AF10645 Maintenance DSC2000.pdf

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All Rights Reserved Document AF10645

MAINTENANCE

DELTA MODEL DSC2000 PHALANX® BARRIER SYSTEMS

IMPORTANT

READ THE SUMMARY ON THE SAFETY ASPECT REGARDING MAINTENANCE ON OR

ABOUT THE BARRIER – PAGE 7 AND 8 OF THIS DOCUMENT

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 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.

A Barrier ramp brace is provided for each Barrier in the system. The Barrier ramp brace should be in place and firmly bolted in position when working under the Barrier ramp. The Barrier ramp brace is stowed in the Barrier frame when not in use. This makes it readily available for use at all times.

Particular attention should be paid to the rigging and lifting equipment used when installing, moving, removing, relocating or servicing any of the heavy elements of the Barrier system. The rigging and lifting gear should be properly sized and attached when lifting heavy components in all instances.

Each Barrier ramp has two attachment points (threaded 3/4"-10 for heavy eye bolts) that are located on the front and rear edges of the ramp and in line with the center of gravity of the ramp.

The rear axle lugs can be also be used to attach the lifting gear to the ramp rear edge. The attachment means between the Barrier ramp and the lifting gear must be sized or designed to take into consideration both the vertical lift as well as side loading conditions.

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 installing the ramp brace (read the summary on the safety aspect regarding maintenance on or about the barrier – page 7 and 8 of this document) and removing the hydraulic cylinder shroud. Conduct a visual inspection of the hydraulic cylinder, optional limit switches and heaters and the underside of the Barrier ramp. Particular attention should be given to the hydraulic cylinder to confirm that the seals are tight and not leaking. Cylinder clevis pins, cotter pins and bushings should be inspected and lubricated as needed. The main Barricade bearings should be inspected at the same time at the rear of the Barricade. Grease the bearing blocks if equipped with grease fittings.

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Should disassembly be necessary:

1) Remove the bearing block inspection plates if equipped.

2) Raise the Barrier ramp to its guard position using the hydraulic pumping unit or an auxiliary means such as a crane, forklift or other properly sized lifting means. The 3/4"-10 threaded attachment point near the front lip of the barrier plate is provided for this purpose. See the

Safety Precautions above dealing with rigging and hoisting.

3) Install the Barrier ramp brace. Bolt firmly in position.

4) Remove the front Barrier visibility panel.

5) Remove the chain assemblies.

6) Remove hydraulic cylinder clevis pins at the Barrier ramp.

7) Secure the Barrier ramp in the up position using a crane, forklift or other properly sized lifting means.

8) Remove the Barrier ramp brace and slowly lower the Barrier ramp to its flush down position.

9) Remove the bearing block bolts at the rear hinge area.

10) Each Barrier ramp has two attachment points (threaded 3/4"-10 for heavy eye bolts) that are located on the front and rear edges of the ramp and in line with the center of gravity of the ramp. The rear axle lugs can be also be used to attach the lifting gear to the ramp rear edge. Using a suitable rope, chain or sling, slowly lift the Barrier ramp plate. Once the front lip is above the foundation frame, the ramp plate can be leveled and guided away from the foundation. Insure that the ramp plate it doesn’t swing or rock while it is moving. Damage to critical components can occur if it is allowed to strike the foundation or its elements, hydraulic cylinders or limit switches.

Full access to the hydraulic lines and the cylinders 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 can be vacuumed of debris and the drain can be cleared as required.

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. Anti-seize compound has been used on the bearing block bolts at factory assembly, reapply if you remove the bolts. The proper torque value is 45 foot-lbs [60 N-M]. Check for sand and construction debris about the bearings and shafts and clean if necessary. Reassemble in reverse order.

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Photo 1 - Safety brace in place and the chain pin removed. The chains are laying on the floor of the

Barrier frame assembly.

Photo 2 - Safely lifting the DSC2000 ramp plate.

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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 worlds leading cities. Hydraulic oil is subject to degradation and contamination with age or if subject to high temperatures (above 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.

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.

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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:

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.

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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.

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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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. Note: Properly install the safety legs before working on, in or around a Barrier in the UP position. Traffic should be controlled around the Barrier during any work so that vehicular accidents do not occur if the Barrier 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.

