high utillzatlon" cat for which a railroad maintains mileage records under 215.25(a), the symbol "HU" followed by-

(i) the reporting mark of that railroad; and

(ii) letters or abbreviated words which identify where the records are located.

(7) After December 31, 1976, except for a car originally constructed or reconditioned within the period required by 215025 for per-iodic inspection, tile symbol "!NSP" followed by -

(i) the menth and vear the cal' was last inspected as prescribed by 215.27;

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(ii) the reporting mark of the railroad that initially operated the car after that inspection; and

(ill) letters or abbreviated words which identify the entity that performed the inspection. Appendix C to this part contains examples of stenciling or other display .required by this paragraph.

(d) To the extent that it is impracticable to stencil in a tabula)' form information described in paragraphs (b) and (c) of this section,this information may be stenciled or otherwise displayed in another form.

(e) Whenever any portion of the information which must be stenciled 01' otherwise displayed On a railroad freigbt car under paragraphs (e) (I) - (5) and (n of this section is mlsalng, incorrect or illegible, the car must be inspected or lubricated as follows:

(1) With respect to the information under paragraphs (e) (1) and (2) of this section, Lbe car must be ~

(i) alter December 31, 1,976. inspected as prescribed by 215.27 unless stenciling or other display under paragraph (c) (7) of this section indicates that the car otherwise complies with the Inspection .raqulrernents of 215.25; and

(li) lubricated as prescribed by 215.97 or 215.99 unless stenciling or other display under paragraphs (0) (3) - 5) of this section indicates that the cal' otherwise cernplies with the

~ L6-

lubrication requirements of 215.97 or 215.99.

(2) With respect to the information under paragraph (e) (3) - (5) of this section, the car must be lubricated as prescribed by 215,97 or 215.99.

(3) With respect "to the information under paragraph (c) (7) of this section, the car must be inspected as prescribed by 2.15.27.

215.15 Designation of Qualified Persons

(a) Each railroad that operates railroad freight cars to which this part applies shall designate persons qualified to inspect railroad freight cars for defects prescribed by this part. Each person designated must have demonstrated to the rajlroad his knowledge and ability to inspect railroad freight cars for compliance with the applicable requirements of this part.

(b) Will, respect to designations under paragraph (8) of this section, each railroad shall maintain written records of -

1) each designation in effect; and (2) th basis for each designation.

21S.17 Waivers

(a) A railroad may petition the Federal Railroad Administrator Ior a waiver of compliance with aoy requirement prescribed in this part.

(b) Each petition for a waiver under this section must be filed in the manner and

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contain the information required by 21l.11 of this chapter.

(c) If the Administrator finds that a waiver of compliance is in the public interest and is consistent with railroad safety, be grants the waiver within 90 days subject 1:0 any conditions he deems necessary. Notice of each waiver granted, including a statement of the reasons therefor. is published in the FEDERAL REGISTER.

215.19 Civil Penalty

Any railroad that operates a railroad freight cal' in violation of any requirement prescribed in this part is liable to a civil penalty of at least $250 but not more than $2,500 for each violation. Each day of each violation constitutes a separate offense.

SUBPART B - INSPECTION

215.21 Scope

Tills subpart prescribe-s requirements for inspection of railroad freight cars.

215.23 Safety mspection Required

(a) After October 31, 1974. each railroad freight car in a train must be inspected for safety, in accordance with instructions approved bythe Federal Railroad Administrator, by a qualified person designated under 215.15 at the point where the car is 'placed in the train-

(b-) Before August I, 1974. each railroad that is in op ration on July 1, 1974, and

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operates railroad freight cars to which this part applies, shall submit to the Federal Railroad Administrator for approval under 215.29 three copies of its instructions for safety inspections of railroad freight cars required by this section. Each zatlroed that commences operations after .Iuly I, 1974 shall submit its instructions to the Administrator for approval at least 90 days before the date it commences operations. Instructions submitted to the Administrator for approval must include procedures to be followed by qualified persons to assure compliance with applicable

reg uirements of this part,

215.25 Perjodic Inspection Required

(a) After December 31. 1976, a railroad may not operate a railroad freight car unless -

(1) In the case of cars other Ulan high utilization cars, the cal" was inspected as prescribed by 215.27 within the preceding 48rnooths or was originally constructed or reconditioned within the preceding 96 mon hs; and

(2) In the case of high utilization cars, the car was inspected as pr-escribed by 215.27 within the preceding 12 months or was originally constructed or reconditioned within the preceding 24 months.

However, a nigh utilization car for which a railroad maintains and makes available to 'the Federal Railr ad Administration a mileage record sufficlent to show that the car traveled less than 25,000 miles during the preceding 12 months may be operated if that car meets the

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inspection requirements of paragraph (8) (1) of this section and is stenciled U1 accordance with 21S.11 (c) (6).

(b) For the purpose of this section, a "high utilization" car' is a car -

(1) specif'ically equipped to carry trucks, automobiles, containers. trailers, or removable trailer bodies l'or the transportation of fL'Gight; 01'

(2) assigned 10 a train which operates in a continuous round trip cycle between the same two points,

(e) Before .June 1, 1974, each railroad that is in operation on January 1, 1974, and has in service railroad freight cars to which this parr applies shall submit to the Federal Railroad Administrator for approval under 215.29 three copies of a program to bring au those cars into compliance with paragraph (a) of this section by January 1, 1917. Each railroad that commences operations after .January 1, 1974, shall submit a programto the Administrator for approval at least 90 clays before the date it commences oper-ations. Each program submitted to the Adrninistrat r £01' approval musl include procedures to be followed by inspection personnel to assure compliance with all, applicable requirements of this part,

~ Periodic Inspection: Suspension and Draft Systems

Each inspection under 215.25 must include an examination, by a person destgnated under 215.15, to determine that aJJ components or a railroad Freight car's -

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(a) suspension system, including wheels, axles, bearings, adapters, and truck components; and

(b) draft system, including couplers, cushioning units, center sill. body bolters, and center plates - comply with the requirements of this par.

