A20600.2 Maintenance TW2015 TW4030 DSC900.pdf

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All Rights Reserved Document A20600.2

MAINTENANCE

TW2015, TW4030 AND DSC900 PHALANX BARRIERS

Safety Precautions

At all times observe good safety practices when working on either the electrical or mechanical system. Particular attention should be paid to the danger of working on the Barrier when the power is on. Barriers are powerful hydraulic presses that can easily crush anything in their way. Keep hands free of the mechanism when the power is on or the HPU is up to pressure. Turn off the electric power and bleed the hydraulic pressure down to zero before working on any part of the system. Traffic should be controlled around the Barrier during any work so that vehicular accidents do not occur if the Barrier should happen to move. After work is complete, do not allow traffic over the Barrier until all control and safety functions have been verified to be properly working.

Barrier Disassembly, Service and Assembly

The Barrier assembly is designed to facilitate easy repair and maintenance. Depending on the environmental conditions, we recommend at least a one month interval of inspection to conform that no debris, sand or dirt is accumulated inside the Barrier that would interfere with its operation.

This can be easily checked by raising the road plate to its full up position and conducting a visual inspection under the road plates. Remove any foreign debris found. During the inspection, grease the bearing blocks if equipped with grease fittings. Open the side door to gain access to the hydraulic cylinder clevis pins and lubricate. Also examine the hydraulic cylinder to confirm that the seals are tight and that fittings are not leaking.

Should disassembly be necessary:

1) Lower the ramp plate fully.

2) Remove the two hinge pins from the Barrier hinge assemblies.

3) Remove the rod end clevis pin from the ramp plate clevis tang. Using suitable wire, tie the cylinder up so that it does not interfere with the removal of the barrier ramp plate.

4) Raise the outboard end of the ramp plate, using a well placed lever and insert a block measuring 3 to 5 inches [75 to 125 mm]. The block should be centered on the outboard end. DO NOT try to use a foot or hand to hold the road plate while placing the block!

With the ramp plate blocked and secure, it can now be moved after slinging using suitable ropes, chain or straps; or by directly lifting with a fork lift taking care to not damage the

Barrier finish with the forks. Lift the ramp plate up and forward, being careful not to damage the hydraulic cylinder and the hinges while lifting the ramp plate away from the frame.

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Ramp Plate Weights:

Model TW2015, 10 foot [305 cm] road plate, approximately 820 pounds [372 Kg].

Model TW4030, 20 foot [610 cm] road plate, approximately 1,640 pounds [743 Kg].

Model DSC900, 20 foot [610 cm] road plate, approximately 1,640 pounds [743 Kg].

5) Place ramp plate on a suitable surface, such as 4 x 4" [100 x 100 mm] blocking.

Full access to the hydraulic lines and cylinder, and the limit switch is made possible by opening the side panels of the end buttress. These devices can be inspected, repaired or replaced as required.

Before reassembly, any rust or other corrosion should be removed and the damaged finish coated with sealer or rust inhibiting paint. The foundation frame can be vacuumed of debris and the drain can be cleared as required.

When all is well, replace parts in reverse order. Use care to not cross thread the hinge pin set screws. We suggest that the threads be coated with anti-seize compound to prevent rusting and galling of the screws.

Inspect and lubricate all bronze style bearings and pins. Graphite/fiberglass bearings should be inspected for any damage and replaced as necessary, lubrication of these style bearings is optional. If any of the cylinder clevis or bearing pins have been deformed during removal, re-chamfer the ends before re-inserting.

Hydraulic System Cleanliness

The cleanliness of the hydraulic fluid directly affects the reliability of the hydraulic system and the longevity of the components. When contaminates are present, component wear and fatigue are accelerated, performance is degraded, valves, hydraulic motors and cylinders can malfunction and the hydraulic fluid may break down.

To maintain system efficiency and reliability great care must be taken to prevent any form of dirt, sand or grit from entering the hydraulic system. Only new, clean filtered hydraulic oil should be used for charging the unit. Unless specifically ordered as filtered, new oil should be pumped through a 25 micron filter when charging. See Commercial Hydraulic Oil Interchangeability Chart in the Mechanical Theory section of this manual for our recommended oils. The tests conducted at the factory on the system have been done with the HPU charged with Shell 'Tellus' 46. This grade is for moderate temperatures and is available in most of the world's leading cities.

Hydraulic oil is subject to degradation and contamination with age or if subject to high temperatures

(above approximately 180 degrees F [82 degrees C]). The contamination can be from the following sources:

1) Particulate (dust, dirt, sand, rust, fibers, paint chips, etc.)

2) Wear metals, silicon and excessive oil additives.

3) Water.

