GKD Spaceguard operation and maintenance - ajhplant.com

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GKD Spaceguard operation and maintenance

Document no AJH075

Author P. Hargreaves

Issue Status: Issue 5

Date: 26/11/2015

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ISSUE 5 Page 2 of 23

CONTENTS

Section Heading Page

Contents 2

1 Issue and revision record 3

2 Introduction 4

3 Defined words 5

4 Document review 6

5 General arrangement 7

5.1 System control 8

5.2 System operation 9

5.3 General 10

6 Maintenance 11

6.1 Maintenance Frequencies 12

6.2 Summary of Jobs 12

6.3.1 Spaceguard operation - Check 14

6.4.1 Earth bonding - Examine 16

6.4.2 Height and virtual walls - Gauge 17

6.5.1 Earth bonding - Test 19

6.5.2 Slew brake - Test 20

6.5.3 Slow down operation - Test 22

7 Torque Table 23

All information, illustrations and specifications in this Maintenance Programme are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. Equipment operators and installers shall be responsible for ensuring that a safe working environment and safe systems of work are in place and in certain circumstances advice and permission from the controlling authority must be sought before any operation, installation or surveying work is carried out.

Prepared by:

Authorised by:

P. Hargreaves C. Chippendale

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1. Issue and Revision Record This document will be updated when necessary by the re-issue of the complete document. Vertical black lines on the left-hand side of the page, adjacent to the relevant information, will mark amendments relevant to the new issue.

Issue/ Revision

Description Date Revised

Page No.

Revised

By.

1 Initial issue 16/12/2013 N/A N/A

2 Page No revision 06/01/2014 ALL P.H

3 Wording changes, Earth bonding

moved to Pre Start 16/01/2014

9,12,14,16,

17,20 P.H

4 Addition of Kobelco SK135 &

Colmar T4300, wording changes 11/03/2014 17, 21 P.H

5 Addition of Volvo Excarailer 220 26/11/2015 21 P.H

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2. Introduction This manual has been produced to cover the safe use and maintenance of the GKD Spaceguard system. It is provided as a supplement to the original manufacturers/converters manual and should be used in conjunction with those to provide safe operation and maintenance. This manual covers the GKD Spaceguard aspects which are over and above the base GKD 3RCI system. It is important that all personnel are fully trained and familiar with the machine and GKD system and that they have read and understood the information contained in this manual before operating or maintaining this machine.

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3. Defined Words

The following outlines the defined words used within this Maintenance Programme.

Term Action required

Adjust Correct to defined limits

Change Remove the original and fit a new or overhauled part or assembly in its place.

Check Determine a particular nominated condition before, during or after repair, for example completeness, security, position

Clean Remove all dirt and deposits

Defective Any fault or faults in a component or assembly, for example structural fractures or weld fractures, which may prevent the component or assembly from fulfilling its designed purpose

Dismantle Take to pieces

Examine Determine general condition before repair, for example wear, cracks, splits, leaks, scoring, erosion, breaks, distortion, looseness

Gauge Determine a nominated dimension by using suitable measuring equipment, for example ruler, micrometer, callipers, feeler gauges or Go/No-Go gauge

Inspect Determine general condition after repair and attention, that is, conformity to required standards

Lubricate Apply lubricant

Overhaul Do what is necessary to make an assembly or sub-assembly re-usable, that is dismantle, strip, clean, examine, fit new parts, repair, re-assemble, test and inspect as required

Paint To impart colour to a surface

Re-assemble Put together

Record Put down in writing a finding from examination, test, inspection or special checks.

Rectify To set right

Refit Put back and re-connect

Remove Disconnect and take off

Renew Remove, scrap the original part and put a new part in its place

Repair Restore an original part to the required condition by hand tooling, machining, build-up, welding, patching, bending, setting, heat-treating, re-securing etc

Strip Remove covering, that is, paint, polish, fabric

Test Prove correct operation by trial

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4. Document Review A review of the following maintenance programme is carried out as follows:

1. The Maintenance Programme is reviewed on an annual basis to investigate:

The potential for improvement.

The maintenance activities.

The vehicle performance and associated components.

National Incident Reports (NIR’s).

Changes in use and/or operating environment.

Manufacturer’s advice.

Directives from Network Rail.

The vehicle’s seven-year review.

