GKD 3RCI User manual

M3000004 v1.2
Covering both Standard and SpaceGuard Systems - V6 to V8 soware only
3RCI Quick Start Guide

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Operator Display Guide
1Foreman Key
switch
Machine Controllers Switch (Foreman’s key switch) allows or denies access to the
user sengs and service menus. Used when there are slew and height limits in
use to avoid accidental changes by the operator.
2
3
4
5
Display Touchscreen colour display which provides user informaon and control of the
system.
Overload
warning LED RED LED illuminates to show when the machine is in an overload condion.
Rated Capacity
warning LED
AMBER LED illuminates to show when the machine is approaching the rated ca-
pacity and overload condion.
System power
Comms OK GREEN LED ashes connuously to indicate power and system operaon.

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Operator Display Guide connued...
1
2
3
4
5
6
ALO Symbol
3RCI SpaceGuard Systems that are cered to work Adjacent Line Open will show
the symbol “ALO √”, 3RCI systems that are not cered to work Adjacent Line
Open, or approved systems without operaonal slew limits or virtual walls, will
show “ALO X”.
In-gauge Shows green when the machine is within gauge to travel. Will also show red
when a slew limit is exceeded or a height limit is exceeded.
Dig Mode If the system is in dig mode this icon shows green and the moon cuts and
alarms on overload are disabled, the blue beacon is not illuminated.
Height Height of li point from ground level (road mode) or rail head (rail mode).
Acve Li
Point
The current acve li point is shown here. Possible opons are BP (Bucket Pin),
ALP (Auxiliary Li Point), QH (Quick hitch), or TLJ (demountable Tele-jib).
If nothing shown here then only one liing point is enable (Bucket Pin).
Radius Radius of current li point from the slew centre of the machine.
1
2
3
4
5
6
78910 11 12 13
14
15
16
1718
Load Displays the current load on hook. This will include any aachments and the
quick hitch.
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Logging
This icon shows the status of the onboard data logging system. There are four
states for the icon. 1) Not shown - logging is disabled. 2) Logging icon - no events
recorded but Logging On. 3) Exclamaon mark - Logging is on and an event has
been recorded. 4) Logging symbol with red cross - Log is inoperave or card full.
Operator Display Guide connued...
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9
10
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12
13
14
15
16
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Status Bar This area shows machine informaon, error messages and current date and me.
Rated Capacity
Shows the maximum permied load for the current height an radius.
Note: when an * appears against this number, it will indicate that either the
machine is in hydraulic limit or the rang displayed is the maximum based on the
hydraulic limitaons of the machine.
Speed Shows the current speed of the machine in MPH.
Duty Indicator This symbol will indicate whether the RCI is switched to Rail dues, Road dues
or LUL (London Underground) dues.
Slew Shows the current slew angle in degrees. 0° is typically over the oscillang axle.
Menu buon
Allows access to user and service funcons.
Note: if the machine controllers key switch is o then the system will not allow
access to service menus or limit funcons.
RCI Status Bar
This bar lls from boom to top and provides a visual reference of the
relaonship between the applied load and the rated capacity. A warning will
occur between 92.5% and 97.5% of the rated capacity. This warning is an AMBER
LED and an audible alarm on the cab. If the applied load should exceed 104% of
the rated capacity then the RED LED is lit and a connuous external siren is
sounded. The machine will then be inhibited to prevent further unsafe
movements.
Axle Lock Icon
Shows the current state of the axle lock. A locked padlock indicates that the axle
locked, an unlocked padlock indicates that the axles are unlocked, and an
unlocked padlock with a cross through it indicates that the axles cannot be
unlocked as it is unsafe to do so as it would put the machine into an overload
condion.
Cant /
Gradient
Shows the current cant and gradient of the machine (rail dues only). Cant will
show as posive (right hand rail high at 0° of slew) or negave (right hand rail low
at 0° of slew), and gradient will show as posive (facing up gradient) or negave
(facing down gradient).
Movement
indicators
These arrows indicate the safe direcon each piece of equipment can be moved.
GREEN indicates movement is safe. RED indicates movement is unsafe.
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Operator Display Guide connued...
Daily Checks
Before starng work, visually inspect the RCI sensors and wiring for damage, ensure that the RCI system is
in good working order and that the values for height, radius, slew posion and load shown on the RCI are
valid. Please refer to the User manual for daily check requirements.
System Start - Up
The 3RCI system should automacally start up when the ignion is turned on. Inially a green LED on the
front panel will blink on and o to indicate that the system is boong up, and then the screen will power
up. Once started up, the internal buzzer will sound connuously unl the operator acknowledges the
system by pressing the “OK” buon. The operator will then need to input his 8 digit PTS number. Where
the operator has a 6 digit Sennel card number, it is suggested that two zeros are typed in rst, followed
by the 6 digit Sennel number. The system will then go to the working screen shown on page 5.
Foreman Key
The RCI display incorporates a foreman key switch to the right of the display. When this key switch is in
the “Locked” posion, most of the buons behind the [MENU] buon will be greyed out and unavailable.
To make them available, turn the foreman key switch to the “unlocked” posion.
Li Point Selecon
Where mulple li points are available, the li point being used should be selected from the opons
programmed into the RCI. The acve li point is shown on the main screen under the Height value (see
item 5 on page 5). To change the acve li point, press the [MENU] buon, and cycle through the
available calibrated li points using the boom le buon.
Possible opons are:
 BP (Bucket Pin)
 ALP (Auxiliary Li Point)
 QH (Quick Hitch)
 TLJB (demountable tele jib)
Only those opons enabled within the soware will be available. Selecng the incorrect li point will not
compromise the safety of the system, but height, radius and load values may be inaccurate.