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4) Sealants (Teflon tape and pastes).

5) Sludge, oxidation and other corrosion products.

6) Acids and other chemicals.

7) Biological and microbes (for high water based fluids or other biodegradable fluids).

The hydraulic fluid should be sampled and tested periodically to ensure contamination and fluid properties are within acceptable levels. We suggest that the first test be done after one year of operation. The frequency of testing will depend upon the results of that test. Most major cities will have hydraulic fluid testing commercially available.

Pump Motor

Electric motors are basically dependable machines and require little maintenance. Too much attention may be worse then none. The following should be helpful in reducing maintenance.

Wherever possible, prevent:

1) Dampness and dripping water.

2) Dirt, especially dust, which may block ventilation.

3) Inaccessible position, in case maintenance is necessary.

4) Excessive heat. Surrounding air (ambient) temperatures must not exceed 104 degrees F

[40 degrees C]. Overloading a motor or operating it in an area where the temperature exceeds 104 degrees F [40 degrees C], may cause it to overheat. Frequent or prolonged starting periods or blocked ventilation are other causes of overheating.

The motor has front and rear ball bearings. The bearings have been given initial lubrication at the factory. Motors without regreasing capability are factory lubricated for normal bearing life. Motors having grease fittings should be lubricated by the procedure noted below if they have been in storage for over one year and at the following service intervals:

1) Every five years based on 5000 hours per year operation.

2) Every two years based on continuous operation.

3) Every six months for continuously high ambient temperature and or dirty or extremely moist locations.

Greasing procedure:

1) Keep grease clean. Lubricate motors at standstill. Do not mix petroleum grease and silicone grease in motor bearings.

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2) Use Shell Oil Company "Dolium R", Chevron "SRI No. 2" or Texaco Inc. "Premium RB".

3) Over-greasing bearings can cause premature bearing failure. If motor is equipped with an

Alemite type fitting, clean tip of fitting and apply grease gun.

Pump Replacement

The following recommendations are given should replacement of the pump be required:

1) Damage to this component is generally caused by debris contamination in the oil.

Replacement of the pump is an indication that the oil must be drained and replaced with clean filtered oil.

2) When changing out the pump, avoid contamination. Do not remove the plastic port plugs until just prior to installing the fittings and hoses. The pump mounting flange must make full contact with the pump/motor adapter. Do not use the pump mounting bolts to force the pump pilot into the pilot hole or to align the pump. To avoid damaging the pump seals and bearings, do not hammer on the pump or shaft to install or remove the pump/motor couplings.

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SUMMARY OF SAFETY ASPECTS REGARDING MAINTENANCE

ON OR ABOUT THE BARRIERS

General

At all times observe good safety practices when working on either the electrical or mechanical system. Particular attention should be paid to the danger of working on the Barrier when the power is on. Barriers are powerful hydraulic presses that can easily crush anything in their way.

Keep hands free of the mechanism when the power is on or the HPU is up to pressure. Turn off the electric power and bleed the hydraulic pressure down to zero before working on any part of the system. Traffic should be controlled around the Barrier during any work so that vehicular accidents do not occur if the Barrier should happen to move. After work is complete, do not allow traffic over the Barrier until all control and safety functions have been verified to be properly working.

Maintenance Work In The Area About Barrier

1) Select Barrier UP or DOWN position as desired from the control panel.

2) Turn control panel key switch to OFF position and remove key.

3) Turn system power OFF at the disconnect on the hydraulic power unit (HPU). Padlock the disconnect with your personnel lock.

4) Proceed with maintenance. DO NOT PREFORM ANY WORK UNDER THE BARRIER OR

INSIDE THE BARRIER ACCESS AREAS! Should work be required under the Barrier or inside the access areas, follow the procedures in the next section.

5) When all work is finished, remove padlock and turn HPU disconnect ON. Return panel key to the control panel.

Maintenance Work Under the Barrier or in the Barrier Access Areas

1) Select Barrier UP or DOWN position as desired from the control panel.

2) Turn control panel key switch to the OFF position and remove key.

3) Turn system power OFF at the disconnect on the hydraulic power unit. Padlock the disconnect with your personnel lock.

4) If Barrier is in the UP position, securely block Barrier to prevent falling. Note: Lifting eyes secured in the tapped holes provided in the road plate can be used for chaining the Barrier in the UP position.

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5) Bleed down the system:

A) Release set screw (or lock nut) on the system bleed down valve. Turn (anti-clockwise) the handle on the valve slightly until hissing sound is heard. Continue to open slowly until pressure on gage reads zero.

B) For added safety, leave valve open while performing maintenance.

6) Check that the Barrier is firmly held against movement.