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 PERFORM 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 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 the Barrier to prevent it from falling. Barrier ramp braces are provided with each Barrier system. The Barrier ramp braces should be in place and firmly bolted in position when working under the Barrier ramp. The Barrier ramp braces are stowed in the Barrier frame when not in use. This makes them readily available for use at all times.

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5) Bleed down the system:

A) If system is equipped with the optional auxiliary emergency fast operate system, release the auxiliary EFO valve override pin by twisting and pulling to the out

B) 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.

C) For added safety, leave the bleed down 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 whenever possible tools with handle extensions.

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.

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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) 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.

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.

8) Check all top plate bolts for tightness. Note any tendencies for the top plate bolts to loosen.

End of First Week Test

Implementation of Safety Procedures

1) Cone off a safe barrier work area and rerouted traffic.

2) Clear the barrier work area of vehicles and pedestrians.

3) Place the barriers in the raised position from the Master Control Panel, Slave Control Panel or Main Direction Valve Solenoid.

4) Turn the Master Control Panel and Slave Control Panel keys to the off position.

5) Verify the Red LED Power indicator was not illuminated.

6) Remove the keys from the Master and Slave Control Panels.

7) Terminate power and lock out/tag out the breakers in the Main Breaker Panel.

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8) Terminate power to the barrier motor at the disconnect panel located in the HPU by moving the lever to the OFF position.

9) Place a lock on the disconnect panel in the HPU.

10) Locate the safety leg and bolts in the HPU and position them on each side of the barrier.

11) Position an observer in front of the barrier to watch for barrier movement prior to installing the safety legs.

12) Install each of the safety legs by aligning the legs with the barrier and threading the bolt into the hole in the barrier top plate.

13) Tighten the safety leg bolts using an adjustable wrench or similar tool.

14) Bleed the hydraulic pressure to zero by turning the system bleed down valve counter-clockwise until a hissing sound was heard.

15) Verify the barrier had lowered until supported by the safety legs.

First Week Preventive Maintenance Inspection

16) Log the HPU pressure as indicated on the Hydraulic Pressure Gauge located in the HPU

(Prior to bleeding pressure off system).

17) Inspect all hoses and fittings for leaks.

18) Tighten fittings when leaks were recognized.

19) Inspect the hoses, ensuring no hoses are resting on the ground.

20) Identify the hydraulic oil filter and replace with adequate replacement filter.

21) Inspect all top plate bolts (hinge cover plates & access box cover plate) for tightness.

22) Inspect all Barrier Skirt (Front & Side) bolts for tightness.

23) Inspect the barrier cavity for proper drainage and drain blockage.

Restoring Barrier to Operational Status

24) Turn the system bleed valve clockwise until tight.

25) Remove the lock and place the disconnect panel lever to the ON position restoring power to the motor.

26) Verify the motor engaged.

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27) Verify the system was building pressure by observing the Hydraulic Pressure Gauge.

28) Verify the barrier motor automatically shut off when hydraulic pressure reached 2150 psig as indicated on the hydraulic pressure gauge.

29) Initiate an UP sequence at the Main Direction Valve Solenoid.

30) Verify the barrier rose to the full UP position and tension was removed from the safety legs.

31) Place an observer in front of the barriers.

32) Remove the safety legs and bolts.

33) Store the safety legs and bolts in the HPU.

34) Restore power to the breakers at the main breaker panel.

Functional Test of Barrier Operation

35) Verify no vehicle or pedestrians were on or near the barriers prior to initiating the functional test.

36) Insert the keys into the Master and Slave Control Panels.

37) Turn the keys in the Master and Slave Control Panels to the ON position.

38) Verify the Red LED Power light illuminated when the key was placed in the ON position.

39) Verify the Red LED barrier status lights were illuminated on the Master and Slave

Control Panel indicating the barriers were in the raised position.

40) Verify the three flashing LED's on the barrier front skirt were operational.

41) Verify the light on the light tree was steady red indicating the barriers were in the up

42) Depress the down button for each barrier.

43) Verify the Barrier status indicator LED on the Master and Slave control panel changed from Red to Green indicating the barrier was in the down position.

44) Verify the barriers were in the down position.

