Checkline II maintenance manual

Fall protection / Documentation

Here you can read the maintenance manual for Checkmate's Checkline II fixed installations.

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1. CHECKMATE Award Winning Lifting & Height Safety Equipment Since 1979 Designed and Built in Great Britain by Great Britons www.checkmateuk.com LET’S INNOVATE sales@checkmateuk.com TM-009 Maintenance Manual Issue. 3 MAINTENANCE MANUAL Issue No. Date Revision Sig 3 8/8/2014 Maintenance Manual Only DB 20. CHECKMATE Award Winning Lifting & Height Safety Equipment Since 1979 Designed and Built in Great Britain by Great Britons www.checkmateuk.com LET’S INNOVATE sales@checkmateuk.com MAINTENANCE MANUAL TM-009 Maintenance Manual Issue. 3 2015 © Checkmate 6. TM - 009 CHECKLINE II Maintenance M anual Issue. 3 This manual is a control document of Checkmate Lifting & Safety L td . It must not be copied or amended without prior written approval from Checkmate Lifting & Safety L td . 6 7. TM - 009 CHECKLINE II Maintenance M anual Issue. 3 This manual is a control document of Checkmate Lifting & Safety L td . It must not be copied or amended without prior written approval from Checkmate Lifting & Safety L td . 7 8. TM - 009 CHECKLINE II Maintenance M anual Issue. 3 This manual is a control document of Checkmate Lifting & Safety L td . It must not be copied or amended without prior written approval from Checkmate Lifting & Safety L td . 8 9. TM - 009 CHECKLINE II Maintenance M anual Issue. 3 This manual is a control document of Checkmate Lifting & Safety L td . It must not be copied or amended without prior written approval from Checkmate Lifting & Safety L td . 9 10. TM - 009 CHECKLINE II Maintenance M anual Issue. 3 This manual is a control document of Checkmate Lifting & Safety L td . It must not be copied or amended without prior written approval from Checkmate Lifting & Safety L td . 10 11. TM - 009 CHECKLINE II Maintenance M anual Issue. 3 This manual is a control document of Checkmate Lifting & Safety L td . It must not be copied or amended without prior written approval from Checkmate Lifting & Safety L td . 11 14. TM - 009 CHECKLINE II Maintenance M anual Issue. 3 This manual is a control document of Checkmate Lifting & Safety L td . It must not be copied or amended without prior written approval from Checkmate Lifting & Safety L td . 14 3 EXAMINATION REPORTS 3.1 Cable System - Periodic Examination Report 15. TM - 009 CHECKLINE II Maintenance M anual Issue. 3 This manual is a control document of Checkmate Lifting & Safety L td . It must not be copied or amended without prior written approval from Checkmate Lifting & Safety L td . 15 3.2 Anchorage Device - Periodic Examination Report 5. TM - 009 CHECKLINE II Maintenance M anual Issue. 3 This manual is a control document of Checkmate Lifting & Safety L td . It must not be copied or amended without prior written approval from Checkmate Lifting & Safety L td . 5 1.5 Parts List for CheckLine II System 17. TM - 009 CHECKLINE II Maintenance M anual Issue. 3 This manual is a control document of Checkmate Lifting & Safety L td . It must not be copied or amended without prior written approval from Checkmate Lifting & Safety L td . 17 4 RISK ASSESSMENT S 4.1 H & S Risk Assessment Example Before the commencement of the installation of the Checkline II system there should be a Risk Assessment and a Method Statement produced, examples of these are shown below . 18. TM - 009 CHECKLINE II Maintenance M anual Issue. 3 This manual is a control document of Checkmate Lifting & Safety L td . It must not be copied or amended without prior written approval from Checkmate Lifting & Safety L td . 18 4.2 Method Statement Exam ple 19. TM - 009 CHECKLINE II Maintenance M anual Issue. 3 This manual is a control document of Checkmate Lifting & Safety L td . It must not be copied or amended without prior written approval from Checkmate Lifting & Safety L td . 19 6 ADDITIONAL INFORMATI ON This manual is written to comply with the relevant British and European Standards and Codes of Practice Systems specified . I nstall ations outside of the guidance of these standards and Cod es of Practice are the responsibility of the installer. Systems installed in countries elsewhere must be specified in accordance with the recognised Standards of that country at that time. All parts of the system are either stainless steel or zinc coated with a powder coated paint finish. Stainless steel can mark by handling resulting in staining of the surface later. All parts must be left in a clean condition by wiping with a bio - degradable cleaner. Parts not supplied by Checkmate Lifting & Safety L td such as anchor bolts must be of a construction grade stainless steel. To avoid bi – metallic corrosion , dissimilar metals must be isolated from each other using a non conductive barrier such as nylon or rubber. Stainless Steel wire rope must be 7x7x 8mm and have a certification of minimum breaking load 38kN. Wire rope must be NO smaller than 7.9mm and No bigger than 8.2mm. (Nominal 8mm.) 16. TM - 009 CHECKLINE II Maintenance M anual Issue. 3 This manual is a control document of Checkmate Lifting & Safety L td . It must not be copied or amended without prior written approval from Checkmate Lifting & Safety L td . 16 3.3 Installation Plate Manufactured in the UK by Checkmate Lifting & Safety LLP, Sheerness, Kent. ME12 1PZ Tel: +44 (0) 1795 580 333 Fax: +44 (0) 1795 668280. www.checkmateuk.com 4. TM - 009 CHECKLINE II Maintenance M anual Issue. 3 This manual is a control document of Checkmate Lifting & Safety L td . It must not be copied or amended without prior written approval from Checkmate Lifting & Safety L td . 