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Operator Display Guide connued...
Liing a load
As a load is lied, the Load on Hook value as displayed on the screen (item 7 on page 5) will show the
weight of the load suspended from the hook. This load is compared to the Rated Capacity (item 9 on
page 5), the calculated value that the machine is allowed to li before an “overload” event occurs, and
the status bar (item 14 on page 5) will ll proporonal to the % of the Rated Capacity currently being
used. As the machine changes posion in terms of height, radius, cant, gradient or slew angle, the Rated
Capacity is connuously recalculated. Axle lock status and Road, Rail or LUL duty changes will also aect
the Rated Capacity value.
Overload
As the RCI detects that the Load on Hook value is approaching the Rated Capacity, the AMBER LED on the
side of the RCI display will light up and the internal buzzer will sound. As the Load on Hook value reaches
the full Rated Capacity value, the RCI will register an Overload state, which is signaled by the RED LED
being lit and the external pping alarm sounding. At the same me, any hydraulic service which will take
the machine further into overload will be cut, and the RCI screen will change the colour of the arrows
represenng available hydraulic services from green to red for any service that has been moon cut.
Any hydraulic service that will result in the load moving to a safer posion will sll be allowed, and the
arrows on screen represenng these services will stay green to signify that the services are sll available.
Axle Lock
The machine’s Rated Capacity will generally be lower with the oscillang axle unlocked than when it is
locked. When working with a locked axle (stac li) and a li and carry duty is required, the axle must be
unlocked. The RCI will monitor the Rated Capacity for both locked and unlocked dues, and if unlocking
the axle will put the machine into overload, the axle unlock signal will be interrupted by the RCI and the
axle will not be allowed to unlock. The axle lock symbol on screen will change to an unlocked padlock
with a red X through it, and the axle will remain locked unl the load is moved to a posion where the RCI
will not be in overload with the axle unlocked. At that point, the axle unlock interrupt will be released and
the axle will be allowed to unlock.
Travel Inhibit
The RCI will inhibit travel under the following condions:
 When the machine is in an overload state.
 When the axle is locked.
 When a height limit has been reached.
 When the air pressure is detected as being low (air brakes).

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Operator Display Guide connued...
Dig Mode
When the machine is not being used as a crane, it may be permied for the system to operate in DIG
mode. In DIG mode all overload warnings and moon cut on overload is turned OFF, and no protecon
against overload will be present. The blue light on the roof will be turned o, and where red / white
indicator lamps are present the white lamp will switch OFF and the red lamp will switch ON. The data log
will record the use of DIG mode. In order to use DIG mode, the foreman key switch must be in the
unlocked posion.
To engage DIG mode, press the [MENU] buon, and press the [DIG IS OFF] buon. DIG mode will then be
turned on. The main screen will indicate that DIG mode is engaged by turning the DIG mode indicator to
green (item 3 on page 5), a yellow circle with an alarm symbol with a cross will be shown next to the
logging symbol top right of the screen and LOGGING DIG MODE will ash in the status bar (item 8 on
page 5).
To turn DIG mode o and return to LIFT mode, press the [MENU] buon and then press the [DIG RAIL
MODE] buon at the top right of the screen.
Backward Stability
The RCI system will monitor the state of the machine to prevent the machine falling over backwards
when working on a cant. With a reduced load on the hook and when working on a cant of more than
50mm with the turret facing up the cant, the RCI may restrict the movement of the stub boom back.
When the maximum boom angle is achieved in a potenally backwardly unstable condion the stub
boom li funcon will be moon cut and a “backward stability” message will be shown. If the boom is far
enough back to trigger a backwardly unstable condion and the machine is slewed towards a potenally
backwardly unstable condion, the “backward stability” message will be shown and the slew funcon
will be cut to prevent the machine reaching a backwardly unstable posion. To rotate the turret further,
lower the stub boom unl the message disappears and slew funcon is restored.
Height Limits
In order to set a height limit, the foreman key switch must be in the unlocked posion.
To set a height limit, press the [MENU] buon and then press the [HEIGHT LIMIT is o] buon.
The system will ask if you wish to Enter a height limit. To enter a height limit (in meters) press [YES].
To capture a height limit from the excavator current boom posion, press [NO] and you will be prompted
to move the excavator to the desired height limit and press [YES]. A height limit will be set that
corresponds with the highest point of the excavator at the moment it was set. Once set, the RCI will
monitor all booms against the set height limit, and will moon cut any hydraulic service that will cause a
boom to move through a set height limit. Services that cause machine movement away from the height
limit will always be allowed.
To turn o a set height limit press [MENU] and the [HEIGHT LIMIT IS ON].
The height limit will be turned o.