~ Approval Procedures

Wltl]TIJ 90 days after receipt of safety inspection instructions 01' periodic inspection program filed under this subpart, the Administrator notifies the railroad of his approval or that modification is necessary to comply with the applicable requirements of this part. The railroad may petition the Administra torto reconsider the notice to modify. The petrnon rnust be filed within 30 days after the railroad receives -the notice. Unless the Administrator specifically decides otherwise, the filing of the petition does not stay tbe. effectiveness of the notice pending a decision by the Administrator.

215.31 Amendment Procedures

(a) The Federal Railroad Administrator may amend any instructions for a safety inspection or periodic inspection program approved under this part -

(1) UPOIl application by the railroad concerned, if the Admmistrator determines that safety in rail 'transportation and the public interest allow the amendment; or

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(2) on his own motion, if the Adrninistrator determines that safety in rail transportation and the public interest require the amendment.

(b) In the case of an amendment proposed under paragraph (a) (2) of this section, the Administrator notifies the railroad in writing of the proposed amendment, filting a reasonable period (but not less than 30 days) within which it may submit written information, Views, and arguments on the amendment. After considering all relevant material the Administrator notifies the railroad of any amendment adopted, or recmds the notice. The amendment becomes effective not less than 30 days after the railroad receives notice of its adoption, unless it petitions the Administrator to reconsider the amendment, in which case its effective date may be stayed by the Administrator. If the Administrator finds that there is an emergency requiring immediate action with respect to safety in rail transportation that makes the prcced ure in this paragraph impracticable or contrary to the public interest, he may issue an amendment effective on the date the railroad receives notice of it. In such a case, the Administrator incorporates the findings and a brief statement of the reasons for his actioo in the notice of amendment.

(c) All applicant must file its application for an amendment of Instructions or inspection program witb the Administrator at least 30 days before the date it proposes for the amendment to become effective.

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SUBPART C - WHEELS

215.41 Scope

This subpart prescribes minimum safety requirements for wheels on railroad freight cars.

215.43 Defective Whee,ls

A wheel is defective Y it has any of the following conditions:

(a) Tbe flange is worn to a thickness of fifteen-sixteenth tnch or less measured at a point three-eights inch above the tread. (See Figure 1)

(b} The flaoge has a flat vertical surface extending one inch or more from the tread. (See Figure 2)

(c) The flange is 1-1/2 inches or more froIll the tread to the top of the [lange. (See Figure 3)

(d) The rim thickness is three-quarters inch or less. (See Figure 4)

(e) A cracked or broken Tim j flange, plate, or nub.

(f) A chip in theflange that is more than 1-1/2 inches in length and one-hall inch in wj.dth.

(g) Contiguous (adjoiiling) pieces of metal shelled out of the cmcumference of the tread.

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METHOD OF MEASURING WHEEL FLANGE THICKNESS USING GAGE NO.1

FIGURE 1

METHOD OF MEASU.RING FLAT VERTICAL SURFACE ON WHEEL FLANGE USING GAGE NO. 1

FIGURE 2

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METHOD OF MEASURING WHEEL TREAD WEAR USING GAGE NO.2

FIGURE 3

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METHOD OF MEASURING WHEEl. RIM THICKNESS USING GAGE NO. :1

FIGURE 4

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(h) A slid-flat spot more than 2-1/2 inches in length 01' two adjoining flat spots each more than 2 inches in length.

(i) A hole through the wheel plate not intended by design.

(j) A circumferential groove in the tread more than one-eighth inch in dept~.

(k) A scrape, dent, or gouge in. the wheel plate surface more than one-eighth inch deep that causes an abrupt change in 'the finish of the plate surface.

(ll A loose wheel, as evidenced by movement on the wheel seat, or oil seepage on the back hub or plate from inside the wheel [it.

(m ) ArJy welding on the wheel.

(o) A wheel whtchhaa heen overheated as evidenced by a reddish-bl'own discoloration from heat 011 front and back face of rim and .plate e:x"tent\ing into the plate one -half of the distance from the tread surface to the axle with decreasing intensIty.

(0) Painted so as to conceal defects.

215.45 Defec.tive Whe~l Sets

A wheel set is defective if the wheels are out of gage so that the distance between the inside faces of the wheel rims is less than 52-15/16" or more than 53-a/B inches.

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SUBPART D - AXLES

215.51 Scope

Tbis subpart preScribes minimum safety requirements for axles on railroad freight cars.

215.53 Defedive Axles

An axle is defective if it has any of the following conditions:

(a) A break or crack.

(b) A scrape, dent, or gouge between the wheel seats more than one-eighth inch deep,

(e) Welding on the axle.

(d) A bend in the axle which produces a .runout of more than three-eighth inch at the center of the axle.

(e) In the case of journals on plain bear-Ing axles, wear beyond the limits set forth in Figure 5.

(f) Fainted so as to conceal defects described by thls section.

215.55 Defective Plain Bearing Journals

A plain bearing journal is defective i1 it has any of the fo llowing eondl nons:

(a) A break in the jOUl'nal collar.

