Sam carbis solutions group, llc Tcg-2500 User manual

INSTRUCTION MANUAL

FOR

MANUALLY OPERATED

TCG-2500 GANGWAY

TABLE OF CONTENTS

Section 1)…..…………………………………………….………………………………………………………………….READ THIS FIRST

Section 2)..…………………...……………………………………………………………………………...................INTRODUCTION

Section 3)………………………………………………………………………………………IMPORTANT SAFETY INFORMATION

Section 4)…………………………….…………………………………………………………………………..PRODUCT DESCRIPTION

Section 5)…………………………………..……….……………………………………………………….……………………….ASSEMBLY

Section 6)………………………………..………….…..………………………………………………………………………….OPERATION

Section 7)………………………………..….……...………………………………………………………………………...MAINTENANCE

Section 8).…..………………..….…...…..….…..………………………………………..EXTENDED INSPECTION ADDENDUM

Section 9)…...……………...…….….…………………………………………..MANUAL BRAKE ADJUSTMENT ADDENDUM

Section 10)……….………………………….…….……….……………………….………..LIFT RESISTING DEVICE ADDENDUM

Section 11)……………..……………….…………………………………………………………DRAWINGS AND SPECIFICATIONS

1) READ THIS FIRST

a) GENERAL

i) This Installation, Operation, and Maintenance manual is considered an integral part of the Carbis

equipment to which it applies. It is the Owner’s responsibility to ensure that personnel who operate and

maintain the Carbis equipment receive comprehensive training in the operation and maintenance of the

equipment, including adjustments where required. Operating and Maintenance personnel must also be

familiar with the basic characteristics of the equipment so as to avert errors that might result in equipment

damage or personnel injury. It is also the Owner’s responsibility to ensure that maintenance activities are

appropriately documented, including any abnormal operating condition and its associated root cause

evaluation, followed by corrective actions implemented to eliminate recurrence.

ii) Aging of equipment and associated service life-limiting variables, such as corrosion, fatigue, wear, etc.,

must be remedied during maintenance periods to preclude operational failure.

iii) While this manual provides guidance to operating personnel in the matter of safe operation and

recommended practices, it is not, and cannot be, a substitute for well-trained operations personnel. For a

successful and trouble-free operation, great reliance must be placed upon the knowledge, background,

and experience of the operating personnel, with this manual serving as a guide. The warranty on the

equipment is automatically voided if the information contained in this manual is disregarded, whether

inadvertently or willfully.

b) VEHICLE POSITIONING

i) Carbis gangways are designed in a variety of standard styles, sizes, and materials to accommodate

customer-specific requirements in applications that include varying heights and types of vehicles.

Subsequently, with each gangway, Carbis provides customer-approved Engineering Drawings and/or scope

data that document key dimensional relationships between the vehicle and the gangway, including safety

cages where applicable. Refer to the specific customer-approved Final Drawings for familiarization with

the dimensional relationships between Carbis equipment and the vehicle to determine the necessary steps

required to position the vehicle for proper operation.

ii) RAIL CAR POSITIONING

With the centerline of the rail car being a fixed, constant relationship with Carbis equipment, the only

remaining position that requires operator input is the position of the rail car along the length of the track.

With Carbis’ standard gangways, the rail car is generally spotted with the access area centered on the

gangway. With Carbis’ pivoting or tracking gangways, the rail car is generally spotted with the access area

contained within the pivoting or tracking range of the gangway.

iii) TRUCK POSITIONING

See the specific customer-approved Final Drawing and/or scope data for the dimensions required to spot

the truck for proper operation. Given the portable nature of the truck, the proper spotting is largely

determined by the skill of the truck driver; therefore, the use of visual spotting aids such as bollards, curbs,

painted guide lines, suspended markers (i.e., tennis balls), etc. can enhance the driver’s skill in spotting the

truck. See FIGURE 1-1 below for the effects of variable truck spotting positions.

