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CARBIS TCG-2500 Instruction Manual

Gangway
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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 1

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Summary of Contents for CARBIS TCG-2500

  • Page 1 INSTRUCTION MANUAL 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 1...
  • Page 2 Section 3) ………………………………………………………………………………………………………………..SAFETY LANGUAGE Section 4) …………………………….……………………………………………………………………………………………. OPERATION Section 5) ………………………………….……….……………………………………………………….…………TROUBLESHOOTING Section 6) ……………………………….…………..….……………………………………………………………………. MAINTENANCE Section 7) ……………………………….….……...………………………………………………………. INSTALLATION AND SETUP Section 8) …..….……………….….…...……..….…………………….……………SPECIFICATION SHEETS AND DRAWINGS REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 2...
  • Page 3 Please carefully read this Installation, Operation, a n d M aintenance Manual as it is an integral pa rt o f yo ur p ur ch ase d Carbis equipment. It is the Owner’s responsibility ensuring all personnel who operate and or maintain the Carbis equipment first receive comprehensive training.

  • Page 4: Vehicle Positioning

    With a railcar centerline considered as a fixed constant relationship with Carbis equipment, correct gangway positioning r e q u i r e s c o r r e c t operator input. Carbis’ standard gangways r e q u i r e the rail car spotted with the r a i l c a r access area centered on the gangway.
  • Page 5 REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 5...
  • Page 6 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.
  • Page 7 Note: Always reference this serial number when contacting Sam Carbis Solutions Group with any questions or concerns. 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.
  • Page 8 FIGURE 2-1 TCG -2500 GANGWAY SIDE ARRANGEMENT 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.
  • Page 9 The cage can bolt in either the high or low position as determined by customer site-specific needs (See figure 2-2). REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 9...
  • Page 10 Rolling carriage assemblies consist of shaft-supported rollers mounted on base tread mounting plate. REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 10...
  • Page 11 When engaged, the manual track lock lever actuates a second brake pad against the track preventing the gangway from inadvertently rolling along the track by any external force such REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 11...
  • Page 12 The pivot-mounting system can be retrofitted to an existing pivot support bracket. FIGURE 2-8 FIGURE 2-9 REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 12...
  • Page 13 Incorrect vehicle positioning or improper use of this equipment increases the risk of serious injury or death. Carbis equipment is designed to function only as described in this manual and depicted on applicable drawings. IT IS THE SOLE RESPONSIBILITY OF THE OWNER TO ENSURE PROPER USE OF CARBIS EQUIPMENT.
  • Page 14 Equipment (PPE), such as gloves, safety glasses, safety shoes, helmet etc. For chain supported Carbis gangways, both locking chains must be correctly engaged in the chain lock slots supporting the gangway before accessing. Slack or unequal chain adjustment may result in unanticipated movement and loss of balance when walking or standing on the equipment.
  • Page 15 SAFETY LABEL DESCRIPTIONS Please ensure the following safety labels below are eligible and properly affixed on the equipment as described in this manual before use. Contact Carbis when requiring replacement labels AL-157.1 AL-159.1 AL-156.1 AL-027-99 top Handrail (Inside right handrail)
  • Page 16 GWLIFT1.5X3.75-1 Used for TCG installation (positioned on outside Left and Right of outboard Uprights See Figures 7-1 and 7-2) AL-163 (Affixed to the LRD™ if installed) REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 16...
  • Page 17 AL-162 FIGURE 3-1 SAFETY LABEL LOCATIONS NOTE: Image shown is TCG-2500 with fixed uprights FIGURE 3-2 TCG-2500-OSP WITH SAF-T CAGE (OPERATOR LOCATED OPERATIONAL SIGN) REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 17...
  • Page 18 FIGURE 3-3 TCG-2500-NF-OSP WITH SAF-T CAGE (OPERATOR LOCATED OPERATIONAL SIGN) FIGURE 3-4 TCG-2500-NCTHR OSP NO CAGE TELESCOPING HANDRAILS (OPERATOR LOCATED OPERATIONAL SIGN) FIGURE 3-4 TCG-2500-NC-OSP WITH NO CAGE (OPERATOR LOCATED OPERATIONAL SIGN REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED...

  • Page 19: Operation

    For systems that include loading arms, see separate instruction manual for operation. DO NOT USE Carbis Equipment if wind speed gusts exceed 35 mph/56 kph. Gangway weight limit design is for single person occupancy with PPE, tools and must not exceed 500 lbs./227 kg.
  • Page 20 Secure the arm. Firmly grab the pull-up rope and raise the gangway to the stored position. REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 20...

  • Page 21: Troubleshooting

    6) MAINTENANCE GENERAL Before performing any maintenance on a Carbis system, is lock and tag out the equipment according to local safety directives. Ensure the gangway is fully up in the stored position with the chains fully secured and taut. If needed, use a properly rated cargo strap to secure the gangway underneath REVISED 08/13/2020 TCG-2500-OSP-M ©...