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PLAI BEARTNG AXLES
J ourne.I s i z e Journal Journal Journal
standal,d c cl.lar, length, diameter,
inohes inch inches inches
(A) (B) (C)
4~ by 8 ...... 't, • 8)1~. 3~~
5 by 9 ....... '1" 9!1~. ~ 4Yz
S~ by 10 .•... '1,. lOIII\~ 5
6 by II ~ . ,. . ~ . '1,. ll"!.. 5:4
672 by 12 ~ ,. . . . '1,. 12111,. 6
7 by 12 ...... 'I, • 12111., 6Yz FIGURE 5

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(b) The surface oC the journal or fillet bas -

(1) A ridge;

(2) A depression;

(3) A ciroumferential score: (4) Corrugation;

(5) A scratch;

(6) A continuous streak;

(7) Pitting; (S) Rus ; or (9) Etching.

(c) A journal whlch has been overheated.

SUBPART E - JOURNAL BEARINGS

215.81 Scope

This subpart prescribes minimum safety requirements for journal bearings on railroad ueigbt cal's.

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215.83 Defective Plain Bearing Boxes

A plain bearing box is defective if it has any of the following conditions:

(a) It does not contain free oil.

(b) The box: lid is missing, broken, or otherwise not preventing contaminants from entering the box,

(e) Il contains any foreign matter which has a detrimental effect on the lubricant,

(d) The box is cracked or has holes so as to permit Ieakage ,

215.85 Defective JOUl'Ilal Lubricating SystfJrn

A journal lubricating system is defective if a lubricating pad is missing or has any 01 the following oonditions:

(al An exposed core or metal part contacting

the journal.

(b) The pad is not contacting the journal. (c) A scorched or burned area.

(d) Glazing over half the pad surface. '(e) Deteriorated 01' decayed fabrdc ,

(0 A tear along tile top, front, back, 01' side more than hall the length of the pad.

215,87 Plain Bearings and Wedges Required

Each rallioad fl:eig!lt cal' must be equipped with the full number of plain beartngs and wedges for which. it is designed.

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215.89 Defective Plain Bearings

A plain beal'ing is defective if it 18 not located in its design position or has any of the {allowing conditions:

(a) A break or crack.

(b) Overheating as evtdencad by -

(1) melted babbit;

(2) smoke from hot 011; or

(3) jpurnal surface damaged.

(c) Wear at either end whioh reduces its length more than one-fourth inch. (Dimenston A in Figure 6).

{dl Combined wear that reduces its length more than thrl/e-eights inch. (Dimenelon A in Figw'e 13).

(e) A lug worn more than one -eighth inch. (Dimension B in Figure 6).

(f) Combined wear on both sides of the lug extension more than one-fourth inch. (Dimension C in Fig. 6).

(g) A 10013e lining or section of llning broken out.

(h) Lining worn through to bl'RSS more than three-eights inch above the lower edge of the brass sidewall. (Dimension D in Figure 6).

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FIGURE 6

215.91 Dafe eti va Plam Bearlllg Wedge B

A plain bearing wedge is defective if it is not located in its design position or has any of the following conditions:

(a) A bend, break, or crack.

(b) Wear measured at the contact surfaces which reduces Its overall length more than three-sixteenths inch. (Dimellsions A in Figure 7).

(c) A bottom surface "Unevenness of more than one- six y fOU;til inch. (Dimension Bin Ftgure 7).

(d) Wear on top beyond the following limits:

NoOlinal Journal Wear Limit Flat

Si~e, Inches LengthWise, Inches

(Dimension C

in Figure 7)

". 3-1/4

4.

4-1/2

5

5-1/2

4-1/4 by 8, .

5 by 9 .

5-1/2 by 10 _ __

6byll , .

6-1/2 by 12 .. , .

215 .. 93 Defective Roller Bearings

(a) A roller bea.ring which has been subjected to any of the follOwing conditions may not be used Mill it 15 tuspected, and repaired if necessary:

(1) Derailment.

(2) Submerged in Watel-.

-34-

FIGURE 1

-35-

(b) A roller bearing is defective if it hils any of the following conditions:

(1) Overheating in excess or 250 degrees, F.

(2) A loose or missing cap Screw.

(3) A. broken, missing (unless by design), or improperly applied cap screw lock.

(4) A missing (unless by design) truck side frame key, pedestal bolt, or stop block.

(5) A loose or nonfunctioning seal.

215.95 Defective Roller Bearjng Adapters

A roller bearing adapter is defective if it has any of the following conditions:

(al A break or crack.

(b) Wear to the extent thal the adapter is marking the seal assembly.

(e) Wear on the crown of the adapter to the extent that lhe frame bears on the relief portion of the adapter, as shown in Figure 8.

(d) Wear the thrust shoulder of narrow adapters more than .02,5 inch on either slde, as measured by Gage No.8. (See FiglJre No.9).

(e) Warp or other distortion.

-36-

FIGURE 8

METHOD OF MEASURING ROLLER BEARING ADAPTER THRUST SHOULDI:R WEAR USING GAGE NO.8.

FIGURE 9

- 37-

Journal Bearing Lubrication 211i.9'1 Plain Bearing Boxes

(a) A plain bsarfng box Is defective if within the preceding 24 months, or in the case of a plain bear-ing box equipped with rear seal, box lid seal, and stabilized journal, within the preceding 30 months -

(1) it was not repacked as prescribed by paragraph (b) of this section; or

(2) the car was not reconditioned or originally constructed.

(b) A plain bearing box must be .repacked according to the following rules:

(1) Remove journal bearing, wedge, and lubricator, and thoroughly clean the box including the tnstde ct lid and front 01 box that may contact the lubrIcator, without using waste material for cleaning purposes;

(2) Examine the journal, journal bearing wedge, journal stop, and box lid seal, and replace each defective part;

(3) Replace old lubricator with a new one'

(4) Rep~ace dust guard plug when miaatng or defe·cl:Lve a:nd apply sealer to top

of plug;

(5) In the case of a wooden dust guard plug, lock it securely in place;

-38 -

(6) If the car truck iii! dismantled, examine the rear seal and replace il defective; and

(7) Add free oil to permi resaturation of the lubricator, then before the car is released for service, check to ensure there is :free oil visible in he bottom of the box.

