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CARBIS TCG-2000 Instruction Manual

Gangway with saf-t cage
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INSTRUCTION MANUAL
FOR
MANUALLY OPERATED
TCG-2000 GANGWAY
WITH SAF-T CAGE
REVISED 12/17/2018
TCG-2000-OSP-M
© SAM CARBIS SOLUTIONS GROUP, LLC, 2018, WITH ALL RIGHTS RESERVED
PAGE 1

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Summary of Contents for CARBIS TCG-2000

  • Page 1 INSTRUCTION MANUAL MANUALLY OPERATED TCG-2000 GANGWAY WITH SAF-T CAGE REVISED 12/17/2018 TCG-2000-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2018, WITH ALL RIGHTS RESERVED PAGE 1...
  • Page 2 Section 4) …………………………….……………………………………………………………………………………………. OPERATION Section 5) ………………………………….……….……………………………………………………….…………TROUBLESHOOTING Section 6) ……………………………….…………. ….……………………………………………………………………. MAINTENANCE Section 7) ……………………………….….……...………………………………………………………. INSTALLATION AND SETUP Section 8) …. ….……………….….…...….…. ….…………………….……………SPECIFICATION SHEETS AND DRAWINGS REVISED 12/17/2018 TCG-2000-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2018, WITH ALL RIGHTS RESERVED PAGE 2...
  • Page 3 Please carefully read this Installation, Operation, a nd M aintenance Manual as it is an integral p a rt o f y o u r p u rc ha sed 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

    Carbis provides customer-approved Engineering Drawings and or scope data documenting key dimensional relationships between a particular-type vehicle and the accessing gangway including safety cages as applicable. P rior 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.
  • Page 5 With a railcar centerline considered as a fixed constant relationship with Carbis equipment, correct railcar positioning is along the length of the track 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 6 Vehicle positioned too far from the TCG-2000. This blocks access to the hatch creating incorrect cage spacing and a fall hazard FIGURE 1-3 REVISED 12/17/2018 TCG-2000-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2018, WITH ALL RIGHTS RESERVED PAGE 6...
  • Page 7 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 MECHANICAL EQUIPMENT (See FIGURE 2-1.)
  • Page 8 When in the stored position, the gangway ‘s attached serial number on the first tread left-hand side is visible. Note: Always reference this serial number when contacting Sam Carbis Solutions Group with any questions or concerns. Gangways have an optional pivoting outboard upright and cage leveling mechanism (see FIGURE 2-2).
  • Page 9 GANGWAY FOOT LOCK 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 10 6) C arriage rolling assemblies consist of shaft-supported rollers mounted on base tread mounting plate. REVISED 12/17/2018 TCG-2000-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2018, 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 as wind. REVISED 12/17/2018 TCG-2000-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2018, WITH ALL RIGHTS RESERVED PAGE 11...
  • Page 12 The pivot-mounting system can be retrofitted to an existing pivot support bracket. FIGURE 2-7 FIGURE 2-8 REVISED 12/17/2018 TCG-2000-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2018, 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 For operator safety, Carbis recommends the equipment be stored and not used when wind speed gusts exceed 35 mph/56 kph. Unit is not to rest on the vehicle at any time.
  • 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 AL-159.1 AL-156 ight top handrail (Inside right of base tread)
  • Page 16 GWLIFT1.5X3.75 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 12/17/2018 TCG-2000-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2018, WITH ALL RIGHTS RESERVED PAGE 16...
  • Page 17 For TCGs with adjustable uprights, see Figure 7-2 for lift label placement. FIGURE 3-1 SAFETY label LOCATIONS NOTE: Image shown is TCG-2000 with fixed uprights FIGURE 3-2 TCG-2000-OSP WITH SAF-T CAGE (OPERATOR LOCATED OPERATIONAL SIGN) REVISED 12/17/2018 TCG-2000-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2018, WITH ALL RIGHTS RESERVED PAGE 17...

  • Page 18: Operation

    PRE-USE INSPECTION For systems including loading arms, see separate instruction manual for operation. DO NOT USE Carbis Equipment if wind speed gusts exceed 35 mph. Gangway weight limit design is for single person occupancy with PPE, tools and must not exceed 500 lbs./227Kg.
  • Page 19 Ensure vehicle correctly spotted per (Figure 1-1) above. If vehicle is not properly centered, a gap may be created which can lead to death REVISED 12/17/2018 TCG-2000-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2018, WITH ALL RIGHTS RESERVED PAGE 19...

