smp no. 28603 issue date: january 12, 1982 revision date ...rpca.com/pdfs/amtraksmp28603.pdf ·...

TITLE: INSPECTION OF PRIVATE CARS

EQUIPMENT TYPE: STANDARD FOR HANDLING PRIVATELY-OWNED CARS IN AMTRAKTRAINS

ISSUE DATE: January 12, 1982

REVISION DATE: June 1, 1991

requirements for the handling ofCarriers may impose additional

STANDARD MAINTENANCE PROCEDURE

AMTRAK EQUIPMENT MAINTENANCE DEPARTMENT

(A) The cars must comply with applicable section of the currentedition of A.A.R. Car Rules, and all sections of the S.M.P.The cars will be sUbjected to a twelve month inspection fromlast inspection and certification by Amtrak MechanicalDepartment or its authorized representative. A copy of PClis to be retained in the car electric locker.

(B) Cars must be equipped with CS, H, F or T coupler on bothends of the cars. Cars must be equipped with roller bearings. Cars must have steam connectors removed. ' Inspectionof private cars can be made at an Amtrak car facility withadvance arrangement with the facility manager. This inspection will be at owner's expense~ Movement to Amtrak facility will be at owner's expense and, if car is not approvedfor movement in Amtrak service, car must be removed fromAmtrak facility within seven (7) days at owner's expense.Annual (PC1) inspection may be made at any location thatowner designates by an Amtrak authorized inspector. If caris found unfit for movement in Amtrak service, car ownerwill be advised in writing of defects necessary to correctbefore car can be reinspected for Amtrak's certification.Amtrak will not be required to make such repairs. The costof all labor and materials consumed by Amtrak or the operating railroad in inspecting private cars will be at owner'sexpense.

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SMP NO. 28603

SCOPE

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This document describes Amtrak'sprivately-owned cars in Amtrak trains.

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requirements.

PROCEDURE

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(M) All work performed must comply with all aspects to theapplicable standards and recommended practices adopted byA.A.R.

(K) All cars must be equipped with Amtrak full 480 head-endpower pass through and 27-point communication system andmain reservoir line.

(L) Cars equipped with cushion draft gear must be blocked inneutral position with 1" maximum draft in Amtrak trainservice.

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Any cost incurred in making an inspection and repairs tocomply with the requirements of this SMP will be for theaccount of the car owner. Routine inspections that occurprior to or during train movement are not chargeable to theowner.

(C)

(D) Cars must be equipped with one or more marker lights thatcomply with 49 CFR Part 221, Rear End Marking Device. Themarker lights must have a battery back up source that willburn for at least 2 hours.

(E) Cars must be equipped with foot plates on both ends and becompatible with Amtrak equipment. If car is not equippedwith foot plate on Observation end, it will be restricted tofirst or rear passenger carrying car in train. Cars notcomplying with paragraph are not guaranteed rear position.

(F) Cars which must operate on the rear because of lack ofdiaphragms or foot plates are subject to cutoff or set outwithout notice due to operational problems.

(G) - The maximum electrical load capacity on private cars whenusing H.E.P. cannot exceed 85 kw effective July 1, 1986.

(H) Prior to first movement in Amtrak trains, ,a clearance form,.MAP-PC-S-Rev. must be completed sent and approved asinstructed on form. Any changes to the configuration, whichalters the dimensions on file must be reported with newform, before next movement.

(I) The car owner will maintain a continuous record of allrepairs and modifications on PC-4 shop report. This reportwill be sent in with PC1 annually.

(J) On completion of the twelve month inspection (PC1) the ownerwill forward a copy of PC1, PC1A, PC3 and PC4 forms to Superintendent of Cars (private cars). Copies of all PC formsmust be kept in electrical locker.

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Cars over 40 years old

Note: Use freight single car testing device whentesting this equipment.

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1. Date shopped and defects.

2. Date released.

3. Repairs made on car.

Private cars when on Amtrak trains or Amtrak property mustdisplay Amtrak I.D. number (800,000 series) as per AmtrakDrawing Number A-002-5079.

When any private car is shopped at any Amtrak facility, thefollowing information must be entered in the ARROW systemcomputer:

(N)

(0)

(1) 200,000 miles from 40 year inspection car will beinspected using MAP PC2A .and PC2A instructions.

(2) 350,000 miles from 40 year inspection car will beinspected using MAP PC2A and PC2A instructions.

(3) 500,000 miles from 40 year inspection car will beinspected using MAP PC2A and PC2A instructions.

(4) In a ten year period if car does not meet mileagecriteria, car must be inspected using Form PC2A andPC2A instructions regardless of the mileage.

(P) Cars equipped with ABDW brake are limited to no more than2 cars per train and not in consecutive order in trainconsist.

In addition to the provisions of item #I above, thefollowing will apply.

(A) The car must undergo a detailed inspection (as described onattached PC1 and PC2 forms and their instructions) by theMechanical Departments of Amtrak, an Amtrak carrier or anauthorized Amtrak Inspector Representative. The firstinspection shall occur within the 40th year from date built.After the initial 40 year inspection, the following inspection schedules and related instruction shall be followed.Cars that have received a previous 40 year inspection underSMP 28603 with the revision date of February 8, 1985, willbe due a new 40 year inspection six (6) years from thatinspection date using current Form PC2 and PC2 instructions.

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(B) The car owner will maintain and report a log of non-Amtrakroutes and mileage traveled (PC3 route mileage log). Amtrakwill maintain route mileage record in Amtrak ARROW systemfor mileage requirements.

(C) On completion of the 40 year inspection and all otherinspections, the owner will forward copies of all PC formsto Superintendent of Cars (private cars) office for file.