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Operator Display Guide connued...
Height Limit connued…
When a height limit is set, you will see the following on the operator main screen.
Angular Slew Limits
In order to set a slew limit, the foreman key switch must be in the unlocked posion.
To set angular slew limits, press the [MENU] buon and then press the [Slew Angle is o] buon.
The system will ask if you wish to enter slew limits. To enter slew limits (in degrees) press [YES].
To capture slew limits using the excavator turret posion, press [NO] and you will be prompted to move
the excavator to the desired clockwise limit posion and press [YES], and then to the desired counter
clockwise posion and press [YES] again. Slew limits will be set as captured from the turret posion
relave to the undercarriage. Once set, the RCI will monitor turret posion against the set limits, and will
moon cut the appropriate hydraulic slew services the limit is reached. Slewing away from the set slew
limit will always be allowed.
To turn o a set slew limit press [MENU] and then [SLEW ANGLE IS ON]. The slew limits will be turned
o.
When a slew limit is set, you will see the following on the operator main screen.
Current highest point
of the machine.
Current set
height limit.
Current counter
clockwise limit.
Current clockwise
limit.

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Virtual Walls
In order to set a slew virtual wall, the foreman key switch must be in the unlocked posion.
To set a virtual wall, press the [MENU] buon and then [VIRTUAL WALLS OFF]. To set the LEFT wall
distance, press [LEFT]. To enter the value for the le wall, in meters from the machine centre, select
[YES]. Alternavely, to capture the wall distance from the bucket pin posion press [NO], move slew le
of 0° of slew and posion the bucket pin at the desired le limit and press [YES]. The right wall is set in
the same way, but slewed to the right of 0° of slew to capture the wall posion. Select either LEFT, RIGHT
or BOTH to acvate the virtual wall/s as required.
To turn the virtual walls o, press the [MENU] buon and then [VIRTUAL WALLS ON], select CANCEL.
Virtual walls will then be turned OFF.
When a slew limit is set, you will see the following on the operator main screen.
Operator Display Guide connued...
Current le
Virtual wall distance
Current right
Virtual wall distance
Distance from bucket
pin to virtual wall
Tandem Li Duty
In order to use Tandem Li, the foreman key switch must be in the unlocked posion.
When using the machine as one of a pair of machines liing a load together, the Tandem Li mode must
be engaged. The eect of the Tandem Li mode is to reduce the li capacity of the machine to provide an
addional safety margin before an overturn occurs, as dictated by Network Rail Tandem Li guidelines.
To engage Tandem Li mode, press [MENU] and then [Tandem is o]. Tandem Li mode will be engaged,
the machine’s li capacity will be recalculated in line with Tandem Li regulaons, and on machines
cered to RIS1530 rev4 and above the blue RCI indicator lamp on the cab will blink on and o at 2
second intervals.
To turn Tandem Li mode OFF press [MENU] and then [Tandem is ON]. Tandem Li mode will be turned
o and the machine li capacity will return to standard li dues.

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SpaceGuard and Safety Mismatch
If a SpaceGuard equipped RCI system detects a mismatch between the primary angle / slew sensors and
the Safety angle / slew sensors, a Safety Mismatch warning is displayed. The mismatch is oen related to
the slew count sensors, and slewing the machine back over the reset sensor at 0° of slew may well clear
the fault. If not, inspect the angle sensors for possible mechanical damage. If a fault sll exists,
an engineer visit may be required.
Troubleshoong
The 3RCI system connuously monitors the system components for correct operaon. In the event that a
problem is detected with the system, the li capacity is reduced to 700kg and an error message is
displayed next to the [MENU] buon indicang the nature of the error detected. In the event that more
than one error is present, only the top line error is indicated. Pressing the [MENU] buon and selecng
the [MORE] tab will bring up a list of all detected errors on the system.
Below is a link to the GKD Knowledge base where you can nd denions of all the error codes for the
3RCI System including SpaceGuard.
helpdesk.gkdtechnik.com/kb
GKD Contact Details
Contact GKD Technologies on:
[phone]
[phone]
[e-mail]
www.gkdtec.com
GKD Technologies reserve the right to change these instrucons in line
with the policy of connuous improvement.
Operator Display Guide connued...