FIGURE 1-1

2) INTRODUCTION

This product has been inspected and meets Carbis’ Quality Control Standards. It is important that the information

contained in this manual be reviewed before operating the unit, including the following:

a) Inspect equipment upon delivery for shipping damage or loose bolts. All fastening hardware that has been

factory installed has been done so to remain tight. If any fastening hardware, whether factory or field installed,

has been loosened, it must be tightened before using the product.

b) It is imperative that operating and maintenance personnel become familiar with the safety information

contained in section 3) IMPORTANT SAFETY INFORMATION.

c) Check that all safety placards, signs, and decals are clearly visible, legible, and in good repair. Operating

personnel must be familiar with the contents of such placards, signs, and decals. See section 3) v) for SAFETY

SIGN DESCRIPTIONS for the description of all safety signs that appear on the equipment described in this

manual.

d) AVOID PROBLEMS WITH STAINLESS STEEL BOLTS. Keep bolts and nuts free of grime and

other contaminants that may get into threads. Lubricate stainless steel bolts and nuts prior to tightening. Avoid

the use of impact speed wrenches. If one is used, a slower speed will allow heat to dissipate as the connection is

tightened.

NOTICE

3) IMPORTANT SAFETY INFORMATION

a) GENERAL

This section is a compilation of all of the various hazards and safety messages relative to the equipment

described herein and as depicted on the drawings. Some are duplicates of safety messages used in various

sections throughout this manual, while others appear only the one time in this section. The hazards shown in

this section are listed in order of greatest to least risk as DANGER, WARNING, CAUTION, and NOTICE, identified

as follows:

i) DANGER: Indicates a hazardous situation that, if not avoided, will result in death or serious injury.

ii) WARNING: Indicates a hazardous situation that, if not avoided, could result in death or serious injury.

iii) CAUTION: Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

iv) NOTICE: Indicates information considered important, but not hazard-related (e.g., messages relating to

property damage).

b) HAZARDS

Following are the safety messages grouped by hazard as used throughout this manual:

(1) This equipment CAN conduct electricity.

(a) Any grounding that may be required is to be performed per the owner’s safety code.

(b) Do NOT allow this unit to come in contact with live electrical wires.

Failure to comply with these warnings WILL result in serious injury or death.

ii)

(1) Correct vehicle positioning and proper deployment of Carbis equipment are imperative to its

function. Incorrectly positioned vehicles, or improper use of this equipment, increase the risk of

serious injury or death. Carbis equipment is designed to function only as described in the manual

and depicted on the drawings. IT IS THE SOLE RESPONSIBILITY OF THE OWNER TO ENSURE PROPER

USE OF CARBIS EQUIPMENT.

(2) Before accessing Carbis equipment, a vehicle must be in the correctly spotted position and the

Carbis equipment properly deployed, supported, and secured.

(3) Personnel must not access Carbis equipment during any controlled operation.

(4) Nonessential personnel must stay clear of Carbis equipment during any controlled operation.

DANGER

WARNING

(5) Operator must be certain that nonessential personnel are clear of Carbis equipment during any

controlled operation.

(6) Operator must not place Carbis equipment in motion while occupying the same equipment.

(7) Carbis equipment must never be forced, by any means, to overcome any seen or unseen obstacle or

obstruction.

(8) Keep hands clear of chains while gangway is in motion.

(9) If the equipment will not function as intended, discontinue use and contact Maintenance

immediately.

(10) Never make repairs of damaged or missing parts. Replace missing parts only with approved equal

parts.

(11) Material being loaded onto/into vehicles or unloaded from vehicles may present a health hazard. It

is the sole responsibility of the owner to ensure that operating personnel are familiar with any

hazards associated with the material, and to implement the appropriate safety measures to protect

personnel against such hazards.

Failure to comply with these warnings COULD result in serious injury or death.

iii)

(1) Read this manual carefully before unpacking or installing Carbis equipment.