III. All cars operating on Amtrak trains must be equipped with Amtrakhead-end power and comply with the following requirements:

(A) Cars must meet Amtrak specifications for head-end powerconversion which include 480 head-end power and 27-pointcommunication systems on both A&B ends and R&L sides. MUinstallation is optional.

(B) All material used in head-end power conversion must meetAmtrak specifications.

(C) Final testing and approval of the head end power conversionwill be done at Amtrak facilities. Inspection charge shallnot exceed two (2) hours.

(D) Single line schematic or equal depicting all loads fed fromhead-end power must be maintained and furnished to Amtrakupon completion of head-end power installation. Phase loadbalance must be within 5%.

(E) On completion of head-end power conversion, a clearancediagram PCS must be completed and furnished to Amtrak.

(F) All cars operating on trains with Superliner Equipmentmust have 2 each 33" 480 extension cables supplied by theowner to ensure proper connection with Superliner equipment •

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Page ~ of 7SMP No. 28603

INSTRUCTIONS FOR PRIVATE cARs 40 YEARS OR OLDERINSPECTION FOR COMPLIANCE OF MAP PC2

~. Jack car and remove and replace trucks.

2. *Clean and inspect truck bolsters, body bolster, bolster centerplates and top center plates. Must comply with instructions andrequirements of SMP 466~7 and SMP 4800~.

3. Remove swing hangers and pins (6 wheel truck). Remove swinghangers, crossbars and pins (4 wheel truck).

4. *Clean and inspect swing hangers and crossbars must comply withinstructions and requirements of SMP 46605 except not necessaryto Brinell test, must Magna-Flux or Dye Check. If any repairsare required on swing hangers or crossbars, they must be heattreated and Brinell tested. Renew swing hanger bushings worn~O% of new. Renew swing hanger pins worn ~O% of new•

5. Remove equalizer bars, springs and spring seats.

6. *Clean and inspect equalizer bars. Must comply withinstructions and requirement of SMP 466~7 and SMP 46603 exceptnot necessary to Brinell test, must Magna-Flux or Dye Check. Ifany repairs are required on equalizer bars, they must be heattreated and Brinell tested.

7. *Clean and inspect equalizer springs.

8. Test springs for resiliency, cracks, or broken springs. Must berenewed if weak, cracked, or broken.

9. *Clean and inspect equalizer spring seat. Must comply withinstructions and requirements of SMP 466~7 and SMP 49602. MustMagna-Flux or Dye Check.

10. *Clean and inspect truck frame and spring plank. Must complywith instructions and requirements of SMP 46617 and SMP 48001and tramming instructions. Truck frame bushings must be renewedwhen worn 10% of new•

13. (A) Inspect wheels and axles in accordance with applicable AARManual, Standard and Recommended Practices (Section G, PartII). In addition, any wheel with flange height of 1 1/4" ormore must be restored to full contour, any wheel with flangethickness of 1" or less must be restored to full contour andany wheel with 1/16" or less above passenger scrap must berenewed. Note: If Spicer drive is not used, remove fromaxle.

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Page 2 of 7 PC2 Instructions

*Clean and inspect pedestal liners for cracks in the parentmetal or in welds holding liners to truck frame. Maximumallowable clearance is 1/4" between the pedestal liners andjournal housing. The total allowable lateral per wheel set withHyatt boxes is a minimum of 3/8 II and a maximum of 5/8 II • Thisincludes the lug liner clearance and the thrust block clearance.The lateral clearance total per wheel set between thrust lugs ofjournal housing and pedestal liners, using 3/8" lug liners is aminimum of 3/8" and a maximum of 5/8". The lateral clearancestotal per wheel set between thrust lugs of journal housing andpedestal liners using 7/16" lug liners is a minimum of 1/4" anda maximum of 9/16". The center wheel of a six (6) wheel truckmust have a minimum lateral clearance of 5/8" and maximumlateral clearance of 7/8" If liners are cracked or worn, theymust be renewed. To determine if wear is in pedestal liner orjournal box liner, the measurements must be made previous todismantling of truck, all cracked welds must be properlyrepaired to ensure proper securement.

*Clean and inspect anchor bars, anchor bar bolts and rubberbushings. Cracked or broken anchor bars must be renewed, anchorbar bolts worn 15% or have pUlled or worn threads must berenewed and anchor bar rubber bushings worn, aged or crackedmust be renewed.

(B) Inspect all disc in accordance with the regulation of AmtrakSMP 03612 for thermo-cracks. Any WABCO bolt on disc withless than 7/16" service metal on either rotor must berenewed. Any Knorr bolt on disc with more than 7mm wear oneither rotor braking surface must be renewed. Inspect theouter periphery of the disc for chips or indentations. Ifchips or· indentations are greater than 3/4" wide radiallyand 1/4" deep into the braking surface, the disc must berenewed. Inspect to ensure all discs are secure, all boltstight and bolt locking tabs properly bent. Any loose discmust be properly secured •

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(D) oil Lubricated

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(C)


Inspect roller bearings and boxes:

1. Grease lubricated: remove roller bearing face plate(where applicable). Remove journal end cap, visuallyinspect bearing box and grease fully, rotate box todetermine any signs of distress either by sound or feel.Inspect grease for any discoloration. (If grease isdiscolored, box must be entirely cleaned and new greaseapplied.)

Reapply journal end caps and torque bolts to proper footpounds as recommended in (Section H, Part II RollerBearing Manual H-II-81). In addition, bolts must besecured with triangular locking plate. Apply rollerbearing box plate and secure bolts with wire (whereapplicable). Grease boxes as recommended in (Section A,Part III) Passenger Car requirements (Section 4.0 ofA-III-263).

Hyatt roller bearing boxes: The lateral must be adjustedaccording to the instruction of Hyatt Roller BearingRailroad Journal Boxes •

Hyatt boxes: drain oil, remove boxes from journal, inspectroller bearings, cages and clean and flush box with lightoil. Remount boxes on journals and fill to capacity withoil as recommended in (Section A, Part III Passenger CarRequirements Section 4.0 of A-III-263). Wire both fill plugand drain plug.