215 . 99 Rolle r Bearings

(a) A roller bearing designed to be per icdicaUy lubricated is de scttve if -

(1) it has not been lubricated as prescribed by the following chart and by paragraphs (b) and (c) of this sectlnn; or

(2) the car was not reconditioned or originally constructed wiUlin the number of months prescribed in the c hal" t for lubri eating 1'o11ell be-axing s:

De.~ e Ir I pti on "r HrMIIlK"

Size of lJ~,,-rinl'l"

Lubricate J3." .... in~ i\ mount nr Wil hi n I he FllllowlDg l,uhricHIl\ Numbers of Monlh.; l\eqll'",d BeJor~ ellr is Oper.

Oillubrica ed ... All ... Fill to, , ., 12 maximum

level

Grease lubricated:

End caps

do not rotate , , All. '. 16 oze. . 18

End caps

rotate, .•.... 12" ... 12 028, • 48

11".,. B 028. , ,. 4,8 or less

-39 -

(b) In the case Q'f an oil lubricated roller bearing, the filling plug must be properly replaced after the bearing is lubricated.

(c) In the case of 8 grease lubricated roller bearing, the lubrication must be performed as follows:

(1) Immediately before the application of grease-

CO Clean the grease fitting to prevent road dirt and foreign material from being forced into the bearings; and

(ii) Test the grease fitting to ensure it has not been damaged; and

2) Insert the amount of grease prescribed in the chart In paragraph (a), using a properly calibrated dispensing device which is equipped wlth a strainer and is checked monthly to accurately measure ounces of grease. Grease inserted must meet or exceed the minimum requirements for GFade B grease, Association of Amer-ican Railroads Specification M-917-64.

(d) In the case of grease lubricated roller bearIngs, only pressure type grease fittings may be used in lubricating the beartngs.

SUBPART F

OTHER TRUCK COMPONENTS

215. 21 Scope

This subpart prescribes rnintmum safety requirements ior truck side Iramea, bolsters, Side bearings, sprIng assemblies, and spring planks on railroad freight car-s.

-40-

\ •

215.123 DeIe eli va Car Tr ucks

A car truck Is defective if it has any of the following conditions:

(a) A side frame or bolster which is -

(1) broke 11, patched, cracked, or reinforced with plate, including a break or cr-ack in a bolster gib;

(2) painted so as to conceal defects described in this section;

(3) welded and not stress relieved; or

(4) worn or corroded through more than 25 per-cant of the cross section; except that surfaces in friction snubber pockets, gibs, column guides. and cast integral brake beam supports which have been worn or corroded through not more than 40 percent of the crOBS section may be restored to the original cross seotion by welding w1thout the nece.ssity for heat treatment, hut all friction surface welds must be smooth and free of slag.

(b) Any part of the truck is less than 2-1/2 inches above the top of rail under maximum spring deflection.

(c) Wi th respect to the side bearings - (1) one is broken or missing;

(2) the bearings at one end of the car on both sides are in contact with the body bolster, except by design;

(3) the bearings atone end of the car have a total clearance [rom the body bolster of more then thr ee-four-ths inch; or

",

-41-

(4) at cliag6nally oPPoSite sides of the car, the bearings have a total clearance ft'om the body bolsters of more than three-fourths inch.

(d) A spring assembly --

(1) with a broken or missing snubber or outer spring;

(2) Which does not maintain travel or load; Or

(3) which is weakened so as to be COInpressed solid.

(e) In the case of a car ruck whose design includes spring planks, a spring plank is misstng, broken, worn, or corroded through more than 25 peroent of its cross section,

SUBPART G - CAR BODIES

215 .. 151 Scope

This subpart prescrrbes minimum safety requrrementa for certain conditions on railroad freight cal' bodies.

215.153 Defective Car Bodies: Loaded or Empty

A car body Is defective if it bas any of the following conditions:

(a) Clearance above top of l'allless than 2 -1!2lnches.

(b) A male portfon of a standard cylindt"ical type center plate extending less than 1 inch tnto the female portion Of the center plate.

-42-

(c) A center plate not secured.

(d) A center plate cracked through more Ulan 30 pe ccerrt of he cress section.

(e) Center sill broken, cracked, or permanently bent more than 2-1/2 inches in any 6-[oot length.

(r) A broken or missing coupler carrier. (g) Sidesill, cz-oasbearer-, or body bolster broken.

(h) Center ptn missing (unlaes by design).

SUBPART R - COUPLERS

215.171 Scope

This subpart prescribes minimum safety requirements for couplers on l'ailroad freight Cal'S.

215" 173 Deie eli va Couplers; Generally

(a) A Type E coupler is defective if it has any. of the following conditions:

.. •

(1) The shank is bent out of alignment with the head more than ninesixteenths inch .

(2) Th shank is worn more than sevensiXteenths inch.

(3) The distance between the guard arm and Ule knuckle nose is more than 5-5/16 inches. (See Figure 10).

-43 -

USE OF GAGE: THE COUPLER CONTOUR IS DEFECTIVE WHEN THE GAGE cAN SE PASSED VERTICALLY THROUGH THE CONTOUR IN THE POSiTION SHOWN

AND POINTS 'A' AND '6' CONTACTING GUARD ARM. MEASUREMENT MUST BE TAKEN WITH

KNUCKLE IN LOCKED AND PULLED POSITION.

