CARBIS TCG-2500 User manual

REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 1
INSTRUCTION MANUAL
FOR
MANUALLY OPERATED
TCG-2500 GANGWAY
WITH SAF-T CAGE

REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 2
TABLE OF CONTENTS
Section 1) ….…………………………………………….…………………………………………………………………. INTRODUCTION
Section 2).…………………...……………………………………………………………………………….....PRODUCT DESCRIPTION
Section 3) ………………………………………………………………………………………………………………..SAFETY LANGUAGE
Section 4) …………………………….……………………………………………………………………………………………. OPERATION
Section 5) ………………………………….……….……………………………………………………….…………TROUBLESHOOTING
Section 6) ……………………………….…………..….……………………………………………………………………. MAINTENANCE
Section 7) ……………………………….….……...………………………………………………………. INSTALLATION AND SETUP
Section 8) …..….……………….….…...……..….…………………….……………SPECIFICATION SHEETS AND DRAWINGS

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1) INTRODUCTION
a) PLEASE READ THIS FIRST PRIOR TO INSTALLATION OR OPERATION
i) On behalf of Sam Carbis Solutions Group LLC., thank you for your purchase of our safety equipment. It is our
pleasure helping you with all your fall protection and product handling needs. We value our customer
relationships and to ensure you get the most out of your equipment, our experienced support team is
available for you to contact throughout your equipment service life. While this manual fully covers our
product, if you should you have any questions or concerns please contact us at 1-800-948-7750 or 1-843-
669-6668 for international customers.
ii) Please carefully read this Installation, Operation, and Maintenance Manual as it is an integral part
of your purchased Carbis equipment. It is the Owner’s responsibility ensuring all personnel who operate
and or maintain the Carbis equipment first receive comprehensive training. It is also the Owner’s
responsibility ensuring appropriately documented maintenance and inspection activities are, including any
abnormal operating condition and its associated root cause evaluation, followed by corrective actions
implemented to eliminate recurrence. Any identified abnormal operating conditions should be cause for
discontinuing use until contacting Sam Carbis Solutions LLC for further assistance.
iii) With aging of equipment and associated service life-limiting variables, such as corrosion, fatigue, wear,
etc., remedy these discrepancies as soon as possible during periodic maintenance to preclude operational
failure.
iv) This manual provides guidance to operating and maintenance personnel in the matter of safe
operation and recommended practices. However, it is not, and cannot be, a substitute for well-trained
personnel. Great reliance must be placed upon the knowledge, background, and experience of the
operating and or maintenance personnel with this manual serving as a guide. Willfully or inadvertently
disregarding the information contained in this equipment manual automatically voids the warranty.
v) This product was inspected prior to shipment and meets Carbis’ Quality Control Standards. It is important
to completely review the information contained in this manual before operating the unit including the
following:
1) Upon delivery, inspect the equipment for shipping damage or any loose or missing hardware. All
factory installed fastening hardware has been tightened prior to shipment. If loosening any fastening
hardware whether factory or field installed, re-tightened accordingly before use.
vi) It is imperative operating and maintenance personnel prior to using the equipment become familiar with
the safety information contained in section 3) SAFETY LANGUAGE.
vii) Visually inspect all safety placards, signs, and decals for serviceability, visibility, and legibility. Operating
personnel must be familiar with the contents of such placards, signs, and decals. See Section 3) b) for
SAFETY LABEL DESCRIPTIONS for the description of all safety label and signs that appear on the equipment

REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 4
described in this manual.
viii) U.S. Patents 6,814,522; 8,479,884; 8,813,912, 9,567,759; 8,745,799; 9,546,458; 8,656,556; and other patents
pending protect the equipment shown in this manual.
b) VEHICLE POSITIONING
i) Carbis designs gangways in a variety of styles, sizes, and materials accommodating specific customer-
requirements in applications including varying heights and types of vehicles. Subsequently, with each
gangway, Carbis provides customer-approved Engineering Drawings and or scope data documenting key
dimensional relationships between customer supplied vehicle information and the accessing gangway
including safety cages as applicable. Prior to operational use refer to the specific customer approved Carbis
equipment Final Drawings for familiarization with vehicle dimensional relationships in determining required
for proper vehicle positioning.
ii) Incorrect gangway positioning on top of the vehicle can cause a dangerous condition leading
to a potential for damage, serious injury or death. The access equipment when extended protrudes into
the standard vehicle clearance envelope. Always leave the gangway in the full upright stored position
until the intended underneath positioned vehicle comes to a complete stop and given proper permission
to access. Always leave the gangway stored when not in use to prevent damage from traversing vehicles.
Keep hands away from moving areas.
iii) RAIL CAR POSITIONING
With a railcar centerline considered as a fixed constant relationship with Carbis equipment, correct
gangway positioning r e qu i r e s c o r re c t operator input. Carbis’ standard gangways r eq uir e the rail
car spotted with the r a il c a r access area centered on the gangway. With Carbis’ pivoting or tracking
gangways, the rail car access area requires spotting within the gangway pivoting range of 10 degrees each
side of center. See FIGURE 1-1 below for proper vehicle positioning with Carbis’gangways. Tracking
gangways allow gangway positioning along the length of the truck.
iv) DEVIATIONS
Unexpected vehicle configuration deviations can cause a hazard even when proper positioning has taken
place. Training for hazard recognition by all operators is required for fall protection equipment (Ref: OSHA
1910.30).