7) Proceed with maintenance. Minimize any exposure to working under the Barrier by using tools with handle extensions when ever possible.

8) When all work is finished, remove padlock and turn HPU disconnect ON. Close any valves opened in the bleed down procedure. Return panel key to the control panel.

System Maintenance

The following maintenance procedures and schedules should be adhered to in order to assure safe, long and trouble free service from your Delta Barrier System:

REMEMBER: SAFETY FIRST !!!

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MAINTENANCE SCHEDULE

FIRST WEEK

Check operation of the Barrier at least once daily. Have the guards or operators report if Barrier fails to operate, or operates with a jerky motion. It is recommended that someone be on call who can explain the operation of the Barrier system to each new guard or operator.

Daily Check

1) Log pressure settings on sheet supplied in this section.

2) Check for leaks around all fittings. Tighten where necessary.

3) Check that hydraulic hoses (if used) are not rubbing on any hard or sharp surfaces.

Especially check where hose enters conduit or where it may contact the ground.

4) Replace oil filter (if applicable) after first week of operation.

5) Check oil level in the site glass after the pump/motor has run to full pressure and shutoff. If level appears to be falling, investigate the HPU and Barrier fittings and the hydraulic lines.

6) See appropriate Trouble Shooting section of the manual if any faults are observed.

7) Check all control functions for complete operation of all features.

8) Check Barrier hinge pin set screws for tightness. Check all fasteners on the buttress covers tightness.

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MONTHLY

Check and service the following at monthly service intervals:

Note: Block traffic during maintenance to prevent accidents.

1) Shut system off and drop system pressure to zero.

2) Check the accumulator pressure while the system is at zero pressure using Delta Charging

Kit 2469-31 or equal. If tool is not available, observe the value that the pressure gage jumps to when power is again turned on. (See Hydraulic Section for details.) Log value and pressure setting on Log sheet provided.

3) Add clean, filtered oil to the top of the site glass. Important! Only add oil to the system when there is no oil pressure on the system. Large oil leak could occur if added when system is at pressure!

4) Replace the oil filter at first monthly maintenance. For systems that are cycled less than

100 cycles per day, replace every third month there after. If system is cycled above this rate, or the location is in a high dust environment, replace filter monthly.

5) Remove Barrier access plates and check for debris build up in the area of the mounting frame. Check for indications of oil leaks around the cylinder and Barrier header fittings.

Tighten fittings and clean debris as necessary.

6) Check the operation of the Barrier heaters if so equipped. They should get warm approximately one minute after energizing.

7) Clean dust and debris from around HPU tank and hydraulic lines. Wipe up any spilled oil.

8) Check Barrier hinge pin set screws for tightness. Check all fasteners on the buttress covers tightness.

9) Turn power on and bring system back to operation.

10) Confirm that the Barrier operates smoothly during the raise and lower cycle. Adjust speeds as desired. (See Start Up section of this manual for proper operating speeds, Do Not operate too fast!)

11) Check all control functions for complete operation of all features.

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YEARLY

Check and service the following at yearly service intervals in addition to the monthly check:

Note: Block traffic during maintenance to prevent accidents.

1) Drain the oil from the reservoir and flush with mineral spirits or clean oil. After wiping down the tank sides and bottom to assure that no contamination remains, replace with clean filtered oil.

2) Remove Barrier inspection covers, check that the hydraulic cylinders are not leaking internally (see Hydraulic Trouble Shooting section for details). Replace cylinder seals or cylinder as necessary.

3) Check cylinder clevis pins for wear, replace as necessary.

4) Examine the mounting frame for debris buildup, check any drain lines and sump wells for drainage. Clean debris.

5) Tighten or replace any loose bolts. Drill and tap to next size or use inserts if threads are stripped.

6) Check condition of the Barrier paint surface. Prepare, prime and touch up areas where the paint has be chipped or worn away. Apply new reflective tape as necessary.

7) Check the hydraulic interconnect lines for kinks, contact wear or bulging. Replace or protect hoses as required.

8) Thoroughly clean the HPU, removing dust and spilled oil. Remove any rust build up on components. Touch up paint where necessary.

9) Check the accumulator pressure while the system is at zero pressure using Delta Charging

Kit 2469-31 or equal. If tool is not available, observe the value that the pressure gage jumps to when power is again turned on. (See Hydraulic Section for details.) Log value and pressure setting on Log sheet provided.

10) Test motor starter overloads by pressing the test button. Replace if necessary or press reset. Auto/Manual switch should be in the Manual position.

11) Check the pressure relief valve by depressing the starter armature and allowing unit to run to the relief pressure value of 1600 psig [110 bar]. Adjust as necessary.