METHOD OF MEASURING GUARD ARM DISTORTION AND CONTOUR Of TYPE E COUPLER

USING GAGE NO.3

FIGURE 10

(4) There is a crack or break in the sidewall exceeding the limits shown in Figure iI, or any crack or break in the unshaded area shown in Fjgure 11.

(b) A Type F coupler is defective if it has any of Ule following condrttons:

(1) A shank is worn more than sevensixteenths of an inch.

(2) The distance between the front [ace and the knuckle nose ts more than 3~13/16 inches. (See Flgure 12),

-44-

FIGURE II

..

CHECKS CONTOUR CONDE'MNING LIMIT

) 1-[ -""l ~.'

; j ~

I, MUST L ""

SEAT ,,\,

- J'~,,, MAX.\\

II

~-j _ _j

\C._ \ '

METHOD Of MEASURING CONTOUR OF TYFE F COUPLER USING GA.GE NO.4

FIGURE 12

~45

(e) A eoup1er is defedi-ve ilit bas any of the following conditions:

(1) The loeklift is inoperative.

(2) The coupler assembly does not have -anticreep protection.

(3) The coupler Lock is missing, inoperative, bent, cracked, nr broken.

215.1'75 Defective Knuckles

(a) A Type E knuckle ta defective if it is worn in excess of the limits indicated by Gage No.5. (See Figure 13).

(b) A Type .F knuckle Is defective if it is worn or stretched in excess of the limits indicated by Gage No, 6, (See Figure 14.).

(e) Any knuckle is defective ti it has any of the {allowing conditions:

(1) It is cracked or broken.

(2) The knuckle pin or knuckle thrower is mtsBing 01' inoperative.

(3) In the case of a hopper car, a gondola car, or a car with a spring supported coupler carrier, the knuckle pin retainer or cotter key is missing.

-46-

T~E NUC~LE 15 DEFECTIVE WHEN POINT '".. CAN BE PASSED VEIHICII.lLY OVER ONE MIl IF OR ",ORE OF NOSE LSP!GTH WITH POINTS '0'. 'P' AND' R' CONiACTING

HIE KNUCKLE

METHOD OF MEASURlNG KNUCKLE .>lOSE WEAR OF TYPE E COUPLER USING GAGE NO, 5

FIGURE 13

..

POINT 'D' MUST NOT TOUCH OR CLEAR MORE THAN W' WITH A, EI, & C SEATED.

METHOO OF MEASURING KNUCKLE NOSE WEAR AND KNUCKLE STRETCH'OF l'YPE F COUPLER liSING GAGE NO.6

FJGlJRE 14

-47 -

215.177 Defective Uncoupling Devices

An uncoupling device is defective if it does not meet the following requirements:

(a) The device must have sufficient vertical and lateral movement to prevent fouling oncorves and unintentional uncoupling.

(b) In the case of a bottom operated coupler , the lever must have at least one-fourth Inch c.learance between the operating rod eye and the locklilt lave I when the coupler is centered and the knuckle is fully closed and locked.

215.179 Defective Interlocking Features on Couplers

In lha case of cars equipped wi th AAR Type F couplers in accordance with 179.14 of

this title, a coupler is defective if it has any of the following condItions:

(a) The distance between the interlocking surfaces of the guard arm is less than 6-3/8 Inches or more than 7 tncbe s. (See Figures 15 and 16).

(b) The distance between the interlocking surfaces of the aligning wing pocket is less than 7-1/8 inches or more than 7-3/4 inches. (See Figures 17 and is).

(c) The guard arm 1s distorted beyond limits indicated by Gage No, 4. {See Figure 19}.

(d) The guard arm or aligning wing pocket is cracked) broken, or missing.

- 4B-

MUST PASS

METHOD OF MEASURING WEAR AND DISTORTION OF TYPE F COUPLER GUARD ARM

USING GAGE NO. 7A

FIGURE 15

-49 -

MUST NOT PASS

METHOD OF MEASURING WEAR AND DISTORTION OF TYPE F COUPl-ER GUARD ARM

USING GAGE NO. 76

FIGURE 16

-50-

I

MUST FA!>S

METHOD OF MEOASURING WEAR ANO DISTORTION OF TYPE F COUPLE~ ALIGNING WING POCKET USING GAGe NO. 7A

FIGURE 17

-51-

MUST NOT PASS

METHOD OF MEASURJNG WEAR AND DISTORTION OF TYPE F COUPLER ALIGNING WING POCKET USING G~GE NO. 7B

FIGURE 1 B

-52 -

MUST SEAT WITH KNUCKLE IN LOCKED AND PULLED POSITION

CHECKS GUARD ARM DISTORTION

METHOD OF MEASURING GUARD ARM DISTORTION ON TYPE F COUPLER

USING GAGE NO.4

FIGURE 19

-53-

SUBPART J - DRAFT SYSTEMS

215.191 Scope

This subpart preseribes-minimum safety requirements for draft systems ror railroad freight cars.

215.193 Defee ti ve Dr aIt Arraugem ant

A draft ar-rangameus is defective if it has allY of the following conditions:

(a) A break in the yoke.

(b) A yoke strap worn more than 25 percent or its cross sectional area.

(cl A missing (except by design) or broken follower plate, draft lugs Dr fasteners, draft gear, draft key, Dr draft ke y retainer.

(d) A draft key worn more than 25 percent of its cross sectional area.

215.197 Defeclive Cushioning Devices

A cushioning device ts defective 1£ it is broken, inoperative. 0.1' missing a part.

-54-

SUBl?ART J - PROHIBITED AND RESTRICTED EQUIPMENT

215.221 Scope

This subpart prohibita the operation of r-al lroad u'eight cars equipped with certain components and restricts tire operation of cars equipped with other components and cars more than

50 years old, .