Hyatt roller bearing boxes: The lateral must be adjustedaccording to the instruction of Hyatt Roller BearingRailroad Journal Boxes.

Timken boxes: drain oil, remove face plate, journal endcap, visually inspect bearings and boxes, fully rotate boxesto determine any sign of distress either by sound or feel.Reapply journal end caps and torque bolts to proper footpounds as recommended in (Section H, Part II) Roller BearingManual H-II-81. In addition, bolts must be secured withtriangular locking plate, apply roller bearing box faceplate and secure bolts with wire. oil boxes as recommendedin (Section A, Part III) Passenger Car Requirements (Section4.0 on A-III-263). Wire both fill plug and drain plug.

15. *Clean, inspect and gauge couplers and operating rods.

14. *Clean and inspect all brake rigging, pins, levers, bushings andcomponent parts for cracks, broken or worn conditions.

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Clasp brake:

(A) Renew all brake pins when worn 10% of new.

(B) Renew all bushings when worn 10% of new.

(C) All tread brake shoe heads must be capable of fully holdingbrake shoe with no side play nor overlap of rim of wheel.

Disc Brake Type:

(A) Inspect all brake tongs, shoe heads, bolts and componentparts for cracked, broken, or worn conditions. Remove allshoe heads and inspect shoe head pins for cracks. Crackedshoe head pins must be renewed. Inspect shoe head retainingbuttons to ensure they are tight and of full contour. Wornor loose buttons must be renewed. All bolts must haveretaining plates or wire •

(B) When equipped with C frames, *clean and inspect C frames forcracks. Rubber back bushing must be renewed.

(C) Inspect rubber donut segments - renew if worn.

(D) All C frames must have safety chains of a minimum of 1/4"through hanger box assembly connecting to truck frametransom.

(A) Tightlock H or T type coupler must meet AAR Manual ofStandards and Recommended Practices (Section A, Part III,Specification 206B-SO).

(B) Tightlock F type coupler must meet AAR Manual of Standardsand Recommended Prac~ices (Section A, Part III,Specification M209B-74). .

(C) Controlled slack type coupler must meet maintenance recommendation of American Steel Foundry Report No. 509A, revisedJune 19, 1960 and AAR Alternative Standard S-026 •

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19. Inspect all areas where the boxes are attached for cracks, wornholes, and fatigued metal. Any of the above conditions foundmust be reinforced.

20. Inspect axle generators, axle generator supports and securingdevices for cracks, fatigued metal, and worn holes. If any ofthe above conditions are found, they must be reinforced. Looseor broken bolts or rivets must be renewed. They must be renewedwith high strength bolts and elastic stop nuts. The tensilestrength of the bolts and nuts must be grade 5 or better.

(C) Controlled Slack 1"

(D) T Type 1"

(A) H Type 1{2"

(B) F Type 1"


16. Inspect draft gear for excessive slack. Must meet AARrequirement for type of coupler:

17. Remove draft gear pan and inspect draft gear, *clean and inspectarea around draft gear for cracks, loose, or worn parts. If anycracks are located, they must be welded and reinforced accordingto AAR Specifications.

18. Inspect battery boxes, air condition units, electrical breakerboxes, equipment boxes and all other boxes attached to car.Inspect for loose or broken bolts or rivets. Boxes with cracksor broken areas must be repaired and reinforced. All boxsupport straps, cracked or broken must be completely renewed.Loose or broken bolts and rivets must be renewed. They must berenewed with high strength bolts and elastic stop nuts. Thetensile strength of the bolts and nuts must be grade 5 orbetter.•

forAll

(A) Belt driven generators must have axle pUlley inspectedcracks, proper mounting and secured with proper bolts.cracked pulleys must be renewed. Inspect all belts forloose, worn and damage. Replace as required.

•(B) Generators with spicer drive, clutch and drive shaft must be

inspected for worn companion flanges, loose and worn driveshafts. If any of the above conditions are found, they mustbe renewed. Drive shaft must have safety hangers and havesafety hangers in good condition. Note: If spicer notused, must be removed •

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(C) Inspect torque arm for excessive play. If any play exists,the torque arm bushings must be renewed (there must be noslack).

(D) Spicer drive must have safety arm.

(E) Check spicer drive for proper oil level and lubricateuniversal joints on drive shaft.

21. Inspect cables, wiring and conduit of cars with 480 power 27point train line systems and head end power systems. Wires andcables with cuts or abrasions, any conduit broken, loose orcracked must be repaired to meet Amtrak engineeringspecifications.

22. Inspect marker lights for proper operation. All lights musthave the capabilities of burning 2 hours from back-up power.

23. Inspect and test with soap suds all air lines and main reservoirlines for leaks. All loose pipes must be tightened and allcracked and broken pipes must be renewed. Inspect all air hosesand main reservoir hoses for defects •

Single car: test cars for proper brake operation and properpiston travel. Must pass single car test according to AARSpecification Instruction Pamphlet No. 5039-4. Piston travelbody mounted cylinders 7". Truck mounted cylinders 5".

25. Inspect, test and stencil handbrake for proper operation. Handbrake must apply and release properly and work in conjunctionwith the airbrake. Handbrake must be located so it can safelybe operated while car is in motion. Lubricate all sheave wheelpins.

26. Inspect all hand holds for proper clearance, application andworn conditions. Hand holds must be constructed of minimum 5/8"diameter, must be tight, free of breaks and cracks and a minimum"clearance of 2". Cracked or broken hand hold must be renewedand comply with FRA Requirements.