45) Verify the light on the light tree changed from Red to Flashing Amber indicating the barrier was in the down position.

46) Depress the UP button for each barrier.

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47) Verify the Barrier status indicator LED on the Master and Slave Control Panel changed from Green to Red.

48) Verify the three flashing LED's on the barrier front skirt were operational.

49) Verify the light on the light tree was steady red indicating the barriers were in the up

50) Depress the down button for each barrier to return the barrier to the down position.

51) Depress the Emergency Fast Operate Button (EFO).

52) Verify the Emergency Red LED on the control panel was illuminated.

53) Verify all Barrier Status Indicator LED on the Master and Slave Control Panel had changed from Green to Red.

54) Press the up/down Barrier control buttons to verify they were inoperable.

55) Verify the three flashing LED's on the barrier front skirt were operational.

56) Verify the light on the light tree was steady red indicating the barriers were in the up

57) Depress the EFO reset button.

58) Verify the Emergency Red LED was no longer illuminated.

59) Depress the down button for each barrier.

60) Verify the barriers returned to the down position.

61) Place the vehicle over each loop detector verifying the UP button would not activate the barrier.

Safety Note: Ensure vehicle is not on barrier.

62) Place a vehicle over each loop detector verifying the EFO button still activated barriers when depressed.

63) Remove all cones and reopen lanes of traffic.

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MONTHLY

Check and service the following at monthly service intervals:

Note: Block traffic during maintenance to prevent accidents.

Implementation of Safety Procedures (Annotate Pressure on Pressure Gauge)

1) Cone off safe barrier work area and rerouted traffic.

2) Remove the bearing inspection plates (if not previously replaced with permanently welded plates) and the access box cover(s).

3) Clear the barrier work area of vehicles and pedestrians.

4) Place the barriers in the raised position from the Master Control Panel, Slave Control

Panel or Main Direction Valve Solenoid.

5) Check the accumulator pressure by applying power to the motor and verified the hydraulic pressure gauge needle position.

6) Turn the Master Control Panel and Slave Control Panel keys to the off position.

7) Verify the Red LED Power indicator was not illuminated,

8) Remove the keys from the Master and Slave Control Panels.

9) Terminate power and lock out/tag out the breakers in the Main Breaker Panel.

10) Terminate power to the barrier motor at the disconnect panel located in the HPU by moving the lever to the OFF position.

11) Place a lock on the disconnect panel in the HPU.

12) Locate the safety leg and bolts in the HPU and position them on each side of the barrier.

13) Position an observer in front of the barrier to watch for barrier movement prior to installing the safety legs.

14) Install each of the safety legs by aligning the legs with the barrier and threading the bolt into the hole in the barrier top plate.

15) Tighten the safety leg bolts using an adjustable wrench or similar tool.

16) Bleed the hydraulic pressure to zero by turning the system bleed down valve counter-

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17) Verify the barrier had lowered until supported by the safety legs.

Monthly Preventive Maintenance Inspection

18) Log this value in the hydraulic pressure log.

19) Inspect all hoses and fittings for leaks.

20) Tighten fittings when leaks were recognized.

21) Inspect the hoses, ensuring no hoses where resting on the ground.

22) 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.

23) Inspect and clean debris within the barrier foundation.

24) Inspect for leaks around the cylinders and barrier header fittings.

25) Tighten loose fittings.

26) Inspect for tightness of barrier block bolts.

27) Reinstall the barrier hinge cover plate verified tightness of all bolts.

28) Verify the barrier heater thermostats were set at 45 degrees.

29) Reinstall the access box cover plate verified tightness of all bolts.

30) Verify the level of the hydraulic fluid was 1-2 inches below the top of the sight glass.

31) Add clean filtered oil as necessary after verification of the fluid level in the sight glass.

32) Inspect the HPU for cleanliness and debris and remove any dust, debris and clean up any spilled oil.

33) Inspect all Barrier Skirt (Front & Side) bolts for tightness.

34) Inspect the barrier cavity for proper drainage and drain blockage.

35) Verify the operation of barrier heaters.

36) Turn the system bleed valve clockwise until tight.

37) Remove the lock and place the disconnect panel lever to the ON position restoring

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38) Verify the motor engaged.

