A30610.1 DSC700 Series Hydraulic Bollard Maintenance.pdf

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All Rights Reserved Document A30610.1

MAINTENANCE

DELTA SERIES DSC700 HYDRAULIC BOLLARD SYSTEMS

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 Bollards when the power is on. The Bollards 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 Bollards during any work so that vehicle accidents do not occur if the Bollards should happen to rise. After work is complete, do not allow traffic over the Barrier until all control and safety functions have been verified to be properly working.

Bollard Disassembly, Service and Assembly

The Bollard 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 confirm that no debris, sand or dirt is accumulated inside the Bollard that would interfere with its operation. This can be easily checked by removing the top cap on the bollard tube and conducting a visual inspection. During the inspection, also examine the hydraulic cylinder to confirm that the seals are tight and that fittings are not leaking. Should disassembly be necessary:

1) Remove all top plates (access box cover) (ground plate) and (cover plate).

2) Remove upper cylinder hanger by removing screws and cylinder cross pin.

3) Remove (3) ¾-10 hex nuts from guide rods surrounding cylinder.

4) Note orientation of notch in stop plate, lift off and set aside stop plate.

5) Bollard is now disconnected and may be lifted and removed. Upper cylinder hanger may be installed upside-down and used as an attachment point for a suitable strap or chain.

Remember, Bollard tube and casting assemblies may weigh up to 900 pounds [408 kg].

6) To remove cylinder the hoses must be disconnected from bulkhead fittings in the access box. Hoses must be capped to protect from debris that has collected in the sweep. Prior to removal, affix an electrical fish tape or a pulling rope to the hoses to aid in re-assembly.

7) Grab and lift the cylinder straight up while feeding the other end of the hoses down through the sweep.

Full access to the hydraulic lines and the cylinder is now possible. These can be inspected, repaired or replaced as required. Before reassembly, any rust or other corrosion should be removed and the area coated with sealer or rust inhibiting paint. The foundation tube can be

Copyright 2014 Delta Scientific Corporation Page 2 of 8 vacuumed of debris and the drain can be cleared as required. Inspect the ¾-10 male threads on the ends of the guide rods. Consider running a thread chaser or die over the threads if they show signs of damage. This will make starting the nuts during reassembly much easier.

When all is well, reassemble by:

1) To re-assemble, orient the hoses directly over the internal sweep in the bollard foundation/ground tube. Make sure that the cylinder basket plate holes line up with the guide rods.

2) While lowering the cylinder and basket assembly in to place, gently pull the hoses up through the sweep.

3) Re-attach cylinder hoses to bulkhead fittings in the access box.

4) Once the basket assembly is fully seated at the bottom of the foundation/ground tube, re-insert the bollard making sure that the limit switch magnets embedded in or attached to the bollard tube (if equipped) are facing the switches in the access box.

5) Reinstall the stop plate, taking care to align the notch in the stop plate with the key welded to the inside of the bollard tube. If the bollard tube was installed correctly, the notch in the stop plate should align as noted in step 4 of the disassembly process.

Install and tighten the ¾-10 nuts and lock washers.

6) Attach the rod-end cylinder clevis to the upper cylinder hanger and then install the upper cylinder hanger inside bollard tube.

7) Finally, re-install all top plates and covers.

It is advised that an anti-seize compound or heavy grease be used on the cylinder clevis pins and the basket sides to assist Bollard disassembly the next time it is required.

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.

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

(above approximately 180ºF [82ºC]. 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.

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’s operation. The frequency of testing will depend upon the results of that test. Most major cities will have hydraulic fluid testing commercially available.

Filters

A filter element is furnished to filter the oil as it is being returned to the oil reservoir. The oil filter housing is only rated at 150 psig [10 bar] or less as the oil in the return line has only to overcome the pressure drop through the filter itself. If the filter should become clogged with particulates from the system, a bypass check valve inside the filter will open and allow the dirty oil to circulate back to the reservoir. For this reason, frequent inspection of the filter is required.

Larger sets of Bollards may be equipped with a pressure type filter that filters the oil immediately after the hydraulic pump. Since these filters see the full system pressure of 1900 psig [131 bar], they are equipped with heavy duty steel housings. Again, the comment about regular filter maintenance applies.

A visual determination of the filter's degree of contamination should be made during filter change outs. Adjust the interval between changes if a high degree of particulates are found.

Pump Motor

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

Wherever possible, prevent:

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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 104ºF [40ºC].

Overloading a motor or operating it in an area where the temperature exceeds 104ºF

[40ºC], 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 regreasing capability should be relubricated 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 moist locations.

Greasing procedure:

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

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

3) Overgreasing bearings can cause premature bearing failure. If motor is equipped with an

Alemite type fitting, clean tip of fitting and apply grease gun. Use only one to two full strokes.

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. A check of the filter and your filter changing procedures is also in order.

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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System Maintenance

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

REMEMBER: SAFETY FIRST !!!

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MAINTENANCE SCHEDULE

FIRST WEEK

Check operation of the Bollards at least once daily. Have the guards or operators report if Bollards fail to operate, or operate with a jerky motion. It is recommended that someone be on call who can explain the operation of the Bollard 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) 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 Bollard fittings and the hydraulic lines.

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

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

7) Replace the oil filter at the end of the first week of operation.

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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) 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.

3) 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.

4) Confirm that the Bollards operate smoothly during the raise and lower cycle. Adjust speeds as desired.

5) Remove Bollard top cap and check for debris build up in the bottom of the foundation tube.

Check for indications of oil leaks around the cylinder and Bollard bulkhead fittings. Tighten fittings and clean debris as necessary.

6) Check the operation of the Bollard heaters. They should get warm in approximately one minute after energization.

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

8) Turn off pump/motor power, bleed system pressure to zero and add clean, filtered oil to the top of the site glass.

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

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

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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 Bollard top cap and road plates, check that the hydraulic cylinder is not leaking internally (see Hydraulic Trouble Shooting section for details). Replace cylinder seals or cylinder as necessary.

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

4) Examine the foundation tubes for debris buildup, check drain lines and sump wells for drainage. Clean debris.

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

6) Check condition of the Bollard 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 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 2200 psig. Adjust as necessary.