27. Inspect all trap door catches for proper securement. Must notbe loose and heavy-weight type must be secured with tapped boltsof not less than 1/4". Trap door must raise enough to clearlocking device when opening to ensure sufficient clearance toavoid personal injury to hands •

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*Any cleaning of areas can be done with any of the following methods:sand or grit blasting. Walnut shelling, wire brushing or highpressure steam cleaning or high pressure water •

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Inspect all entrance steps for proper securement and conditionsof step treads and risers. They must not be loose, cracked orbroken. All loose steps must be secured with high strengthbolts and elastic stop nuts or welded. Heavy-weight type risersbroken or cracked must be renewed with a minimum 1/4", wroughtiron or steel. step treads must have a nonskid tread•

OWNER'S NAME _

AMTRAK AUTHORIZED INSPECTOR NAME _

MAP inspection and repairs~ comply with attached instructions by item numberslisted•

ZIP CODE _

PHONE NO.

C.O.T.&S. DATE

DATE BUILT _

MAP PC2SMP NO. 28603Page 1 of 3Requires PCl, PC-lA, PC-3, PC-4

BUSINESS PHONE NUMBER _

STATE _

ADDRESS _

PRIVATE CAR 40 YEAR OR OLDER INSPECTION

AMTRAK ID NO.

CAR NAME/NUMBER _

LUBE DATE

CITY _

STREET ADDRESS _

TITLE _

COMPANY _

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• Inspector's Signature Final InspectionNote: This inspec- Signaturetion when trucks torn Trucks under car anddown. all work complete.

l. Jack car and remove trucks.

2. Clean and inspect truck bol-sters, body bolsters, bolstercenter plates, and top centerplates.

3. Remove swing hangers and pins(6 wheel truck). Remove swinghangers, crossbars and pins(4 wheel truck).

4. Clean and inspect swing hangersand crossbars.

5. Remove equalizer bars, springsand spring seats.

6. Clean and inspect equalizerbars.

7. Clean and inspect equalizersprings.

8. Test springs for resiliency,cracks or broken.

9. Remove, clean and inspect springseats.

Inspector's Signature Final InspectionNote: . This inspec- Signaturetion when trucks torn Trucks under car anddown. all work complete.

10. Clean and inspect truck frameand sprinq planks.

11. Clean and inspect pedestalliners.

12. Clean and inspect anchor bars,anchor bar bolts and rubberbushings.

13. Inspect wheels, axles, discs androller bearing boxes.

14. Clean and inspect brake rigging,pins, levers, bushings andcomponent parts.

15. Clean and inspect and gaugecoupler and coupler operationrods.

16. Inspect draft gear for excessiveslack.

17. Remove draft gear pan. *Cleanand inspect area around draftgear.

18. Inspect battery boxes, air con-ditioning units, electricalbreaker boxes, equipment boxesand all other boxes attachedto car.

19. Inspect all areas where boxesare attached.

20. Inspect generators, generatorsupports and securing devices.

21- Inspect cables, wiring and con-duit on cars with 480 power and27-point train line systems.

22. Inspect marker lights for properoperation.

23. Test and inspect all air linesand main reservoir lines forleaks.

24. Single car test car for properbrake operation.

25. Inspect, test and stencil handbrake.

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Page 2 of 3 of PC2

Inspector's Signature Final InspectionNote: This inspec- Signaturetion when trucks torn Trucks under car anddown. all work complete.

26. Inspect all hand holds forproper clearance, applicationand worn conditions.

27. Inspect all trap doors forproper securement.

28. Inspect all entrance steps forproper securement and conditionsof step treads and risers.

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Page 3 of 3 of PC2

I certify each item on the PC form was inspected by me and found in compliance•

Inspector Signature _

Date of Inspection __

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6. Inspect truck frame for worn conditions, cracks or broken. If anydefects are noted, they must comply with instructions and requirements of SMP 4661.7 and SMP 48001. Truck frame bushings must berenewed when worn 1.0% of new.

7. Inspect pedestal liners for cracks in the parent metal or in weldsholding liners to track frame. Maximum allowable clearance is1./4" between the pedestal liners and journal housing. The totalallowable lateral per wheel set with Hyatt boxes in a minimum of3/8" and a maximum of 5/8". This includes the Lug Liner Clearanceand the Thrust Block Clearance. The lateral clearance total perwheel set between thrust lugs of journal housing and pedestalliners using 3/8" Lug Liners is a minimum of 3/8" and a maximum of5/8". The lateral clearances total per wheel set between thrustlugs of journal housing and pedestal liners using 7/16" lug linersis a minimum of 1/4" and a maximum of 9/16". The center wheel ofa 6-wheel truck must have a minimum lateral clearance of 5/8" anda maximum lateral clearance of 7/8". If liners are cracked orworn they must be renewed. To determine if wear is in pedestalliner or journal box liner, the measurements must be made beforeremoval of wheels. All cracked welds must be properly repaired toensure proper securement.

INSTRUCTIONS FOR PRIVATE CAR INSPECTION200,000 THROUGH 500,000 MILES AFTER 40 YEARSAMTRAK INSPECTION FOR COMPLIANCE OF MAP PC2A

1.. Jack car and remove and replace trucks. Do not disassembletrucks unless necessary to repair defects found.

2. Inspect truck bolsters, body bolsters, bolster center platesand top center plates for worn conditions, cracks or broken.If any defects are noted, they must be repaired to comply withinstructions and requirements of SMP 4661.7 and SMP 48001..

3. Inspect swing hangers, crossbars and pins for worn conditions,cracks, or broken. If any defects are found, they must berepaired to comply with instructions and requirements of AmtrakSMP 46605 inclUding heat treating, Brinell testing, Magna-Fluxor Dye Checking. Renew swing hanger bushings worn 1.0% of new.Renew swing hanger pins worn 1.0% of new.