(2) Only qualified personnel in good physical condition, trained in the proper operation of this

equipment, should be permitted to operate it.

(3) Appropriate Personnel Protective Equipment (PPE), such as gloves, safety glasses, safety shoes, etc.,

should be worn at all times during operation of this equipment.

(4) For chain-supported Carbis gangways, both chains must be properly and equally engaged in the

chain locks to support the gangway before accessing. Slack or unequal chain adjustment may result

in unanticipated movement and loss of balance when standing or walking.

(5) For operator safety, equipment should be stored and not used if wind speed exceeds Carbis’

recommended safe working wind speed limit of 35 mph.

Failure to comply with these cautions COULD result in personnel injury or damage to equipment.

iv)

(1) The gangway assembly ships with the chain links engaged in the slots of the chain locks to hold the

gangway secure in the stored position. Do not disengage the chain links from holding the gangway

secure in the stored position until after the gangway base tread has been securely installed.

v) SAFETY SIGN DESCRIPTIONS

Following are the descriptions of the safety signs that appear on the equipment described in this manual.

CAUTION

NOTICE

AL-156

AL-159

AL-157

AL-027-99

AL-305

AL-163

AL-162

AL-160

4) PRODUCT DESCRIPTION:

MANUALLY OPERATED TCG-2500 GANGWAY

SEE PROJECT-SPECIFIC DRAWINGS, FIGURES WITHIN THIS SECTION,

AND SECTION 11) DRAWINGS AND SPECIFICATIONS

a) GENERAL

The TCG-2500 Series Gangway is a manually operated, spring-assisted, articulating gangway that provides safe

access to the tops of various types of truck and rail car vehicles of varying heights for operators to safely

perform the work required on the vehicles within fall protection enclosures that are typically associated with the

gangway.

i) The TCG-2500 Series Gangway requires assembly before use. See section 5) ASSEMBLY for instructions.

ii) The load capacity for Carbis series TCG-2500 gangways is 500 lbs.

b) MECHANICAL EQUIPMENT

See FIGURE 4-1 below.

i) GANGWAY

The TCG-2500 Series Gangway includes the following features:

(1) A galvanized steel base tread that is either fixed mounted directly to a platform, horizontally pivot

mounted, or track mounted

(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 are so 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

(d) G – Galvanized Steel

(3) A platform extension with an extension handle is mounted under the main gangway walk surface,

and telescoping handrails are mounted on the top handrail.

(4) Bumpers mounted on the bottom leading edge of the stringers give added protection against vehicle

damage.

(5) A foot lock mounted on the base tread holds the gangway in the upright stored position. For

gangways without foot locks, the use of chains noted below are required to hold the gangway in the

stored position.

(6) Adjustable chains that are attached to the stringers and 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. 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 a variety of vehicles to be

accessed. The chains should be used for overnight or long-term storage of the gangway.

(7) Covered springs mounted between the uprights and the stringers provide tension adjustment to

minimize the push/pull force required to articulate the gangway.

(8) A pull-up rope aids in returning the gangway to the upright stored position.

(9) 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.

(10) Each gangway includes a specific serial number located on the inside end of the right stringer

toeboard and is visible when the gangway is stored.

FIGURE 4-1

ii) MODIFIED GANGWAY

For any TCG-2500 that has been modified, or that includes the addition of ancillary components not

otherwise identified above, see project-specific drawings that reflect the modification or addition.

c) OPTIONAL TCG TRACK AND CARRIAGE WITH TCG-S910.1 TRACK LOCK MECHANISM

i) TRACK AND CARRIAGE

See FIGURE 4-2 and FIGURE 4-3 below.

The galvanized steel track and carriage system includes the following features:

(1) A track assembly that is either integral with a platform structure or a separate assembly that bolts to

the face of a fixed platform structure

(2) A gangway base tread mounted on a carriage that rolls on the track

(3) The track top section captures the top rollers and the bottom section supports the carriage rollers.

(4) A removable stop inserted through end holes in the top surface prevents the carriage from rolling

past the ends of the track.