  • Page 20: Troubleshooting

    Failure to comply with these warnings CAN result in serious injury, death, or damage to equipment. It is the Owner’s responsibility to ensure procedures in this manual are correctly followed. Ensure maintenance personnel troubleshooting Carbis equipment are completely familiar with the equipment, have thoroughly read this manual, and possess the necessary maintenance skillset to work on this equipment.

  • Page 21: Maintenance

    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 and use lower pressures focusing on the walkway area to remove grease, product build up etc.
  • Page 22 Inspect component surface welds including those hidden from view for cracks, distortion, and corrosion. If found discontinue use until addressing items. Contact Carbis for guidance. Never repair damaged parts. Replace damaged and missing parts only with Carbis approved parts.
  • Page 23 ½” increments adjust the spring ear downward until proper force is achieved. FIGURE 6-2 ADJUST VIEW FOR TCGs HAVING 4 OF MORE STEPS REVISED 12/17/2018 TCG-2000-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2018, WITH ALL RIGHTS RESERVED PAGE 23...
  • Page 24 Adjust the ear to its original position. Untie the gangway test the unit. adjustments required, see iv) Spring Adjustment iv) Unlocking the Spring Adjustment Nut: REVISED 12/17/2018 TCG-2000-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2018, WITH ALL RIGHTS RESERVED PAGE 24...
  • Page 25 If the gangway foot lock is misaligned or the locking pin does not properly engage with the foot lock mechanism, follow the procedure below for realigning the locking pin with the foot lock mechanism. The following procedure applies to all Carbis manually operated TCG-2000 gangways with a single 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: Installation And Setup

    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. FIGURE 6-4 TCG-S910.1 TRACK LOCK MECHANISM MANUAL BRAKE SUB-ASSEMBLY 7) INSTALLATION AND SET UP GENERAL AVOID PROBLEMS WITH STAINLESS STEEL BOLTS.
  • Page 28 Sam 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: 1) Removal and/or relocation of existing obstructions.
  • Page 29 Attain snug condition by a few rotations of an impact wrench or the full effort of a man using an ordinary wrench. Carbis’ standard bolt installation is snug tight in a bearing type connection. Different requirements will be specifically detailed on the drawings.
  • Page 30 ALUMINUM 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 31 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 32 8) From the stored position, raise and lower the gangway several times verifying the TCG S910.1 Track Lock Mechanism operation. 9) Install the manual track lock lever and Carbis-supplied mounting hardware as shown in FIGURE 7- 5 below. 10) Ensure the manual track lock brake correctly engages the track firmly holding the gangway in place.
  • Page 33 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. 1) Gangway and cage type may vary from that shown; however, the bolting arrangement and configuration are the same.
  • Page 34 2) To LOWER the cage: a) Back off NUT 1 on the fixed outboard upright. b) Tighten NUT 2 until the cage becomes level. c) Tighten NUT 1. REVISED 12/17/2018 TCG-2000-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2018, WITH ALL RIGHTS RESERVED PAGE 34...
  • Page 35 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 12/17/2018 TCG-2000-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2018, WITH ALL RIGHTS RESERVED PAGE 35...
  • Page 36 FIGURE 7-8 LRD™ INSTALLATION LOCATION NOTE: Gangway and cage configuration may vary from that shown. REVISED 12/17/2018 TCG-2000-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2018, WITH ALL RIGHTS RESERVED PAGE 36...
  • Page 37 8) SPECIFICATION SHEETS AND DRAWINGS a) MECHANICAL DRAWINGS AND SPECIFICATIONS REVISED 12/17/2018 TCG-2000-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2018, WITH ALL RIGHTS RESERVED PAGE 37...
  • Page 38 FIGURE 8-1 TCG-2000 GANGWAY GENERAL SPECIFICATIONS FIGURE 8-2 OPTIONAL LIFT RESTRICTING DEVICE (LRD)™ GENERAL SPECIFICATIONS REVISED 12/17/2018 TCG-2000-OSP-M © SAM CARBIS SOLUTIONS GROUP, LLC, 2018, WITH ALL RIGHTS RESERVED PAGE 38...