Page 1. of 5SMP No. 28603

5. Inspect equalizer springs and equalizer spring seats for worn conditions, cracks or broken. Broken or cracked equalizer springsmust be renewed. Equalizer spring seats must be repaired to comply with instructions and requirements of SMP 4661.7 and SMP 49602.

4. Inspect equalizer bars for worn conditions, cracks, broken orgouged. If any defects are found, they must be repaired tocomply with instructions and requirements of Amtrak SMP 4661.7and SMP 46603 inclUding heat treating and Brinell testing.

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Clasp brake:

(B) Renew all bushings when worn 10% of new.

(A) Renew all brake pins when worn 10% of new.

Page 2 of 5 PC2A Instructions

(C) All tread brake shoe heads must be capable of fully holdingbrake shoe with no side play nor overlap of rim of wheel.

Disc Brake Type:

(A) Inspect all brake tongs, shoe heads, bolts and component partsfor cracked, broken, or worn conditions. Remove all shoeheads and inspect shoe head pins for cracks. cracked shoehead pins must be renewed. Inspect show head retaining buttons to ensure they are tight and of full contour. Worn orloose buttons must be renewed. All bolts must have retainingplates or wire.

8. Inspect anchor bars, anchor bar bolts and rubber bushings.Cracked or broken anchor bars must be renewed, anchor bar boltswith pulled or worn threads must be· renewed and anchor bar rubberbushing worn or aged cracked must be renewed.

9. Inspect wheels and axles in accordance with applicable AAR Manual,Standards and Recommended Practices (Section G, Part II). Inaddition, any wheel with height of 1 1/4" or more must be restoredto full contour, any wheel with flange thickness of 1" or lessmust be must be restored to full contour and any wheel with 1/16"or less above passenger scrap must be renewed.

Roller bearing and boxes:

Remove face plate (where applicable) journal end cap and inspectboxes for any discoloration of grease or oil or any visiblebearing problems. Reapply journal end caps and torque bolts toproper foot pounds as recommended in section H, Part II, RollerBearing Manual (H-II-81). In addition, bolts must be secured withtriangular locking plate. Apply roller bearing box face plate(where applicable) and secure bolts with wire. Grease or oilboxes as recommended in section A, Part III, Passenger CarRequirements, section 4.0 of A-III-263 •

Hyatt roller bearing boxes:

The lateral must be adjusted according to the instruction of HyattRoller Bearing Railroad Journal Boxes.

10. Inspect all brake rigging, pins, levers, bushings and componentparts for cracks, broken or worn conditions.

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of S PC2A Instructions

(B) When equipped with C frames, worn or torn rubber bushings mustbe renewed.

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Must meet AAR requirement

(C) Controlled Slack 111

(A) H Type 1/211

(B) F Type 111

(D) T Type 111

(C) Controlled slack type coupler must meet maintenance recommendation of American Steel Foundry Report No. S09A, revisedJune 19, 1960 and AAR Alternative Standard S-026.

(C) Inspect rubber donut segments - renew if worn.

(D) All C frames must have safety chains of a minimum of 1/4"through hanger box assembly connecting to truck frame transom.

11. Inspect and gauge couplers and operating rods.

(A) Tightlock H or T type coupler must meet AAR Manual ofStandards and Recommended Practices (Section A, Part III,Specification M 206B-SO).

(B) Tightlock F type coupler must meet AAR Manual of Standardsand Recommended Practices (Section A, Part III, SpecificationM 209B-74).

13. Thoroughly inspect area around draft gear for cracks, loose, orworn parts. If any cracks are located, they must be welded andreinforced.

14. Inspect battery boxes, air condition units, electrical breakerboxes, equipment boxes and all other boxes attached to car.Inspect for loose or broken bolts or rivets. Boxes with cracks orbroken areas must be repa~red and reinforced. All box supportstraps, cracked or broken must be completely re~ewed. Loose orbroken bolts and rivets must be renewed. They m~st be renewedwith high strength bolts and elastic stop nuts. The tensilestrength of the bolts and nuts must be grade S or better.

15. Inspect all areas where the boxes are attached for cracks, wornholes, and fatigued metal. Any of the above conditions found mustbe reinforced .

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12. Inspect draft gear for excessive slack.for type of coupler:

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19. Inspect and test with soap suds all air lines and main reservoirlines for leaks. All loose pipes must be tightened and allcracked and broken pipes must be renewed. Inspect all air hosesand main reservoir hoses for defects.

20. Single car: test cars for proper brake operation and proper piston travel. Must pass single car test according to AAR Specification Instruction Pamphlet No. 5039-4. Piston travel body mountedcylinders 7". Truck mounted cylinders 5" •

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(C) Inspect torque arm for excessive play. If any play exists,the torque arm bushings must be renewed (there must be noslack) •

(D) Spicer drive must have safety arm.

(E) Check spicer drive for proper oil level and lubricateuniversal joints on drive shaft.

16. Inspect axle generators, axle generator supports and securingdevices for cracks, fatigued metal, and worn holes. If any of theabove conditions are found, they must be reinforced to meet AmtrakEngineering specifications. Loose or broken bolts or rivets mustbe renewed. They must be renewed with high strength bolts andelastic stop nuts. The tensile strength of the bolts and nutsmust be grade 5 or better.

(A) Belt driven generators must have axle pulley inspected forcracks, proper mounting and secured with proper bolts. Allcracked pulleys must be renewed. Inspect all belts for loose,worn and damage. Replace as required.

(B) Generators with spicer drive, clutch and drive shaft must beinspected for worn companion flanges, loose and worn driveshafts. If any of the above conditions are found, they mustbe renewed. Drive shaft must have safety hangers and havesafety hangers in good condition. Note: If ~picer not used,must be removed.