215.223 Prohibited Cars

A railroad may not operate a railroad freight car equipped with any design or component listed in Section I or Appendix B to this part after -

(a) December 31, 1973 to transport commodi ies subject to the hazardous materials regulations in Parts 170-189 and requiring placards under Subpart C of Par-t 174 ofthis Title,

(b) December 31, 19'74, ii!:he car has racei ved its initial pe rio die tnspe ction under 215.25 or a railroad knows,

or bas notice, that the car is equipped with the design or component.

(c) December 31 1976.

215.225 Re striated Cars

(a) TWs section restrlet.s the operation of any ra.iLroad freight car which is -

(1) more than 50 years Old, measured Ir-orn the date of original construc!:1on;

(2) equipped with any design or type component lis ed in section IT of Appendix B to this part; or

-55-

(3) equipped with a Duryea underfra:me constructed before April 1 1950, except for a caboose which is operated as the last car in a train.

(b) Subject to the requirements of paragraph (d) of this section, a railroad may operate zaflroad freight car-e desc:ribed In paragraph (a) of this section only under conditions approved by the Federal Railroad Administrator .• after December 31, 1974, if the car has received its initial pel'iodic inspection under 215.25

or the railroad knows or has notice that the car is equipped with the design or component; or December 31, 1976. Petitions for approval must be submitted to lbe Adminstrator in triplicate at least 90 days before the date the approval is requer;Jted to become effective. Each petition for approval must state;

(1) The name and principal business address 01 lile petitioning railroad;

(2) the name and address of the entity that controls the operation and maintenance of the cars involved;

(3) the number, type, capacity, reporting mark and car numbers of the cars their condilion, status and age measured from date of ·original construction, and any design or type component or other reason wbrch causes them to be restricted;

(4) the maximum load the cars would carry;

(5) the maximum speed at which the cars would be operated;

- S6-

(6) the territorial limits in which the cars would be operated; and

(7) if the cars would be interchanged with other railroads, the names of those raitroads.

(B) that each car has been examined by a person designated under

215. 15 and found to be safe to operate under the conditions set forth in the petition.

(e) Within 45 days after receipt of a petition for approval filed under paragraph (b) of this section, the Administrator notifies the railroad of bis decision. The railroad may petition the Administrator 'to reconsider hls decision. A petition for reconsideration must be filed within 30 days after the railroad receives notice of

the decision.

(d) A railroad may not use a car described . in paragraph (a) of this section to transport commodities identified by the Hazardous Materials Regulations in Parts 170-189 of this title, and which is required to be placarded under Subpart C or Part 174 of this Title.

APPENDIX A - DEFECT DETECTION GAGES

General: Each gage must be -

(a) fabricated as specified in this appendix; (b) ground on a llgaging surfaces; and

(el stamped with the appropriate markinga.

-57 -

~------ ~:~ ------~

GAGE NO. I • WHSEL DEFECT GAGE (A.A.R. GAGE NO. 34.401)

!.I, A. T ERIAL, 313'2" 51 EEL PLA TE·HA.RDENEO, RUST PROOF FINISH

- 58-

ToO !!Iof :S;r<*J""CD O),foBC111'1 ,IIDEI

.",r "lit.

GAGE NO.2 - SIMPLIFIED STEEL WHEEL GAGE (A.A.R. GAGE· SIMPLI FlED WHEEL)

MA TE RI AI.: 3/32" STEEL PLA TE·HARDEN ED; RUH PROOF FINISH

-59-

-60 -

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APPENDIX B - RAILROAD FREIGHT CAR COMPONENTS

I. List of components whose use is prohibited by this part:

A. Ail- Brakes: The "K" Type.

B. Axles:

(1) .Former AAR Alternate Standard Tubular Type.

(2) Axle with Letters "RJII Stamped on the End of the J ournal.

C. Roller Bearings:

(1) Nippon Sieko Kabushiki Kalsh (NSK) size S~" x 12" (marked "AAR i1").

(2) Hyatt Cylindrical Bearing, All Sizes (marked rrAAR 2").

(3) SKF "Plggybacke.r" Spherical Roller size 6" x 11" (marked "AAR 7").

D. Truck Bolsters:

A bolster with one or the following pattern numbers listed according to manufadurer-

Dresser Lenoir
A.S.F. (Symington) Btrdsbor-o Car
Works
21183-B BO 5234 1458 CS-184
1468
21183-N EO 5263 1471 CS-611
EO 7076
21648-C BO 7076 A
20056-E BO n15 •

-66-

E. Truck Side Frames:

A side frame with one of the following pattern numbers listed according to manufacturer -

A.S.F.

National Buckeye Dominion Castings

7273 33793-1 B 3-1776 TF-SIOO

7323 F-420

21362 (cast

prior to June 1941).

Pittsburgh Scullin Betten- Canadian
steel Steel dod Steel
Foundry Foundry
31673 42-CS-IBO UT 456 26565
{-1862
3-1674 4665
4-2045 4'170
12897 4942
12921 5220
21263 5364
53M-C
5364-1':
5Bll-A
5B6.9-B
6577-A -67-

F. Wheels:

(1) Cast Iron WheeL

(2) Cast Steel Wheel Marked ilAAR X-2". (3) Souther-n, Cast Steel Wheel Manufactured Before May 7 .• 1958.

(4) Griffin, Three -Riser Cas t S tee 1 Whe e 1, Ball Rim Design, 70-Tbn Capacity.

(5) GrUnn, Three-Riser Cast Steel Wheel, Two-Wear, 70- and ~O-Ton Capacity 33 inch. (Marked X-5 or CS-2).

