GKD 3RCI User manual

M3000001 v1.4
Covering both Standard and SpaceGuard Systems
3RCI User Manual

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GKD Technik LtdM3000001
Issue Date Changes Job
v1.0 23/10/2013 New issue for V8 3RCI
v1.1 11/11/2013 Add swing / swivel boom informaon and “Limit Set” orange beacon
(SpaceGuard)
v1.2 18/11/2013 Add “Beyond Limit” feature / screen
v1.3 23/02/2016 General update and reformat of enre document
v1.31 11/03/2016 Added system layouts and made amendments
v1.4 20/11/2017 Updated to new branding and part numbers
Change History

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GKD Technik LtdM3000001
Contents
Change History 2
Page no
Introducon
Warning
Backwards Stability
In-gauge indicator
SpaceGuard
5
5
5
5
5
6
7
10
System Layout
Daily Checks
10
10
10
11
11
12
13
Switching On
External Indicator Beacons
On/O Tracking and Rail Gear Interlocks
Moon Cuts
13
13
14
15
18
20
Touchscreen
Operaon
Auto-diagnoscs
Denions
Axle Lock
Drive Cut
User Sengs
Height Restricon
Slew Restricon
Virtual Walls
Exceeding Set Limits 21

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Contents - connued...
22
Page no
22
23
23
23
24
24
25
28
Calculator
Dig Mode
Backward Stability
Li Point Selecon
Override Key Switch
Oset Boom / Swing Boom Machines
Stub Release
SpaceGuard System
Troubleshoong
System Layouts
30

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GKD Technik LtdM3000001
Introducon
The GKD rated capacity indicator is an integrated road-rail rated capacity indicator system.
The system incorporates state of the art sensing and processing to provide audible and visual warning
plus machine control signals. This manual applies to GKD 3RCi systems version 8 only.
Informaon contained in this instrucon guide may not apply to previous versions.
This manual covers both 3RCI and 3RCI SpaceGuard variants of the system.
Warning
During normal operaon the SWL (Rated Capacity) of a crane should not be exceeded. Therefore the
warning of overload should not be used as a normal operang facility. It should be noted that certain
statutory requirements do not permit the safe working load to be exceeded except for the purpose of
tesng.
THIS RCI IS NOT SUITABLE FOR USE IN EXPLOSIVE ATMOSPHERES. ADJUSTMENT BY UNAUTHORISED
PERSONS WILL INVALIDATE ANY WARRANTY OR CERTIFICATION SUPPLIED. IF A PROBLEM ARISES
WHICH CANNOT BE RECTIFIED USING THESE INSTRUCTIONS, AUTHORISED SERVICE SHOULD BE
SOUGHT.
THIS DEVICE IS CERTIFIED TO MEET CURRENT UK & EC SAFETY REGULATIONS FOR EXCAVATORS USED
AS CRANES, AND IS COMPLIANT WITH RSSB STANDARD RIS-1530-PLT Issue 4.
3RCI SPACEGUARD IS CERTIFIED TO MEET THE CONDITIONS OF NETWORK RAIL REMIT MLD-R003 FOR
MOVEMENT LIMITING DEVICES WORKING ADJACENT LINE OPEN AND UNDER LIVE OVERHEAD CABLES,
PROVIDED IT HAS BEEN INSTALLED AND CONFIGURED IN ACCORDANCE WITH GKD INSTALLATION AND
CALIBRATION INSTRUCTIONS, IS USED IN ACCORDANCE WITH THE GKD OPERATING INSTRUCTIONS,
AND IS SUBJECT TO REGULAR TESTS TO ENSURE CORRECT OPERATION.
Backwards Stability
The working condions of these machines mean it is possible under extreme situaons of cant and
gradient to p the machine over backwards. In parcular this may occur with high boom angles when
working up the gradient or with the counterweight down the cant. The GKD indicator automacally
monitors for backward stability when working on rails. The system has two levels of protecon, 50 mm
and 150 mm cant. In the event of a backward stability warning being shown, do not remove any load
from the machine unl it has been returned to a safe posion.
In-gauge indicator
The indicator includes an aid to drivers with an in-gauge warning. This is designed as a guide only and will
not take into account any aachments or modicaons made to the machine. The operator must check
the machine suitability to travel parcularly for height. No liability is accepted for any damage or
consequenal loss caused by travelling this machine with or without the in-gauge indicator.
SpaceGuard
3RCI SpaceGuard systems can be cered to work under OLE and system 1,2 and 3 ALO condions.
It is the responsibility of the operator to ensure that the system is fully operaonal and that the
dimensions of any load or aachment is taken into account when seng limits. In operaon, the slew
speed of the machine should never exceed 2 meters per second measured at the bucket pin when a slew
limit or virtual wall is set.