17. Inspect cables, wiring and conduit of cars with 480 power and 27point train line systems. Wires and cables with cuts orabrasions, any conduit broken, loose or cracked must be repairedto meet Amtrak engineering specifications.

18. Inspect marker lights for proper operation. All lights must havethe capabilities of burning 2 hours from back-Up power.

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Inspect, test and stencil handbrake for proper operation. Handbrake must apply and release properly and work in conjunction withthe airbrake. Handbrake must be located so it can safely beoperated while car is in motion. Lubricate all sheave wheel pins.

Inspect all hand holds for proper clearance, application and wornconditions. Hand holds must be constructed of minimum 5/8"diameter, must be tight, free of breaks and cracks and a minimum"clearance of 2". Cracked or broken hand hold must be renewed andcomply with FRA Requirements.

Inspect all trap door catches for proper securement. Must not beloose and heavy-weight type must be secured with tapped bolts ofnot less than 1/4". Trap door must raise enough to clear lockingdevice when opening to ensure sufficient clearance to avoidpersonal injury to hands.

Inspect all entrance steps for proper securement and conditions ofstep treads and risers. They must not be loose, cracked orbroken. All loose steps must be secured with high strength boltsand elastic stop nuts or welded. Heavy-weight type risers brokenor cracked must be renewed with a minimum 1/4", wrought iron orsteel. Step treads must have a nonskid tread•

OWNER'S NAME _

COMPANY BUSINESS PHONE NUMBER _

ZIP CODE

MAP PC2ASMP NO. 28603Page 1 of 2(Requires PC1, PC-LA, PC-3, PC-4)

PHONE NO.

DATE LAST 40 YEAR INSPECTION -I.(::..P.=C.:::,2.' _

C.O.T.&S. DATE

STATE

PRIVATE CAR 200,000 MILE INSPECTIONAFTER AMTRAK 40 YEAR INSPECTION

Final InspectionInspector's Signature SignatureNote: Truck out from Truck applied tounder car. car.


2. Inspect truck bolsters, bodybolsters, bolster center plates,and top center plates.

3. Inspect swing hangers, crossbars and pins.

4. Inspect equalizer bars.

5. Inspect equalizer springs andequalizer spring seats.

6. Inspect truck frame.

7. Inspect pedestal liners.

8. Inspect anchor bars, anchor barbolts and rubber bushings.


10. Inspect all brake rigging pins,levers, bushings and componentparts.

AMTRAK ID NO.

AMTRAK AUTHORIZED INSPECTOR NAME

CITY _

CAR NAME/NUMBER _

LUBE DATE

TITLE ADDRESS

STREET ADDRESS

•

Map inspection and repairs must comply with attached instructions by item numberselisted.

Final InspectionInspector's Signature SignatureNote: . Truck out from Truck applied tounder car. car.

11. Inspect and gauge couplers andcoupler operating rc;>ds.


13. Inspect area around draft gear.

14. Inspect battery boxes, air con-ditioning units, electricalbreaker boxes, equipment boxesand all other boxes attached tocar.

15. Inspect all areas where theboxes are attached for cracks,worn holes and fatigued metal.


17. Inspect cables, wiring and con-duit on cars with 480 power and27-point train line systems.




21- Inspect, test and stencil handbrake.




•Page 2 of 2 of PC2A

I certify each item on the PC form was inspected by me and found in compliance.

Inspector Signature

Date of Inspection


OWNER'S NAME _




3. Inspect swing hangers, crossbars and 1)ins.


S. Inspect equalizer springs andequalizer spring seats.




9. Inspect wheels, axles, discs androller bearing boxes •


ZIP CODE _

PHONE NO.

DATE LAST 40 YEAR INSPECTION --lo,(=..P,:::C:::,2.,L.) _

C.O.T.&S. DATE

STATE

ADDRESS


MAP PC2ASMP NO. 28603Page 1 of 2(Requires PCl, PC-lA, PC-3, PC-4)


Map inspection and repairs must comply with attached instructions by item numberslisted•

AMTRAK ID NO.

CAR NAME/NUMBER _

LUBE DATE _

CITY _

STREET ADDRESS _

COMPANY _

TITLE _

•

•

'.


11. Inspect and gauge couplers andcoupler operating rods.




15. Inspect all areas where theboxes are attached for cracks,worn holes and fatiqued metal.






21- Inspect, test and stencil handbrake.




•

•

•

Page 2 of 2 of PC2A


Inspector Signature __

Date of Inspection ___

Map inspection and repairs must comply with attached instructions by item numbers

OWNER'S NAME _

ZIP CODE _

MAP PC2ASMP NO. 28603Page 1 of 2(Requires PCl, PC-lA, PC-3, PC-4)

PHONE NO.


DATE LAST 40 YEAR INSPECTION ....l.{.:;.P::::C~2.J..) _

C.O.T.&S. DATE

STATE _

ADDRESS _


CITY

COMPANY _

AMTRAK ID NO.

CAR NAME/NUMBER _

LUBE DATE

STREET ADDRESS


TITLE

listed.




3. Inspect swing hangers, crossbars and pins.


5. Inspect equalizer springs andequalizer spring seats.






•

Final InspectionInspector's Signature signatureNote: Truck out from Truck applied tounder car. car.

ll. Inspect and gauge couplers andcoupler operating rods.




15. Inspect all areas where theboxes are attached for cracks,worn holes and fatigued metal.

16. Inspect generators, generatorsupports and securing devices •



19. Test and inspect. all air linesand main reservoir lines forleaks.

0.


21. Inspect, test and stencil handbrake.




•

•

•

Page 2 of 2 of PC2A

I certify each item on the PC form was inspected by me and found in compliance •

Inspector Signature _

Date of Inspection __

OWNER'S NAME _

Initial1- Check bearings for signs of overheating and

bearinq seals for leakinq.