2. A record of any decisions taken at this review are retained.

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5. General arrangement The GKD 3RCI is an integrated road-rail vehicle (RRV) rated capacity indicator (RCI) system. It is a passive control system in that it has no ability to move the machine it only has the ability to stop movement. The system incorporates state of the art angle and location sensing, together with processing to provide audible and visual warning of the parameters of the machine. The RCI has the capability of inhibiting further movement when safe preset capacity ratings are exceeded. The speed of operation of RRV base excavators is designed for maximum digging throughput. This speed can cause a limit overshoots. The slew operation is particularly vulnerable as the slew brakes are not able to stop the motion instantly. The standard ‘3RCI’ does not include ‘fail to safe’ functionality and whilst this is acceptable for its intended duty, i.e. as an aid to the machine operator, where the machine is being used under live overhead lines or next to open traffic lines this is not adequate. The 3RCI ‘Spaceguard’ system has been designed where virtual limits can be set for height, slew and walls. In the event that the machine exceeds these preset limits, or exceed the machines capacity, the indicator will stop the machine from further movement. The ‘Spaceguard’ system provides dual functionality and redundancy via diverse systems for all key sensors relating to position measurement. In addition calculations of position are independently verified for maximum protection. If a sensor should fail but the output remain within an allowable range, a second and diverse duplicate sensor will detect this error condition. With this ‘Spaceguard’ system a high level of integrity is achieved and can be considered ‘fail to safe’ based on its mean time between dangerous failures.

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5.1. System control The Spaceguard system is operated in the same way that the standard GKD 3RCi system is used, additional safety features are fitted for slew and height limits in the Spaceguard system. It can be proven that a machine has Spaceguard installed by looking at the touchscreen in the cab, machines with this fitted have ‘ALO’ with a tick by the side. As shown in Fig 1. Fig 1

For detailed user instructions refer to the GKD version 8 user instruction manual.

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5.2. System operation

On the side of the screen is a keyswitch which is used to lock the slew and height limits when active to avoid inadvertent deactivation.

If the System displays any errors or “BEYOND LIMIT” on the screen at any point during use the machine must be removed from service.

The system is equipped with a datalogger to record when the system is active and whether any system faults have occurred.

If the machine is not functioning correctly it must be removed from service until repairs have been carried out.

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5.3. General

During the course of maintenance and testing, all missing items must be replaced; defective items must be repaired or renewed; all faults rectified and equipment correctly adjusted. Replacement parts shall be identical to the original parts in fit, function and performance.

In order to carry out this Maintenance Programme, the following minimum level of facilities is required, appropriate to the jobs being undertaken: a) Clean, dry, covered accommodation for dealing with bearings,

mechanical, hydraulic and electrical components, etc. b) Adequate illumination for inspection of components. c) Cleaning facilities which will not cause damage to the components. d) Handling facilities for removal and refitting of components. e) Protection from the weather of vulnerable areas of the vehicles and

its components. f) Any specific requirements additional to those listed are identified on

the applicable job description.

Maintenance action is intended to ensure the continued safe operation of the GKD Spaceguard system and host vehicle. The maintenance programme has been derived from reliability and safety apportionment’s and failure by the owner to follow these activities would invalidate both warranty and safety systems given for the product. Auditable records of maintenance carried in accordance with this manual shall be kept including any measurements taken. Following any maintenance being carried out the vehicle log book must be updated with the date and exam type.

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6. Maintenance The following Maintenance Programme specified on the appropriate VAB certification for each product is as follows: In order to carry out this Maintenance Programme in a manner that

achieves the required safety and quality, the following minimum level of competence is required:

a) For all activities the person leading the task must be able to follow

and carry out the instruction detailed in this document. All Safety Critical Work must be carried out by persons competent in accordance with: Health and safety executive publication “Railway safety principles and guidance” part 3 section A.ORR railway safety publication 1 “Developing and maintaining staff competence” March 2007.

b) All work relating to the maintenance and overhaul of axle bearings should be carried out by competent persons. Requirements for axle bearings are set out in GMGN2646; these do not apply to possession-only rail vehicles but may be used as a source of information.

c) Staff undertaking this work must have been trained and hold certificates of competency such as: SCW ID; apprentice-Trained Craftsman/NVQ level 3 in Plant Maintenance; Certificate issued by a CITB/CTA approved body – operation for maintenance purposes only; Re-assessment of competency in accordance with RPA Standards etc.

d) All staff to have undergone the training course for the appropriate equipment, to the extent of the responsibilities and the tasks they are asked to be perform by the machine and equipment owners and their agents.

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6.1. Maintenance Frequencies

The machine is to be examined at frequencies no greater than the limits set out below: Type of exam Calendar Time A Pre Start B 3 Monthly C Yearly

6.2. Summary of Jobs Schedule of work

Job Title Intent Job No A B C D

Pre Start 6.3

Spaceguard operation Check 6.3.1 ∗ ∗ ∗ ∗

Earth bonding Examine 6.3.2 ∗ ∗ ∗ ∗

Three Monthly Maintenance 6.4

Height and virtual walls Gauge 6.4.2 ∗ ∗ ∗

Yearly Maintenance 6.6

Earth bonding Test 6.5.1 ∗

Slew Brake Test 6.5.2 ∗

Slow down operation Test 6.5.3 ∗

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Maintenance instructions

Scheduled Work is that mandatory work which should be undertaken at the prescribed examinations. Arising Work is that work that is done to rectify the defects found in the course of carrying out Scheduled work. The items numbers of the two parts correspond, i.e. the work to be done to rectify a defect in item 2 of scheduled work will be found in item 2 of the arising work.