  • Page 22: Periodic Inspection And Cleaning

    Carbis does not advocate pressure washer use for cleaning as it could damage bearing and cylinder seals, damage surfaces, and inadvertently remove safety labels. However, if used wear proper PPE using lower pressures focusing on the walkway area to remove grease, product build up etc.
  • Page 23 See Figure 6-2 for TCGs with 4 steps or more or Figure 6-3 for a TCG with 3 Steps for adjustments procedures reference. To adjust spring tension or replace a spring, follow the instructions noted below: Spring Adjustment REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 23...
  • Page 24 FIGURE 6-2 ADJUST VIEW FOR TCGs HAVING 4 OF MORE STEPS FIGURE 6-3 TCG 3-STEP GANGWAY ADJUSTMENT PERFORMED IN STORED POSITION (CUT AWAY VIEW) REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 24...
  • Page 25 The following procedure applies to all Carbis manually operated TCG-2500 gangways with a foot lock: For safety reasons, ensure the system is properly locked and tagged out preventing inadvertent gangway operation during the foot lock adjustment procedure.
  • Page 26 Only qualified maintenance personnel trained in safe and proper maintenance procedures should perform adjustments on Carbis equipment in accordance with the most recent industry practices. Failure to do so could cause personnel injury or damage to equipment. iii) Prior to the adjustment of any component, it is imperative that system Lockout/Tagout Procedures be performed per company safety regulations and requirements.
  • Page 27 If the brake engagement is insufficient or if the lever is still too tight, repeat steps 1) thru 4) to achieve the desired results. For any assistance, replacement parts, comments, or questions, contact Carbis. Please have your model number, serial number, or drawing number available to expedite your request.

  • Page 28: Installation And Setup

    FIGURE 7-1 Labels placed on outside of Fixed Uprights (2 locations) with arrows facing downward and FIGURE 7-2 Labels placed on outside of Adjustable Uprights (4 places) with arrows facing inward REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 28...
  • Page 29 Carbis Solutions Group, LLC equipment. The structure shall also be sufficient for supporting all imposed equipment loads. Improper load support can negatively affect equipment operation. ii) It is the owner’s responsibility to prepare the site prior to installing Carbis equipment. Site preparation includes, but is not limited to, the following: Removal and/or relocation of existing obstructions.
  • Page 30 Lubricate stainless steel bolts and nuts prior to tightening. Any bolts less than 1/2” diameter, torque to 60 in.-lbs./6.75NM. A qualified contractor with an understanding of Carbis equipment should perform the final assembly and installation of the Carbis equipment in conformity with industry standards, local building code requirements, and in accordance with the most recent industry practices for safe rigging.
  • Page 31 TCG-2500 GANGWAY MOUNTING SPECIFICATIONS FIGURE 7-3 f) GANGWAY MOUNT INSTALLATION Carbis will supply the mounting hardware for Carbis supplied gangway mounted platforms. Otherwise use customer-supplied hardware when installing the gangway mount to a platform per the following sequence: Bolt the gangway base tread to the platform structure.
  • Page 32 TRACK AND CARRIAGE OPTION WITH TCG-S910.1 TRACK LOCK MECHANISM For existing platforms, always use Carbis special bolts (199) to mount the tracks to the platform. For Carbis-supplied platforms, Carbis will drill the bolt holes and supply the tracks mounting bolts 199).
  • Page 33 From the stored position, raise and lower the gangway several times verifying the TCG S910.1 Track Lock Mechanism operation. Install the manual track lock lever and Carbis-supplied mounting hardware as shown in FIGURE 7-5 below. Ensure the manual track lock brake correctly engages the track firmly holding the gangway in place.
  • Page 34 TCG-S910.1 RACK LOCK MECHANISM FIGURE 7-5 CAGE ASSEMBLY OPTION For gangways with included safety cage options, use Carbis-supplied hardware to install the cage per FIGURE 7-6 below. Gangway and cage type may vary from that shown; however, the bolting arrangement and configuration are the same.
  • Page 35 To LOWER the cage: Back off NUT 1 on the fixed outboard upright. Tighten NUT 2 until the cage becomes level. Tighten NUT 1. REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 35...
  • Page 36 If retrofitting an existing gangway with the LRD™ assembly, the existing lifting rope can be removed. Perform the lifting function using the rope attached to the LRD™ lever arm. REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 36...
  • Page 37 FIGURE 7-8 LRD™ INSTALLATION LOCATION NOTE: Gangway and cage configuration may vary from that shown. FIGURE 7-9 OPTIONAL LIFT RESTRICTING DEVICE (LRD)™ GENERAL SPECIFICATIONS REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 37...
  • Page 38 8) SPECIFICATION SHEETS AND DRAWINGS a) MECHANICAL DRAWINGS AND SPECIFICATIONS REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 38...
  • Page 39 TCG-2500 GANGWAY MODEL SPECIFICATIONS FIGURE 8-1 TCG-2500 GANGWAY GENERAL SPECIFICATIONS REVISED 08/13/2020 TCG-2500-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2020, WITH ALL RIGHTS RESERVED PAGE 39...