39) Verify the system was building pressure by observing the Hydraulic Pressure Gauge.

40) Verify the barrier motor automatically shut off when hydraulic pressure reached 2150 psig as indicated on the hydraulic pressure gauge.

41) Initiate an UP sequence at the Main Direction Valve Solenoid.

42) Verify the barrier rose to the full UP position and tension was removed from the safety legs.

43) Place an observer in front of the barriers.

44) Remove the safety legs and bolts.

45) Stored the safety legs and bolts in the HPU.

46) Restore power to the breakers at the main breaker panel.

47) Verify no vehicle or pedestrians were on or near the barriers prior to initiating the

48) Insert the keys into the Master and Slave Control Panels.

49) Turn the keys in the Master and Slave Control Panels to the ON position.

50) Verify the Red LED Power light illuminated when the key was placed in the ON position.

51) Verify the Red LED barrier status lights were illuminated on the Master and Slave

52) Verify the three flashing LED's on the barrier front skirt were operational.

53) Verify the light on the light tree was steady red indicating the barriers were in the up

54) Depress the down button for each barrier.

55) Verify the Barrier status indicator LED on the Master and Slave control panel changed

56) Verify the barriers were in the down position.

57) Verify the light on the light tree changed from Red to Flashing Amber indicating the

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58) Depress the UP button for each barrier.

59) Verify the Barrier status indicator LED on the Master and Slave Control Panel changed

60) Verify the three flashing LED's on the barrier front skirt were operational.

61) Verify the light on the light tree was steady red indicating the barriers were in the up

62) Depress the down button for each barrier to return the barrier to the down position.

63) Depress the Emergency Fast Operate Button (EFO).

64) Verify the Emergency Red LED on the control panel was illuminate.

65) Verify all Barrier Status Indicator LED on the Master and Slave Control Panel had

66) Press the up/down Barrier control buttons to verified they were inoperable.

67) Verify the three flashing LED's on the barrier front skirt were operational.

68) Verify the light on the light tree was steady red indicating the barriers were in the up

69) Depress the EFO reset button.

70) Verify the Emergency Red LED was no longer illuminated.

71) Depress the down button for each barrier.

72) Verify the barrier returned to the down position.

73) Place a vehicle over each loop detector verified the up button would not activate the

74) Place a vehicle each loop detector verified the EFO button still activated barriers when depressed.

75) Remove all cones and reopen lanes of traffic.

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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.

Implementation of Safety Procedures

1) Cone off a safe barrier work area and rerouted traffic.

2) Clear the barrier work area of vehicles and pedestrians.

3) Place the barriers in the raised position from the Master Control Panel, Slave Control

Panel or Main Direction Valve Solenoid.

4) Check the accumulator pressure by applying power to the motor on and verifying on the hydraulic pressure gauge the needle position.

5) Turn the Master Control Panel and Slave Control Panel keys to the off position.

6) Verify the Red LED Power indicator was not illuminated.

7) Remove the keys from the Master and Slave Control Panels.

8) Terminate power and locked out/tagged out the breakers in the Main Breaker Panel.

9) Terminate power to the barrier motor at the disconnect panel located in the HPU by moving the lever to the OFF position.

10) Place a lock on the disconnect panel in the HPU.

11) Locate the safety leg and bolts in the HPU and position them on each side of the barrier.

12) Position an observer in front of the barrier to watch for barrier movement prior to installing the safety legs.

13) Install each of the safety legs by aligning the legs with the barrier and threading the bolt into the hole in the barrier top plate.

14) Tighten the safety leg bolts using an adjustable wrench or similar tool.

15) Bleed the hydraulic pressure to zero by turning the system bleed down valve counter-

16) Verify the barrier had lowered until supported by the safety legs.

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Annual Preventive Maintenance Inspection

17) Remove all top plates (hinge cover plate and access box cover plate).

18) Drain the oil reservoir and flushed with mineral spirits or clean oil.

19) Refill the reservoir with clean filtered oil.

20) Inspect the hydraulic ram cylinders for internal and external leaks.

21) Inspect the cylinder clevis pins for wear and replaced as necessary.

22) Inspect the barrier top plate, frame and barrier cavity for paint condition and/or corrosion.