4 Under no circumstances can the system be used if the cable tension is in the Red zone. 1.3.1 Correct Tension for TopFix Installations On TopFix installation s refer to 1.4 for examples of allowable sag in the cable. This is to be used as a guide to the m inimum tension in the system. W hen using TopFix posts , lower tensions are recommended than structural systems. This is controlled by the top scale on the loadcell, marked “TopFix systems” , and is indicated by the pin sitting entirely within the green zone. As a rule, tension the system until the pin just sits fully in the green zone, and provided the sag is within the limits set out in 1.4 , do not tension further. Allow at least 30 minutes for the system to stabilise and equalise across its entirety. Check tensions again and adjust if necessary. 1.3.2 Correct Tension for Wall Installations When installing a system directly onto a wall, the cable can be tensioned more than in the case of the TopFix system. The bottom scale labelled “IDS systems” is to set the tension on wall installations. The green zone is extended to allow f or more tension to be applied to the system. 1.4 Sag Allowa nce in W ire. With no deflection (sag) the c able lays 200mm above the ground ( measured to the centre line of the cable ) . Figure 1 and Figure 2 demonstrate example sag values for 5 and 10m spans. These are based on a system which has been correctly tensioned, and should be used as a guide to the expected amount of sag in a system. Cable sag should not be a cause for co ncern unless the amount of sag exceeds these levels. 1.4.1 5m span Figure 1 : 5m S pa n with W ire S ag of 35mm 1.4.2 10m span Figure 2 : 10m S pan with W ire S ag of 10 0mm 165mm 100mm 3. TM - 009 CHECKLINE II Maintenance M anual Issue. 3 This manual is a control document of Checkmate Lifting & Safety L td . It must not be copied or amended without prior written approval from Checkmate Lifting & Safety L td . 3 1 CHECKLINE II MAINTENANCE INFORMATION 1.1 Overview The Checkmate CheckLine II syst em requires maintenance at leas t annually by a Checkmate trained competent person working for a Check m a te approved authorised service agent. This manual provides details of the maintenance requirements 1.2 Function of the CheckL ine II System The CheckLine II system provides a continuous anchor point for a harness connection , via a lanyard , where there is a risk of a fall from height. Permanently fixed lifelines are categorised into two types , see below . A fall restraint system is much safer th a n fall arrest, which must only be used when a fall restraint system cannot be configured.  Fall R estraint – This tethers the user and prevents him from reaching a position from which he may fall. This provides the bes t protection and eliminates the need for a rescue , by removing the possibility of a fall occurring while the user is attached to the system .  Fall Arrest – This also tethers the user but does not limit movement to a fall restraint. It p rovides a safe work ing environment where it is not possible to configure a fall restraint system. The user is not prevented from falling, but is protected in the event of a fall. If a fall occurs the system wi ll absorb energy and bring the user to rest suspended from the s ystem. When a fall occurs a rescue must be undertaken by trained personnel using full safety equipment . It is imperative to the health of the user that a rescue is performed as soon as possible. 1.3 Cable Tension The tension in the cable is important to ensure the correct operation of the system. If the tension is too little , the cable will sa g excessively , possibly lay on the floor, a nd may also caus e problems with the trolley pas sing over the brackets smoothly . I f the tension is too great the system will not offer the required energy absorption properties to minimise injury if a fall occurs. I t may also damage the system or the surface to which the system is attached. Systems of greater than 20 metres, or those which have more than two corners, must be fitted with an adjuster at each end. For a simple system under this length it may be sufficient to have a n adjuster at one end only. Different types of adjuster are explained i n section Error! Reference source not found. , along with procedures for applying the correct level of tension in the system . The correct tension must take into account the span between fixing points and the weight of the cable. Refer to 1.4 for examples of allowable sag in the cable when the system is fully tensioned. 13. TM - 009 CHECKLINE II Maintenance M anual Issue. 3 This manual is a control document of Checkmate Lifting & Safety L td . It must not be copied or amended without prior written approval from Checkmate Lifting & Safety L td . 13  Where necessary clean the system and lubricate with PTFE aerosol.  Check all user equipment on site.  While moving along the system checking the components and t he cable, a check shoul d also be made to the structure the system is attached to. Any signs of deterioration of the building fabric should be reported as it could comprise the safety of the system. 2.4 Replacement of Damaged Parts  Slacken the cable.  Cut awa y swaged components from the cable as close to the item as possible.  Replace the swaged component and add an additional cable connector to compensate for the reduced length.  Reconnect the system to the end anchor points and re - tension the cable. 2.5 Examination R eport A full report of the examination should be made (using the official report sheet which lists all parts of the system with appropriate ‘tick’ boxes , see 3 ) and signed and dated by the competent person making the examination. The recommendations for repairs or replacement of parts should be included and the system should under no circumstances be used until any repair work has been completed and the system fully tested. If a system after inspection is deemed unsafe by the competent person, a “Red unsafe to use” tag must be attached to the exit/entry points. Report sheet format: 1 Complete list of all parts of system with tick boxes indicating: A) Good condition b) Unserviceable 2 List of all recommendations for repair or replacement of parts 3 List of all work carried out 4 Test result 5 Signed and dated by a competent person 12. TM - 009 CHECKLINE II Maintenance M anual Issue. 