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GKD Technik LtdM3000001
Denions
An arculang boom is a boom comprised of two pieces with a
hydraulically adjustable centre secon.
Arculated Boom
A liing operaon where two machines are used to li a heavy or
large load. The liing capacity of the machines is reduced to increase
the safety margin.
Tandem Liing
When towing with the RRV, any loss of hydraulic brake pressure will
be detected by the 3RCI and an alarm and error message will occur.
Trailer Breakaway
Height of bucket pin measured from the virtual plane created by the
supporng wheels. This height may not correspond to the measured
height between the ground and the bucket pin when operang on
canted and gradient rail.
Height
Radius is dened as the horizontal distance between the slew centre
line and the bucket pin. This is the slew centre line measured at the
joint between the upper and lower machine structure.
Radius
A planning chart comprises of a series of charts giving rated load
capacity of the excavator at dierent radius and heights. This
informaon is used to determine that the machine is capable of
performing the liing operaon.
Planning Chart
The maximum load that may be lied at the current radius and
height. The weight is shown in tonnes. This is usually determined
as a percentage of the load that will p the machine.
Rated Capacity
The angle measured in degrees that the turret is posioned referred
to the zero slew point. Zero slew angle is when the turret (and
operator) is facing the oang axle and direcon of travel of the
machine.
Slew Angle
Safe Working Load. Term which has been replaced by Rated Capacity.
S.W.L.
Undercarriage Module. The signal processing system on the lower
half of the machine. Located adjacent to the slew ring.
UCM
External module providing inputs, outputs or addional processing.
Typical installaons may use four or ve modules in total.
Module
A wheel upon which the load is reduced from the normal balanced
status of the machine.
Unloaded Wheel
During the on-tracking or o-tracking operaon it is possible to have
a situaon where there is no rail wheel braking and a potenal
uncontrolled runaway may occur. To avoid this dangerous situaon
the 3RCi can be congured to control the rail gear deployment.
Rail Gear Interlock

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GKD Technik LtdM3000001
System Layout
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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System Layout 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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GKD Technik LtdM3000001
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.
System Layout connued...
8
9
10
11
12
13
14
15
16
17
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 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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Operaon
Auto-diagnoscs
During the start up procedure, and during normal operaon, the system performs constant checks on all
inputs and systems to ensure that the data is within prescribed limits. If an input data is in error then the
system will issue a warning. Depending on the severity of the error, the system may connue to operate
at a de-rated performance or forbid further operaon. The system may request the operator to slew
through the zero reset. (Over the front of the machine). The operator will be required to acknowledge
the message to remove the warning.
Daily Checks
Before operang this system the operator should check the following on a daily basis:
 Visually inspect the angle sensors and pressure sensors for damage or misalignment.
 Visually inspect angle sensor and pressure sensor cables for damage and proper connecon.
 Visually inspect the rail gear detecon switches and cabling (if ed).
 Start the machine allow RCI to complete start-up procedure. Note any errors and call service if
required.
 Raise boom and then slew through 360 degrees to ensure the slew counts correctly and allow a
reset of slew to be carried out (Important if machine has been idle for a long period of me).
Ensure the slew counts in both direcons.
 Operate the booms and verify that the height and radius displayed on the screen correspond with
the actual height and radius to the selected li point, and that the displayed height and radius
change as appropriate when the booms are moved.
 Select the MENU screen and press the TEST tab, and then press the alarm test buon. The external
indicator lamps and alarms should be acvated one by one in sequence as reported on the 3RCI
screen. Verify that they all work as expected.
For SpaceGuard systems the following checks should be carried out, in addion to those listed above,
prior to commencing works in a restricted area. These checks should form part of a pre-use work
procedure which should be signed by the operator and witnessed by a competent person.
 Set a height limit. Operate the machine at full speed to aempt to exceed the height limit.
 Set slew limits. Operate the machine at full speed to aempt to exceed the slew limit.
 Set virtual wall limits. Operate the machine at full speed to aempt to exceed the wall limits.
Touchscreen
The 3RCi system uses a colour touchscreen for control of the indicator funcons. The touchscreen is
designed for use by nger or gloved hand or with an approved stylus.
DO NOT ATTEMPT TO USE ANY SHARP OR HEAVY ITEMS TO OPERATE THE INDICATOR.
USE OF UNAUTHORIZED OBJECTS MAY SCRATCH THE OVERLAY OR DAMAGE THE SCREEN GLASS AND
THIS DAMAGE WILL NOT BE COVERED UNDER WARRANTY.