23) Correct identified paint/corrosion discrepancies through preparation of the surface, priming and touch up painting.

24) Inspect all hoses for leaks, wear, kinks and/or bulging.

25) Log this value of the hydraulic pressure log.

26) Inspect all fittings and tightened fittings where leaks were recognized.

27) Inspect hoses ensuring no hoses where resting on the ground.

28) Identified the hydraulic oil filter and replaced with adequate replacement filter.

29) Inspect and cleaned debris within the barrier foundation.

30) Inspect for leaks around the cylinders and barrier header fittings.

31) Tighten any loose fittings.

32) Inspect for tightness of barrier block bolts.

33) Verify the operation of barrier heaters.

34) Verify the barrier heater thermostats are set at 45 degrees.

35) Reinstall the access box cover plate verifying tightness of all bolts.

36) Inspect all Barrier Skirt (Front & Side) bolts for tightness.

37) Inspect the barrier cavity for proper drainage and drain blockage.

38) Verify the level of the hydraulic fluid was 1-2 inches below the top of the sight glass.

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39) Add clean filtered oil as necessary after verification of the fluid level in the sight glass.

40) Inspect the HPU for cleanliness, corrosion; and debris; and remove any dust, debris, clean up any spilled oil and prep and paint rusted areas.

41) Demonstrate a test of the motor overload switch by ensuring the auto/manual switch is in the manual position and pressing the “test” button.

42) Demonstrate a check of the pressure relief valve by depressing the starter armature and allowing the unit to run to the relief pressure value of 2400 psig.

43) Reinstall the barrier hinge cover plate verifying tightness of all bolts.

44) Turn the system bleed valve clockwise until tight.

45) Remove the lock and place the disconnect panel lever to the ON position restoring power to the motor.

46) Verify the motor engaged.

47) Verify the system was building pressure by observing the Hydraulic Pressure Gauge.

48) Verify the barrier motor automatically shut off when hydraulic pressure reached 2150 psig as indicated on the hydraulic pressure gauge.

49) Initiate an UP sequence at the Main Direction Valve Solenoid.

50) Verify the barrier rose to the full UP position and tension was removed from the safety legs.

51) Place an observer in front of the barriers.

52) Remove the safety legs and bolts.

53) Store the safety legs and bolts in the HPU.

54) Restore power to the breakers at the main breaker panel.

55) Verify no vehicle or pedestrians were on or near the barriers prior to initiating the

56) Insert the keys into the Master and Slave Control Panels.

57) Turn the keys in the Master and Slave Control Panels to the ON position.

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58) Verify the Red LED Power light illuminated when the key was placed in the ON position.

59) Verify the Red LED barrier status lights were illuminated on the Master and Slave

60) Verify the three flashing LED's on the barrier front skirt were operational.

61) Verify the light on the light tree was steady red indicating the barriers were in the up

62) Depress the down button for each barrier.

63) Verify the Barrier status indicator LED on the Master and Slave control panel changed

64) Verify the barriers were in the down position.

65) Verify the light on the light tree changed from Red to Flashing Amber indicating the

66) Depress the UP button for each barrier.

67) Verify the Barrier status indicator LED on the Master and Slave Control Panel changed

68) Verify the three flashing LED's on the barrier front skirt were operational.

69) Verify the light on the light tree was steady red indicating the barriers were in the up

70) Depress the down button for each barrier to return the barrier to the down position.

71) Depress the Emergency Fast Operate Button (EFO).

72) Verify the Emergency Red LED on the control panel was illuminated.

73) Verify all Barrier Status Indicator LED on the Master and Slave Control Panel had

74) Press the up/down Barrier control buttons to verify they were inoperable.

75) Verify the three flashing LED's on the barrier front skirt were operational.

76) Verify the light on the light tree was steady red indicating the barriers were in the up

77) Depress the EFO reset button.

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78) Verify the Emergency Red LED was no longer illuminated.

79) Depress the down button for each barrier.

80) Verify the barrier returned to the down position.

81) Place a vehicle over each loop detector verifying the up button would not activate the

82) Place a vehicle each loop detector verifying the EFO button still activated barriers when depressed.

83) Remove all cones and reopen lanes of traffic