3 This manual is a control document of Checkmate Lifting & Safety L td . It must not be copied or amended without prior written approval from Checkmate Lifting & Safety L td . 12 2 MAINTENANCE 2.1 Regular Maintenance Regular m aintenance checks must be carried out at least once every twelve months, and include the following checks.  V isual c heck on the condition of: 1) The cable for corrosion or damage . 2) The brackets and corner assemblies . 3) The structure the CheckLine II is attached to .  The operation of the trolley . 2.2 After a Fall Arrest If a fall occurs the system must undergo a complete examination, as explained fully in section 2.3 . This must include the following points.  Replacement of all dam aged or suspected damaged parts .  Complete check that the system is restored to safe working condition.  Record all work carried out using the supplied record sheets. 2.3 Examination The complete system should be examined and possible causes of corrosion or de terioration in both the system and the structure it is attached to must be reported.  If there is any reason to doubt the safety of the system being examined, then the technician examining it must ensure that alternative safety equipment is used whilst con ducting the inspection.  Attention should be paid to any signs of corrosion or damage as a result of scuffing or misuse of the system. Damage from attack by acids should also be checked. Any abnormal wear requires the cable to be replaced. Any signs of dis colouration or variations of colour in the cable should be taken as a sign of possible corrosion. Particular attention should be paid to the condition of swaged attachments and they should be checked for cracking, or movement. Points where the cable enters the brackets should also be checked for cracking, bending or distortion, and signs of corrosion from within the guide tubes.  Brackets must be checked for cracks or damage and mounting bushes, rivets or bolts should all be checked for tightness and conditi on.  Ensure that the trolleys are in good condition and that the attachment mechanisms operate freely.  Ensure the Load cell and Damper are functioning properly. Test by pulling on the cable and check locking nuts are tightened.  Where entry/exit gates are i nstalled, check that the mechanism works freely and that there are no cracks or bent components. 2. TM - 009 CHECKLINE II Maintenance M anual Issue. 3 This manual is a control document of Checkmate Lifting & Safety L td . It must not be copied or amended without prior written approval from Checkmate Lifting & Safety L td . 2 CONTENTS 1 CHECKLINE II MAINTEN ANCE INFORMATION ................................ .... 3 1.1 Overview ................................ ................................ ................................ ................................ ........ 3 1.2 Function of the CheckLine II System ................................ ................................ .......................... 3 1.3 Cable Tension ................................ ................................ ................................ ................................ 3 1.3.1 Correct Tension for TopFix I nstallations ................................ ................................ .............. 4 1.3.2 Correct Tension for Wall Installations ................................ ................................ .................. 4 1.4 Sag Allowance in Wire. ................................ ................................ ................................ ................. 4 1.4.1 5m span ................................ ................................ ................................ ................................ . 4 1.4.2 10m span ................................ ................................ ................................ ............................... 4 1.5 Parts List for CheckLine II System ................................ ................................ ............................. 5 2 MAINTENANCE ................................ ................................ ..................... 12 2.1 Regular Maintenance ................................ ................................ ................................ .................. 12 2.2 After a Fall Arrest ................................ ................................ ................................ ....................... 12 2.3 Examination ................................ ................................ ................................ ................................ 12 2.4 Replacement of Damaged Parts ................................ ................................ ................................ . 13 2.5 Examination Report ................................ ................................ ................................ .................... 13 3 EXAMINATION REPORTS ................................ ................................ .... 14 3.1 Cable System - Periodic Examination Report ................................ ................................ .......... 14 3.2 Anchorage Device - Periodic Examination Report ................................ ................................ ... 15 3.3 Installation Plate ................................ ................................ ................................ ......................... 16 4 RISK ASSESSMENTS ................................ ................................ ........... 17 4.1 H & S Risk Assessment Example ................................ ................................ ............................... 17 4.2 Method Statement Example ................................ ................................ ................................ ....... 18 6 ADDITIONAL INFORMATI ON ................................ ............................... 19

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