2. Check past due roller bearing lubricationdates. *Oil - 30 Day Grease - 90 Day - APbearinq 1 year (not necessary to lube NFL).

3. Check for defective roller bearing boxes*cracked - excessive wear or broken.

4. Check roller bearing cap screws and lockplates/safety wire.

5. Check pedestal jaws and liners for visibledefects - *broken-loose-bent and broken weld.

6. Check journal box stop for securement, atleast one side required. *Loose or missing.

7. Check air brake past due* COTS UC 15 months,022-24 months, 26C 36 months, ABO ABDW6 years, ABDG-3 years.

8. Check brake pipe hose A&B end *8 years oldoverdue or damaged.

9. Check main reservoir hoses A&B ends. *Eightyears old overdue or damaged.

10. Inspect, test hand brake for proper operationand stencil date and location tested •

Initial on each line denotes compliance or notes defect. Car not equipped shouldbe marked N/A on line. Car must have defects repaired before submitting movementrequest •

DATE BUILT _

MAP PClSHE» NO. 28603Page 1 of 3Requires PC-LA, PC-3, PC-4PCS First Inspection

B

PHONE NO.

LOCATION _


C.O.T.&S. DATE - LOC.

ADDRESS _

CAR NAME/NUMBER _

TYPE COUPLER A _

PRIVATE CAR ANNUAL INSPECTION REPORT

AMTRAK ID NO.

LUBE DATEAB TYP~ _

INSPECTION DATE _

ADDRESS

AMTRAK AUTHORIZED INSPECTOR NAME

COMPANY _TITLE

•

•

••

of 3 of PCl

Initial

11. Visually inspect under car equipment.*Equipment securement, loose pipes, frayedwires, etc.

12. Visual inspection of equalizers, shockabsorbers, swing hangers, springs, truckframes and spring planks for unusual wear ordefective conditions. *Cracked, broken col-lapsed springs, shiny/rubbing area, loosebolsters anchor rods.

13. Visual inspection of axles and brake discsfor defects. Check spicer drive unit forproper amount of lubrication (dip sticklevel) • Inspect drive shaft clutch andspicer. *Loose/cracked discs, loose bolts,check play in universal joints and grease.Cracked disc comply with Amtrak Drawing No.A-007087.

14. Check brake shoes to ensure adequate serviceand in alignment and proper application.1/4" Amtrak standard on disc pads. 3/4" ontread shoes.

15. Steam connector removed and remaining pipeproperly secured.

16. Visual inspection of couplers and components.Check operating rod clearance, *maximumheight 35", preferred height 34 1/2", minimumheight 34". *Worn knuckles, loose carrieriron bolts, broken springs.

17. Inspect and check operation of diaphragm,buffer, suspension rods, springs A&B ends.*Buffer height or adapter is 53" from top ofrail.

18. Check slack adjuster, brake rigging, bush-ings, brake cylinders and brake heads.*Loose bolts, pins and worn bushings.

19. Check sill steps, hand holds and other safetyappliances for compliance with FRA/AAR SafetyAppliance Standards. *Hand holds must haveminimum clearance of 2".

20. Amtrak ID number on left and right side B-endor blind end, Amtrak Drawing A-002-S079.

21. Marker light FRA approved 49CFR Part 221,rear end marking device with battery back upsource. Batteries should be self-containedfor back up source. Water tight container.

22. Inspect all 480 cables for defects anddeterioration in the insulation. *Debrisdamage cracking or fraying of insulation.Inspect conduit over trucks for securement.

•

*Note the star items are only a suggested defect list and not complete.


Inspector Signature __

Date of Inspection _

23. Check call bell A&B end for proper operation.

FLANGE THICKNESS

Initial

Page 3 of 3 of PCl

FLANGE HEIGHT

24. Car equipped with HU control lines.Yes No

25. Verify that PCs Clearance Form when lastfiled the exterior measurements have notchanqed. Yes No

26. Gauge all wheels and record dimensions in16th or 64ths. Inspect for other defects.

•

•

Circle or Answer Ev~ Item

(1003)CMNER _

PC-1-AIncludes PC-1

PHONE _

(1002) ORIGINAL DATE BLT. _(100) CAR NAME NUMBER _

ADDRESS _

(1004) INSPEX:'IOR _

ADDRESS _

DATE _

(1000) AMI'RAK ID t _8;;.;;0;.;.0__

(1016)STANDBY 64V:: YES-NO (1017)NFL BEARING:: YES-NO (1018)E;JPD. MAIN RES LINE:: YES-NO(1019) STANDBY 220V:: YES-NO (1020)I1JB GREASE:: YES-NO (1021) 27 PT .JUiIPER A-END:: YES-NO(IU22) STANDBY 480V:: YES-NO (1023) LOB OIL:: YES-NO (1024) 27 PT JUMPER B-END:: YES-NO(1025) SELF-<:oNl' ELECTRICAL:: YES-NO (1026) PIDPANE:: YES-NO(1027) 480 mPD A-END R-SD:: YES-NO (1028) 480 BJPD A-END L-SD:: YES-OO(1029) 480 mPD B-END R-SD:: YES-OO (1030) 480 mPD B-END L-SD:: YES-NO(1031) DIA-AMF A-END:: YES-NO (1032) DIA AMF B-END:: YES-OO(1033) DIA SUPERLINER A-END:: YES-OO (1034) DIA SUPERLINER B-END:: YES-NO(1035)DIA TUBE STYLE A-END:: YES-NO (1036)DIA TOBE STn.E B-END:: YES-ro(1037)VESTIBtJLE A-END:: YES-NO (1038) VESTIBULE B-END:: YES-OO(1039)BLIND END A-END:: YES-NO (1040)BLIND END B-END:: YES-NO(1041) OPEN PI.la'FORM A-END:: YES-NO (1042) OPEN PIATFORM B-END:: YES-NO(1043) roUND OBSERV. A-END:: YES-NO (1044) roUND OBSERV. B-END:: YES-NJ(1045) SELF-CONT 'IDn.ETS:: YES-NO NUMBER 'roILETS ON CAR THAT DUMP ON TRACK(1046)FRA MARKER A-END:: YES-NO (1047)FRA MARKERS B-END:: YES-NO ---

THIS FORM MOST BE CCMPLETED EACH AND EVERY ANNUAL INSPECl'ION AND SENT WITH THE PC-U FORMTO KEEP INFORMATION CURRENT ON FILE.