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2) PRODUCT DESCRIPTION:
MANUALLY OPERATED TCG-2500 GANGWAY WITH SAF-T CAGE
SEE PROJECT-SPECIFIC DRAWINGS, FIGURES WITHIN THIS SECTION,
AND SECTION 8) SPECIFICATION SHEETS AND DRAWINGS
Only the person performing the work can operate Carbis equipment. No other personnel are
authorized to operate at any time. Failure to adhere to this caution may cause a person to fall risking injury
or damage to equipment. All other personnel should maintain a 10-foot/3-meter clearance while Carbis
Equipment is in motion.
Do not operate Carbis Equipment for any other purpose other than its intended design. Do
not modify Carbis equipment to perform beyond its factory settings. Failure to do so could cause a
malfunction possibly damaging equipment and causing injury. Contact Carbis for service.
a) MECHANICAL EQUIPMENT (SEE FIGURE 2-1.)
i) GANGWAY
The TCG-2500 Series Gangway is a manually operated, spring-assisted, articulating gangway with a foot lock
(if installed) for storage, and an adjustable platform extension providing safe access to the tops of various
types liquid rail cars of varying heights for operators to safely perform the work required on the vehicles.
1) A galvanized steel base tread that is either fixed mounted directly to a platform, horizontally pivot
mounted, or track mounted.
a) The TCG-2500 Operated Gangway requires assembly, connections, and startup before use. See
section 7) INSTALLATION AND SET UP for instructions.
b) The live load capacity for Carbis series TCG-2500 gangways including user, PPE, and any
equipment is 500 lbs./227 Kg.
2) The gangway consists of stringers that articulate about the base tread and top handrails and midrails
that pivot about the base tread uprights. The outboard uprights support the outer end of the top
handrails and midrails and serve as a support for safety cages or Seatainer treads. Walk surface
options are open serrated metal plank, fiberglass, or serrated bar grating, and noted on the Final
Drawings. Gangway material options, as designated by the letter in the model number noted on the
Final Drawings, are:
a) A –Aluminum
b) S –Mill Steel
c) P –Primed Steel
d) G –Galvanized Steel
3) A platform extension with an extension handle mounted under the main gangway walk surface, and,
where applicable, telescoping handrails are mounted on the top handrail.

REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 7
4) Stringer bottom leading edge mounted bumpers give added protection against vehicle damage.
5) A base tread foot lock (if installed) secures the gangway in the upright stored position. For
gangways without foot locks, the use of slotted chain locks secures the gangway in the stored
position. The upright stored position is typically 85 degrees above horizontal
6) For gangways without a foot lock, the use of slotted chain locks must be used to secure
the gangway in the stored position. Failure to secure the gangway could cause the gangway to
protrude into the standard vehicle clearance envelope. Gangways without a foot lock usually store
less than 70 degrees storage above horizon.
7) Stringer attached adjustable chains supported by slotted tube chain locks on the base tread uprights
hold the gangway in any desired position within the normal working range of 15 degrees above to
15 degrees below horizontal. The range may be modified within the limits to accommodate options.
8) The slotted tube design keeps the chain locked throughout the full range of gangway movement
from the lowest working position up to the fully raised stored position. The chains add strength and
stability to the equipment while allowing access to a variety of vehicles. NOTE: The chains when
correctly slotted into the chain locks secure the gangway when not in use.
9) Covered springs mounted between the uprights and the stringers provide tension adjustment to
minimize the push/pull force required to articulate the gangway
10) An attached pull-up rope aids the operator to return the gangway to the upright stored position.
11) For any gangway used in concert with elevating cages, platforms, and Modals, additional grab
rails are employed perpendicular to the outboard uprights each side of the gangway to cover
the gap created by the opening in the inboard handrail that accommodates the gangway.
12) When in the stored position, the gangway’s attached serial number is visible on the inside end of the
right stringer toe board. Note: Always reference this serial number when contacting Sam Carbis
Solutions Group with any questions or concerns.
13) TCG-2500 gangways can be equipped with an optional pivoting outboard upright and cage leveling
mechanism (see FIGURE 2-2). Mounted on the upper half of each left and right pivoting outboard
upright, the cage leveling mechanism consists of back-to-back channels: one on the gangway fixed
upright and one on the pivoting upright. Mounted between the channels is a thru threaded rod
with a series of back-to-back adjustment nuts and washers on both sides of each channel.

REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 8
FIGURE 2-1 TCG -2500 GANGWAY SIDE ARRANGEMENT
ii) GANGWAY FOOT LOCK (IF INSTALLED)
Most Carbis manual sprung gangways employ a single manually functioning foot lock. A single base tread
mounted foot lever when depressed activates the foot lock unlocking function. When lowering the gangway,
depressing the foot lever while pushing forward on the handrails extends the foot lock spring and releasing
the mechanical foot lock for the gangway to extend. The gangway locking function engages when fully raised
to the stored position.
For gangways without foot locks, the use of slotted chain locks is required to secure the
gangway in the stored position to prevent the gangway from drifting down into the standard vehicle
envelope.
iii)LIFT RESTRICTING DEVICE (SEE FIGURE 2-2)
(NOTE: Not all TCG-2500 gangways include the Lift Restricting Device)
The Lift Restricting Device (LRD™) design impedes the gangway from inadvertent or premature raising while
operating personnel occupy the top of the vehicle. The Lever Arm Release Handle design releases the LRD™
while simultaneously raising the gangway to the stored position as an operator exits the gangway. A
protective cover prevents personnel from overriding the LRD™ while on the vehicle. The LRD™ mounts
between the inner end of the top rail and the upper half of the outboard upright and consists of the following:

REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 9
1) A linear rail with ratcheting angled teeth mounted on the underside; the rail is pinned on one end to
a lug supported on the top rail of the gangway by double U-bolts. The opposite end of the rail slides
into an extension tube pinned to a support bolted to the outboard handrail of the gangway.
2) Pinned to a lug mounted on the underside of the linear tube is a ratcheting pawl with a pivoting catch
engaging a tooth of the linear rail and holding the gangway in place, impeding gangway lift.
3) The LRD™ Lever Arm Release Handle design actuates by a pull-up rope supplied with the LRD. The
Release Handle mounts on the LRD™ ratcheting pawl. Pulling the pull-up rope pulls the handle
towards the platform causes the ratcheting pawl to pivot, releasing the catch from its engagement
with the rail gear tooth and raises the gangway to the stored position with the LRD™ pull-up rope.
FIGURE 2-2 (4 Step LRD™)
b) MODIFIED GANGWAY
i) For any modified gangway including the addition of ancillary components not otherwise identified above,
see project-specific drawings that reflect the modification or addition.
ii) SAF-T CAGE (IF INSTALLED)
1) The Cage is an aluminum structure bolting directly to the gangway outboard upright. The cage is
specifically designed to supplement railcar crash box rail heights to achieve as close to 42” as
measured from vehicle walk surface. The cage can bolt in either the high or low position as
determined by customer site-specific needs (See figure 2-2).

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FIGURE 2-3 TCG-2500 GANGWAY WITH OPTIONAL CAGE LEVELING SYSTEM
2) For gangways without a cage, post gangway protection is the responsibility of the
owner. The employer must provide for prompt rescue of each employee in the event of a fall. The
employer must have a rescue plan in the event of a fall occurring and the ability to implement a
rescue. See OSHA 1910.140 and ANSI/ASSP Z359.2 for guidelines on fall protection system.
c) OPTIONAL TCG TRACK AND CARRIAGE WITH TCG-S910.1 TRACK LOCK MECHANISM (SEE FIGURE 2-4 AND
FIGURE 2-5)
i) The galvanized steel track and carriage system includes the following features:
1) A track assembly integrated to a platform structure or as a separate assembly bolting to the face of
a fixed platform structure.
2) A carriage mounted gangway base tread that rolls on the track assembly.
3) A track top section capturing the top rollers with the bottom section supporting the carriage rollers.
4) A removable stop inserted through the top surface end holes preventing the carriage from rolling
past the track ends.
5) The main carriage assembly consists of a plate weldment with top and bottom rollers mounted
at each end. The top rollers ride on the vertical inside track leg and the bottom rollers ride along
the bottom outside face of the carriage mounting plate and are bolted to the backside of the
gangway.
6) Rolling carriage assemblies consist of shaft-supported rollers mounted on base tread mounting
plate.