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6.3.1. Spaceguard operation - Check Scheduled Work

1. Check all Spaceguard components are securely attached and free from damage paying particular attention to the direct drive sensors (Fig 2).

2. Check all cabling routing to sensors are free from damage paying particular attention to sensor connections plugs.

3. Ensure keyswitch for GKD screen is available and can be removed from the cab when required.

4. Ensure the machine is in a safe area free from obstructions, activate the height limit and virtual walls at 5m to the left and 5m to the right of the machine.

5. Raise the boom at the fastest speed possible, this should be noticeably slower than when the limits are not set.

6. Ensure the limit is not breached (A warning will be displayed if the limit is breached).

7. Slew towards the left virtual wall at the fastest speed possible, this should be noticeably slower than when the system is not set.


9. Slew towards the Right virtual wall at the fastest speed possible, this should be noticeably slower than when the system is not set.


Arising work Renew missing / Faulty components.

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Fig 2

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6.3.2. Earth bonding – Examine Scheduled Work

1. Examine the earth bond leads for fraying or damage. 2. Flex each end of the earth bond leads to check for loose or broken strands. 3. Check for loose or missing fasteners.

Arising work Renew defective or damaged cables. Renew loose or missing fasteners. After replacing or repairing any components carry out job 6.5.1 Earth bonding – Test.

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6.4.2. Height and virtual walls - Gauge Scheduled Work

1. Place the machine on track with rail gear fully deployed in a safe area free from obstructions.

2. Set a height limit of 3500mm, raise the machines arms until the motion cuts prevent any further operation. (dipper, boom and artic functions must be checked)

3. Measure the height of the highest point of the machine from the top of the rail head and ensure a height of 3500mm is not exceeded (Fig 3).

Fig 3

4. Turn off the height limit then set the Left and Right Virtual wall limits to 500mm less than the maximum radius of the machine.

5. Slew the machine to 90 degrees then extend the machines arm out until no further movement out is possible on the dipper, boom and Artic (If applicable).

6. Measure the distance from the centre of the machine to the end of the dipper. Ensure the limit has not been breached.

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7. Slew the machine to 270 degrees then extend the machines arm out until the system prevents any further operation.

8. Measure the distance from the centre of the machine to the end of the dipper. Ensure the limit has not been breached.

Arising work

Check machine data is correct. Re calibrate RCI system.

If this measurement is exceeded the machine must be removed from service immediately until the fault is rectified.

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6.5.1. Earth bonding – Test Scheduled Work

1. Using a suitably rated calibrated milliohm meter, measure the resistance from the end of the dipper arm down to both rail wheel sets. The maximum

permitted resistance is 0.15.

Arising work Use a suitably rated calibrated milliohm meter locate the high resistance connections or cables e.g. wheelsets to underframe. Renew defective components. Clean terminations and contact surfaces. Retest.

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6.5.2. Slew brake – Test Scheduled Work

1. Ensure the machine is in a safe area, free from obstructions and on a level surface.

2. Extend the machines arm out to maximum radius. 3. Record the slew angle show on the 3RCI display and turn off the machine. 4. Using a suitable calibrated load cell and another machine or suitable pulling

equipment apply a side load to the slew brake at 90 degrees to the dipper end as shown in Fig 4 and Table 1.

5. Leave the load applied for 30 minutes, ensure the load has not dropped off in this period, then remove the load.

6. Turn the machine ignition on and then check the slew angle is the same a previously recorded. Fig 4

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Table 1

MACHINE PULL FORCE

Colmar T10000 1986kg

GIGA 12 (SHORT ARM) 940kg

GIGA 12 (LONG ARM) 730kg

Case CX135 626kg

Kobelco SK135 628kg

Colmar T4300 1092kg

Volvo Excarailer 220 694kg

Arising work

Replace any faulty / damaged parts.

If the slew brake fails this test the machine must be removed from service immediately until the fault is rectified.

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6.5.3. Slow down operation – Test Scheduled Work

1. Ensure machine is in a safe area free from surrounding obstacles. 2. Set a virtual wall at 10m away from the machine. 3. Slew the machine right at full speed. 4. Record the time it takes for the machine to complete 1 full revolution. This

should be 21 seconds. 5. Slew the machine left at full speed. 6. Record the time it takes for the machine to complete 1 full revolution. This

should be 21 seconds. 7. Locate and Remove Din plug from solenoid coil labelled SDV6. 8. Slew the machine right at full speed. 9. Record the time it takes for the machine to complete 1 full revolution. This

should be 42 seconds. Slew the machine left at full speed.

10. Record the time it takes for the machine to complete 1 full revolution. This should be 42 seconds.

11. Re-fit Din plug to solenoid coil SDV6. 12. Set a height limit of 10m check the boom up, dipper up and Artic up

function if applicable, the raise speed should be significantly slower than when the height limit is not set.

Arising work

Replace any faulty / damaged parts. Consult manufacturer for slow down speed adjustment procedure.

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7. Torque Tables

Documents

GKD Spaceguard operation and maintenance - ajhplant.com