(1005)PC-1 D'l':: (1006)PC-1-IJX:: _(1007)PC-2 D'l':: (1008)PC-2-IJX::(1009) MAX-SPEED: : 90-110 MPH (1010)c:::LEARANCE RESTRICTIOO:: A(NR) B""'(WEST="""'-OF~=CHI=C""')--"C~(NC1INY==)~

•

(1011)COUPLER TYPE::2)AB 'ITPE:: (1013)AB DATE: (1014)AB CLEAN BY WHO AND IOCATION: _5)GEN INroRMATION:: (E.G. dare sleePer lounge diner, etc.)

•

ALL ITEMS ON FORM MLTST BE ANSWERED•

•

All cars must fill out columns 1 and 2 of the following table. All cars with Rim Stamped,Straillht Plate Wheels using Tread Brakes require a Dye Penetrant Test on the wheel rimas part of the yearly inspection. The results of the test shall be made available for theinspector. This fonn must be updated when wheels are changed.

Wheel AAR Wheel Stamp Type Dye Test Perfonned Dye Test ResultNo. Type Yes/No Pass / Fail

1

23

45

67

8

9

10

11

12

Amtrak ID No. : _

FonnPC-IBRequired Supplementto PC-INRPC 8/95

H = Hub Stamped

Submitted by:

Car Name:

Brake Type: ( Circle all that apply) Tread Disc

Stamp Type: R= Rim Stamped

•

•

•Inspector Signature: ( If Required ) _

Date of Inspection: (If Required) _

ROUTEOE?ARTURE TRAIN [INCLUDE INTERMEDIATE POINTS IF

DATE NO. NECESSARY FOR ROUTE IDENTIFICATION} CARRIER MIL:.AGE

IIIIII

I I:

I" II I iI- II II I

.

I . II

I III

:AR NAME

ROUTE/MILEAGE LOG

CAR NUMBER

MA?·PC·3

DATE BUILT _

~.iAP·PC

STOCK NO.1

DATE BUILT _

SHOP REPORTCAR NUMBER _

TRUCKS _

COUPLERS ___

SHOP SHOP DATE DATE \\'ORK PERFORMED SHOPLOCATIO~ OWNER IN OUT (USE AS ~tA.'lY LINES AS NECESSARy) SUPERINTE:--:DENT

I '

I

Ij- II I'

. I

I

. ,,-AR DATA ARE TO BE FULLY RECORDED AT THE TOP OF THIS FOR~f. KEEP ORIGI:-.iAL OF THIS REPORTCAR ELECTRICAL lOCKER. FORWARD O~E COpy OF THIS REPORT TO THE A~ITRAK CHIEF .\IECHA~IC.-\L OFFICEF

REV 4i85

• .1"R ;":A~lE _(

'. 10t:R~Al BE..1.RI~GS _

BRAKE SCHEDt:lE _

PC-5pg.l

2) Car must be located on level, straight track for measurement.

3) Provide measurements for the following critical appliances.

Height abovetop of rail

DATE KEASORED _

ADDRESS _

____ft in(max)___ft__in(max)____ft in(max)____ft in(min)__ft__in(min)__ft in(min)__ft in(min)____ft in(min)__ft in(min)____ft in(min)__ft__in(min)

Y or NY or NY or.NY or NY or NY or NY or NY or NY or NY or NY or N

Applicable

AXTRAKOFFICE OF THE CLEARANCE EHGDiEER

PRIVATE CAR CLEARANCE FORK- PC-S REV 6/92 -

KEASOREDBY _

CAR OWNER -:--_

PHONE HOKBER _

CAR HUHBER _

CAR HAKE _

INSTRUCTIONS:1) A separate form is to be completed for each private car. Arevised form must be submitted following exterior modification ofthe car. It is the responsibility of the car owner to ensurethat measurements are accurate and complete. Failure to provideaccurate and complete measurements will result in withdrawal ofauthorization for movement on AMTRAK trains.

Appliance Name

AntennaExhaust StackSide Marker LightsGrab IronsSteps (stirrup)Steps(Vestibule Fixed)Steps(Vestibule Folding)Battery BoxGenerator BoxWater TankMiscellaneous Box/Tank

4) Complete the general car diagrams on the reverse of this formto clarify measurements of critical appliances and to provideoverall car dimensions (height, width, length).

5) Return completed:form to:

AKTRAKOffice of the Clearance Engineer30th street station', 3rd Floor SOuthPhiladelphia PA 19104

•

".

Notes:Max - Show maximum height of applianceMin - Show minimum height of appliance

....•.................................. ------------....

page 2

PC-5 . .

i1 ~o~lr ,r;.1 rb::=r-~----I . . ill

! II .I ~ 1~ I ." J

'-+-L.:-J ~------ ---------1 ------ --T------1----------- --1

LI Il . ,...+I~~J -J ~Jr-if-o--· .I !o4-1---· .I 1~4----· .I 114------· .I '

0 D DO 0 0-CJ . ~I II II IU U I

.--_._-_._._..:._._._._._._._._._._._._._._._._._._._.-: _.-._._._.

•

•

smp no. 28603 issue date: january 12, 1982 revision date ...rpca.com/pdfs/amtraksmp28603.pdf ·...

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