(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 leg of the track, and the bottom rollers ride on

the bottom outside face of the carriage mounting plate that is bolted to the back side of the

gangway.

(6) The carriage rolling assemblies consist of rollers supported by shafts mounted on the base tread

mounting plate.

FIGURE 4-2 FIGURE 4-3

MIDRAIL

OUTBOARD

UPRIGHT

COMBINATION

TRACK LOCK

STRINGER

TOP HANDRAIL

TRACK ASSEMBLY

(STYLE MAY VARY)

MANUAL TRACK

LOCK

CARRIAGE

12”

8”

EXTENSION

ii) TCG-S910.1 TRACK LOCK MECHANISM

See FIGURE 4-4 below.

Any TCG gangway that includes the track and carriage option also includes the TCG-S910.1 Track Lock

Mechanism, which is a safety device designed to prevent a manually tracked gangway from being rolled

along the track when the gangway is not in the upright stored position. The mechanism consists of a

combination of both automatic and manual lock functions as described below. NOTE: There is a

patent/patent pending for the TCG-S910.1 Track Lock Mechanism.

(1) The automatic function of the mechanism consists of the following features:

(a) The TCG-S910.1 Track Lock Mechanism is an assembly that contains a housing with a curved

release lever arm on one end and a brake pad pivot arm on the opposite end. The two arms

are sandwiched between and bolted to the side plates of the housing at the upper pivot point

of each arm. Bolted between the arms below the housing is a pair of flat bar spacers that allow

the arms to pivot together. Pinned between a bottom extension on each arm is an extension

spring that changes the geometry of the top end of each arm as the spring is extended or

released.

(b) The assembly bolts through holes in the side plate of the gangway base tread. The top of the

curved release lever arm includes a bent leg that engages with the top edge of the gangway

stringer as the gangway is raised to the stored position. The brake pad on the brake pad pivot

arm engages with the outer surface of the track on which the gangway rolls.

release lever arm which causes the spring to extend. As the spring extends, the brake pad pivot

arm pivots which causes the brake pad to disengage from the track. With the gangway fully

raised in the stored position, the brake pad is released from the track which allows the

gangway to be manually tracked.

(d) Whenever the gangway is deployed in any position that is not stored, and the release lever arm

is disengaged from the stringer, the spring causes the brake pad to press against the track,

thereby preventing the gangway from tracking while deployed.

(2) Whenever the gangway is stored, the automatic lock function of the track lock mechanism is

inactive, which allows the gangway to freely roll along the length of the track. As an added safety

feature, the track lock mechanism includes a manual track lock lever that is only deployed when the

gangway is in the stored position and not being used. When engaged, the manual track lock lever

causes a second brake pad to engage with the track, which prevents the gangway from being

inadvertently rolled along the track by any external force such as wind.

FIGURE 4-4

d) OPTIONAL TCG PIVOT MOUNT

See FIGURE 4-5 and FIGURE 4-6 below.

i) The pivot mount system consists of a gangway base tread with a male pivot post mounted on the

underside and a tread extension mounted on the platform side of the tread, and includes the following

features:

(1) The male pivot post engages with a female pivot-mounting sleeve and rests on a wear pad.

(2) The range of pivot rotation is 10 degrees each side of center.

(3) Brackets that are bolted or welded to a platform, either surface mounted or underslung below the

platform structure, support the female pivot-mounting sleeve.

(4) The pivot-mounting system can also be modified to retrofit an existing pivot support bracket.