II. List of components whose use is restricted by this part:

A. Couplers:

(1) AAR Type "D", Top or Bottom Operated.

(2) AAR Type "E", with 5" x 7" Shank.

B. Draft Arrangement:

(1) Miner FR-16 and FR-19-F Draft Gears.

(2) Farlow Draft Attachment.

C. Plain Jmu'nal Bearings: Cartridge Type.

D. Trucks:

(l) ArCh Bar Type.

(2) Truck with Cast Ste-el Pedestal Side Frame Short Wheel Base, and no Bolster.

-68-

E. Truck Bolsters;

(1) Bolster cast Before 1927.

(2) Bolster Without an Identification Marl>: or Pattern Number.

F. Truck Side Frames:

(1) Side Frame Cast Before 1927.

(2) Side Frame Without an Identification Mark or PatternNwnber.

(3) Side Frame with an "1'\ "T", or "L" Section Compression 01' Tension Member.

G. Wheels:

(1) Wrougbl Steel 'Wheel Manufactured Before 1927 J as Indicated by Marking on Wheel.

(2) Cast Steel Wheel Marked AAR X-4.

(3) Davis Cast Steel Wheel.

H. Yokes:

(1) Riveted Type. (2) Keyless Type.

(3) Vertical Key Type.

-69-

APPENDIX C - STENCILING EXAMPLES

This appendix contains examples of stenciling or oth r display required by &15.1l(c)

Example 1:

In September 1980, a railroad operates a railroad freight car that was originally constructed in August 1958. It is a high utilization cal' as deUned by 215.25(b), for which the Chessie System has recorda at its office In Baltimore I Mary1and to show that the cal' traveled less than 25,000 miles in the preceding 12 months. The car has been reconditioned twice, the last time in July 1973, by the Best Forge and Foundry before it was released to the Penn Central. The car is equipped with plain bearing boxes with rear seals, box lid seals, and stabilized journals. The most recent lubrication under 215.97 was performed by the

Southern Pacific at its facility in Sacramento, California in June 1979.

215.11 (c), Clause ~

Stenciling 01' Other Display

(1) BLT

(2) RCD

(3)- (5) .. RPKD-30

(6) RU

(7) , ( )

8-58 7-73 PC 6-79 Sl,'

C&O/B&O BALTO

(*1 (*)

(*) No enh'Y required under clause (7) because under 215.25 a high utilization car for which mfteage records are kept need not be inspected within 96 months after the car is reconditioned.

II

-70-

RAILROAD FRElGBT CAR SAFETY.8TANDARDS

Uniform Periodic Inspection Procedures

Procedure to be followed by inspection personnel to assure that freight cars comply with the FRA Standards at the time they receive periodic inspection:

L Shops selected t-o perform FRA Periodic Inspections must be equipped with all necessary tools. gages, and all technical manuals as required for performance of the work as outlined in the FHA Freight Car Safety Standards, Part 215. ACI label maintenance must be performed in accordance with Interchange Rule 73.

2. If a preliminary inspecti n reveals defects which are beyond the capability of the inspecting shop to repair. then arrangements must be made to saIely move the car to home shop.

3. Persons designated by the railroad to perform FAA periodic tnspection must have the knowledge and ability to inspect railroad freight cars for compliance with the requir ments of Part 215.

4. The procedure shown below should be followed when making periodic inspections:

a. Check for prohibited or restricted couplers

b. Inspect and gage couplers for defects. Type F couplers manufactured before March 1970 and T'ype E couplers, Grade B mater'ial, must be removed for

~7 -

215.223 215.225

215.173 215.175 215.179

(when applicable)

a close inspection of the shank and butt area.

c. Inspect the uncoupling

n icchanism rOi' defects and operate to assure that e mechanism and knuckle function properly.

d. Inspect side bearings for defects at AlllOcatlollS.

e. Inspect carbody tor defects. This includes minimum height above the rail, coupler carriers,

entersills, body bolsters, body bolster center plates, center pins, cross bearers, and side sills. Check for prohibited and restricted items.

Inspect draft gear support; plate and fasteners, inspect yoke, draft gear. follower plate, draft lugs, fasteners, draft .key, key retainer and retainer Jock for defects. Excessive free slack (normally more than 1") indicates a part may be missing, broken or excessively worn and requires a closer inspection and/or disassembly. Check for prohibited and restricted components.

I.

215.177

21S,123(c)

215.153

215.223 215.225

215.193

215.223 215.225

g. Inspect cushioning devices For 215.197 broken or missing parts and

inability to assume neutral

position.

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b. Inspect truck bolsters and side frames for defects. Check for restricted and prohibited pattern numbers and types.

1. Inspect spring plank (if so

equipped) for defects. 215,123(e)

j. Inspect 'spring assemblies 215.123(d)

for defective .and/or

missing springs and snubbers (includes all friction snubbers).

k. Inspect wheels and axles for defects. Check for restricted and prohibited items.

ID. The procedure shown below should be followed on cars equipped with plain journal bearings:

215. 123(a; 215.223 215.225

215.43 215.45 21S.S3

215.223 215225

1. Inspect box lid for defects 2IS.83Cb) and check [or proper

opening and closure.

2. Inspect journal boxes for defects.

3. Inspect journal stops (if so equipped) to see they are in place and properly secured.

4. Inspect journal, journal bearing, wedge and seals for visible defects.

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215.83(a) (d)

215.97(b) (2)

215.55 215.89 215.91 215.97

S. Inspect Jubrfcator pad for visible defects and lubrication for contamination.

2aS.85 21S.83(c)

6. periodic repacking (when 215.97

applicable) must be

performed in accordance

with the FRA Railroad

Frejght Car Standards.