FIGURE 4-5 FIGURE 4-6

5) ASSEMBLY

SEE PROJECT-SPECIFIC DRAWINGS, FIGURES WITHIN THIS SECTION,

AND SECTION 11) DRAWINGS AND SPECIFICATIONS

a) GENERAL

i) Carbis must approve any alterations required to this system.

ii) It is the Owner’s responsibility to:

(1) Ensure that their existing structure supports new Carbis equipment

(2) Identify to Carbis any conditions or obstructions that may interfere with the location or proper

operation of Carbis equipment

(3) Remove or relocate any obstructions in preparation for installation of the new Carbis equipment

b) INSPECTION AND OFF-LOADING

i) Care has been taken to package Carbis equipment and components in the best manner possible for safe

shipping and practical off-loading purposes.

ii) The gangway assembly will ship with the gangway locked in the stored position and the chain links so

engaged as to hold the gangway locked in the stored position.

Do not disengage the chain links from holding the gangway in the stored position until

after the gangway base tread has been securely installed.

iii) It is the owner’s responsibility to inspect the shipment for completeness by comparing the shipment with

the parts identified in the Parts Lists, including the items identified in the Hardware and Pneumatic

Component Lists. Check for any shipping damages or missing components, and report the same to Carbis.

iv) It is also the owner’s responsibility to provide the appropriate off-loading devices to safely and effectively

rig and handle the Carbis equipment and components during the off-loading process, paying particular

attention to eccentric loading conditions such as counterweighted components, including those whose

eccentric loads are visually apparent.

v) Some components may ship pre-assembled.

vi) GANGWAY LIFT POINTS

See FIGURE 5-0 below.

Make certain when lifting the gangway to secure any external lifting device only at the lift points identified

by the yellow “LIFT HERE” labels posted on the outside faces of the top horizontal cross members of the

outboard uprights as identified in FIGURE 5-0 below.

NOTICE

c) SITE PREPARATION

i) It is the owner’s responsibility to prepare the site for new Carbis equipment. Site preparation includes, but

is not limited to, the following:

(1) Removal and/or relocation of existing obstructions

(2) Field drilling mounting holes, where required, per mounting hole patterns as shown on the Final

Drawings

(3) Adding any new customer-supplied members to existing structures as required by the new Carbis

equipment

(4) Any foundation work required by new Carbis equipment should be constructed using only the

information on the Final Drawings.

d) ASSEMBLY

i) REQUIRED BOLT TENSIONING FOR STRUCTURAL CONNECTIONS

(1) A325 Bolts - Snug Tight Condition

(a) The snug tight condition is defined as the tightness that exists when all plies in a joint are in

firm contact. This may be attained by a few impacts of an impact wrench or the full effort of a

man using an ordinary spud wrench. Carbis’ standard bolt installation is snug tight in a bearing

type connection. Different requirements will be specifically detailed on the drawings.

(b) Any bolts less than 1/2” diameter, torque to 60 in.-lbs.

(2) Stainless Hardware - Snug Tight Condition

(a) The snug tight condition is defined as the tightness that exists when all plies in a joint are in

firm contact. This may be attained by the full effort of a man using an ordinary spud wrench.

Carbis’ standard bolt installation is snug tight in a bearing type connection. Different

requirements will be specifically detailed on the drawings.

(b) Keep bolts and nuts free of grime and other contaminants that may get into threads. Lubricate

stainless steel bolts and nuts prior to tightening.

ii) A qualified erector should perform the assembly and installation of the Carbis equipment in conformity

with industry standards and local building code requirements, and in accordance with the most recent

industry practices for safe rigging. The procedures outlined in this section describe safe and practical

sequences. Any deviation preferred by the erector/rigger must be in conformance with the above-

referenced standards, codes, and practices. See Final/Assembly Drawing for Carbis-supplied components

and hardware lists. Foundation anchor bolts to be supplied by customer.

iii) TRACK AND CARRIAGE OPTION WITH TCG-S910.1 TRACK LOCK MECHANISM

For existing platforms, use customer-supplied hardware to mount the tracks to the platform.

For Carbis-supplied platforms, Carbis will drill the bolt holes and supply the hardware for mounting the

tracks.

Install the track and carriage per the following sequence; for Carbis-supplied platforms with built-in tracks,

skip steps (1) and (2):

(1) Bolt track section(s) to platform.