Bearings repacked on a

3D-month cycle must have

rear seals, box lids seals and stabilized journals, (i.e.,

journal stops or hi-hat or flat

back bearing).

n, The procedure shown below would be followed on cars equipped with journal roUer bearings.

1. Inspect for prohibtted or restricted roller bearmgs,

2. Check for overheated bearings.

3. inspect adapters for broken, cracked, warped or other: distorted condition and excessive wear.

215.223 215.225

215.93(b) (1)

21S.95(b) 215.9S(c) 215.9.5(d)

4. Check for: loose, broken 21S.93(b) (2) or missing cap scr:ews 21S.93(h) (3) andimproperly applied

locking plate.

S. Inspect for loose or defective seals.

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21S,93(b) (5)

6. Check for missing truck side frarn e key (pedestal key) or pedestal bah.

7. On Integral box side frames, check to determine that stop block is

properly secured.

8. Periodic lubrication when applicable must be performed in .aceordance with the FHA Railroad Freight Car Safety Standards.

0. Stenciling

21S.93(JJ) (4)

215.93(b) (4)

215.99

1. Check car owner 215.11(a)

reporting marks and cal'

number foi compliance

with FRA Standards ..

2. Apply consolidated stencil 215.11

to comply With ERA

Standards.

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INSTRUCTIONS FOR SAFETY INSPECTJON

At designated inspection and maintenance terminals, wbere qualified personnel are on duty for the primary purpose of inspecting freight cars, each car placed in train, or those cars not having received such inspection at point where originally placed in train outside this terminal, shall receive safety inspection in accordance with the Iollcwing. If any of the listed defects are found, the cars shall Dot be continued in service except they may be moved for repair:

1. A freight car with any defect that makes it unsafe for movement sball be corrected or set out of train.

2. No part of the freight CEIl'. nor anything attached to rhecar, may be hanging low enough to foul a Toad crossing or track structure and must have a minimum clearance of 21/2" above top of rail.

3. Open top loads, including trailers and containers on flat cars, must be safely loaded.

4. Where width or height appears close to clearance lines, it must be known that the movement bas been cleared with the proper authority.

s. Freight cars carrying bad order tags, that are safe for movement, may be taken in rraln to the point where repairs can be made.

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B. Wheels,

1. Thin Flange: Flange 15/16" or less in thickness.

2. Vertical Flange: Flange having vertical surface extending 1" or more from tread.

3. High Flange: Flange 1.lJ2" or more high above the' approximate centerline of tread.

4. Thin Rim: Rim 3f4" or less in thickness.

S. Broken: Broken or cracked rim, flange, plate or hub except fine superficial lines or checks Oil the surface of the wheel tread.

6. Shelled-Tread: Tread having pieces of metal broken out of the' surface more or less continuously around the Tim of wheel.

7. Slid Flat: Flat spot more than 2112" in length or two adjolning spots each more than 2" in length.

8. Loose Wheel: Evidence of movement on wheel seat or oil seepage on the back-plate from inside of wheel fit.

9. Overheated Wheel: Wheel which bas

been overheated as evidenced by

reddisb brown discoloration from heat

on front and backface of rim and plate extending into the plate ¥2 of the distance from the tread surface to the axle With decreasing intensity.

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C. Other Truck Components.

1. Side frame or bolster broken, or cracked to the extent it has lost structural integrity.

2. (aJ Side bearings or roller missing or br:oken.

(bl Side bearings at ant:. end of car on both sides are in contact with body bolster except by design.

3. Spring plank broken or missing except by design.

4 . .Spning assembly solid or snubber broken or missing.

D. Couplers and Draft Arrangements.

1. Couplers: Coupler height varying more than 4" on adjacent coupled cars or coupler shank or knuckle broken, cracked or worn to the extent it bas lost structural integrity. Uncoupling lever or lock lifter inoperative or bent -so as to interfere with other parts on curves and result in unintentional uncoupling, as indicated by visual inspection.

2. (a) Broken or missing draft gear or yoke.

(b) Draft gear carrier broken, missing, cracked or worn to the extent that it has lost structural integrity.

(c) Cross Key retainer missing or broken cross key.

3. A cushioning device broken, Inoperattve or missing a part may be set out of train

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but.mnst no be moved for repair until a qualified person determines under what conditions it is safe to move for repair.

E. Car Body.

1. Car Sides and Ends: Spread beyond published line clearances or defective to the extent of failing to secure, restrain or contain the load, unless car bas been cleared fai_' movement to unloading or load transfer point

2. Underframe: Cerrtersill broken or cracked to the extent it bas lost structural integrity.

1. Journal boxes or roller bearings not repacked or lubricated within the interval as indicated by stenciling.

F. Journal Bearings.

2. Roller Bearings: Evidence of overheating, loose or missing cap screw 01' adaptor broken, out of place or worn to the extent it is marking seal assembly.

G. General.

1. Safety appliance and air brake equipment must comply with Federal requirements.

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INSTRUCTJONS FOR SAFETY INSPECTION

Each car placed in train, where personnel are not all duty for the primary purpose of inspecting freight 8t'S, may be moved after receiving safety inspection in accordance with the l'ollowit)g standards:

1. A [I'eight car with -any defect that makes ,it unsafe for movement shall be corrected or set out of traln,

2. No part of the freight cal', nor anything attached to the car, may be hanging low enough to foul II road crossing or track structure.

3. Open cop loads, including trailers and containers on flat cars, must be safely loaded,

4. Where width 0]' height appeal'S close to clearance lines, it lU.IJSt be known that the movement has been cleared with the propel' a uthortty.

S . .Freight cars carrying bad order tags. that are saf for movement, may be taken in train to the point where repairs are to be made.

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