(2) Tighten track mounting bolts only after all track sections have been installed.

(3) Insert track stop components at one end of the track run.

(4) Slide gangway into the track section.

(5) Insert track stop components at opposite end of the track run.

(6) With the gangway locked in the upright stored position, push the manual track lock lever down to

engage the brake to prevent the gangway from free-rolling along the track.

(7) Disengage the chains from holding the gangway in the stored position, and reposition the chains

with the next to the last link engaged in the slot of the chain lock to begin operation.

(8) For retrofit of the TCG-S910.1 Track Lock Mechanism on an existing gangway, see section 7)

MAINTENANCE for the installation procedure.

iv) PIVOT MOUNT OPTION

See FIGURE 5-1 below.

If Carbis supplies the platform for pivot-mounted gangways, then Carbis will supply the mounting

hardware; otherwise, use customer-supplied hardware to install the pivot mount per the following

sequence:

(1) Attach the pivot mount receiver sleeve support component (face mounted or underslung mounted)

to the platform structure.

(2) Install the wear pad on the top of the sleeve opening.

(3) Insert the base tread pivot post into the sleeve.

(4) Disengage the chains from holding the gangway in the stored position, and reposition the chains

with the next to the last link engaged in the slot of the chain lock to begin operation.

FIGURE 5-1

v) GANGWAY MOUNT

If Carbis supplies the platform for the gangway, then Carbis will supply the mounting hardware; otherwise,

use customer-supplied hardware to install the gangway per the following sequence:

(1) Bolt the base tread of the gangway to the platform structure.

(2) Disengage the chains from holding the gangway in the stored position, and reposition the chains

with the next to the last link engaged in the slot of the chain lock to begin operation. (NOTE: If cage

option is included, do not try to lower gangway until cage is installed.)

vi) CAGE ASSEMBLY OPTION

For gangways that include safety cage options, use Carbis-supplied hardware to install the cage per FIGURE

5-2 below. Gangway and cage type may vary from that shown; however, the bolting arrangement and

configuration are the same. Refer to the Final Drawings and/or Assembly Drawings to determine the site-

specific cage position requirement.

FIGURE 5-2

6) OPERATION

a) GENERAL

i) For systems that include loading arms, see separate instruction manual for operation of the loading arms.

ii) The gangway design load limit is 500 lbs., single person occupancy.

iii) Verify that all safety placards, signs, and decals are clearly visible, legible, and in good repair. Operating

personnel must be familiar with the contents of such placards, signs, and decals. See section 3)

IMPORTANT SAFETY INFORMATION v) SAFETY SIGN DESCRIPTIONS for the description of all safety signs

that appear on the equipment described in this manual.

b) PRE-OPERATIONAL SAFETY INFORMATION

Following are the pre-operational safety messages grouped by hazard:

(1) This equipment CAN conduct electricity.

(a) Any grounding that may be required is to be performed per the owner’s safety code.

(b) Do NOT allow this unit to come in contact with live electrical wires.

Failure to comply with these warnings WILL result in serious injury or death.

ii)

(1) Correct vehicle positioning and proper deployment of Carbis equipment are imperative to its

function. Incorrectly positioned vehicles, or improper use of this equipment, increase the risk of

serious injury or death. Carbis equipment is designed to function only as described in the manual

and depicted on the drawings. IT IS THE SOLE RESPONSIBILITY OF THE OWNER TO ENSURE PROPER

USE OF CARBIS EQUIPMENT.

(2) Before accessing Carbis equipment, a vehicle must be in the correctly spotted position and the

Carbis equipment properly deployed, supported, and secured.

(3) Personnel must not access Carbis equipment during any controlled operation.

(4) Nonessential personnel must stay clear of Carbis equipment during any controlled operation.

(5) Operator must be certain that nonessential personnel are clear of Carbis equipment during any

controlled operation.

(6) Operator must not place Carbis equipment in motion while occupying the same equipment.

DANGER

WARNING

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