Attach__2_Appendix_C-_O M.pdf

OPERATORS AND MAINTENANCE MANUAL

REV (9-18-15)

RB 4400 - FLUSH MOUNT ROADBLADE SYSTEM

Distributed by:

PMG, Inc.

170 North 17th Street Wheeling, WV 26003

Phone: (304) 277-4057

Email: pmg@roadblade.com www.roadblade.com

FA4600-16-T-A001 Appendix C- O&M Attachment #2

A) Safety Precautions………………………………………………… 1

B) Operator Pre-Start…………………………………………………. 2

C) Startup, Shutdown, and Post-Shutdown Procedures…………

D) Normal Operations………………………………………………… 4

E) Emergency Operations……………………………………………… 5

F) Deactivating the System - Blades Stuck Up

G) Operator Daily Service Requirements……………………………… 7

H) Environmental Conditions…………………………………….….. 8

I) Preventive Maintenance Plan and Schedule……………………... 9

J) Lubrication Data…………………………………………………… 10

K) Troubleshooting Guides and Diagnostic Techniques…………

L) Maintenance and Repair Procedures……………………………... 12

M) Adjusting the RoadBlade system ....……………………………... 13

N) Blade Maintenance and Removal ..……………………………... 14

O) Actuator Box Removal and Replacement …………………………. 15

P) Spare Parts and Supply List………………………………………... 17

Q) Parts Identification………………………………………………… 18

R) Manufacturer Information…..................…………………………. 25

S) Warranty…………………………………………………………….. 26

( I )

TABLE OF INDEX

A) Safety Precautions

Keep pedestrians away from the RoadBlade while the blades are in the up position.

Keep hands or feet away from the modules while activating the system.

Keep hands and feet away from the RoadBlade system when retracting the blades.

The pole mount box should not be opened during inclement weather conditions – if needed protect the inside electronic components as best as possible.

If heating elements are installed - Use separate breaker for heaters.

When working on electronic components inside of the pole mount box, turn off all breakers and remove power to the backup battery to prevent shock hazard.

Make arrangements to have traffic halted during routine activation to clean the system.

If traffic arms are installed - Do not pull down on the arm – excessive force will cause the hinge pin to snap and break.

During operations in the DC power mode the 110 Volt traffic light will not work because it runs off of AC power. During this operation do not use the traffic light as a visual indicator of status of the system.

( 1 )

B) Operator Pre-Start

During shift changes visually walk around the RoadBlade system and verify the blades are free and clean from large debris.

Inspect rubber covers for wear and tear.

If any large debris is found, remove it.

Is stainless steel junction box is not installed behind actuator box verify MIL SPEC plugs located at the back of the actuator box are secure to base.

If traffic arms are installed - Inspect the swing arm and verify the arm is securely in place.

( 2 )

C) Startup, Shutdown, and Post-Shutdown Procedures

Startup

Open the pole mount box to turn the AC power breakers on.

The systems are provided with AC power via breakers in the pole mount box. If the breakers are in the off position, flip the breakers to the on position.

If traffic arms are installed: During this initial power up the arm will send a power surge out of the relay output and will cause the arm and blades to cycle. – STOP TRAFFIC DURING INITIAL POWER UP

TO PREVENT ACCIDENTIAL TIRE SHREDDINGS.

The RoadBlade back up battery is located in the pole mount box.

Verify that battery back up is connected to the RoadBalde system.

The backup batteries provide the temporary power to the RoadBlade system only, the blades and pilot lights, if the AC power were to be lost.

PMG recommends replacing these batteries on a yearly basis.

Shutdown

If traffic arms are installed: Make sure the arm is in the up position.

Verify the blades are down before shutdown procedures begin.

If the systems need to be deactivated for any reason, first disconnect the backup battery if not, when the AC power is turned off, the backup batteries will immediately be switched on providing power to the blade system.

After the backup batteries are disconnected, turn off the main power breakers located inside of the pole mount box. This will ensure all power, both AC and DC are disconnected from the system.

For complete power shutdown. Turn power off at the main supply to the pole mount box.

Post-shutdown procedures.

After power has been turned off to the systems close the pole mount box.

If traffic arms are installed: Replace the arm access panel.

Proceed with normal traffic operations while the system is shutdown.

( 3 )

D) Normal Operations

Activation Station boxes (typically located inside of a guard shack) are used to give the commands to raise and lower the tire shredder blades during times of maintenance or traffic control situations.

Each Activation Station has its own Red and Green push button set, as well as its own Red and Green indicator status lights (some systems will have lighted red and green push buttons). If the blades are down and the operator wants to raise the blades for maintenance, simply depress the red button for the appropriate lane the operator wants to raise.

Once the system has completed its cycle the red light indicator on the activation station will be lit and the 110 volt light will indicate a flashing red (or a solid red light if a Red/Green light is in-stalled), informing the operator and motoring traffic the road is closed (blades up).

To deactivate the system depress the green button on the front panel (directly below the red button the operator just depressed) of the activation station and the blades will go down.

Once the blades are down, the green indicator light on the activation station will be lit and the 110 volt light will either stop flashing red or change to green (if green light is installed), informing the operator and motoring traffic the road is open (blades down).

If multiple activation stations are used; such as an extra box located at an overwatch location, com-mand to the RoadBlade systems activations can be achieved from either location. As long as the same command is being sent to the system (both the guard shack and overwatch location depresses the red button to raise the blades) the blades will raise up and the other command is ignored. How-ever if the guard shack depresses the Red up button and the overwatch depresses the Green down button, the blades will raise up and then immediately go down.

( 4 )

Siren Siren

Green push button Green push button

Red push button Red push button

Green light indicator Green light indicator

Red light indicator Red light indicator

When sirens are beeping and flashing - indicates that the system lost its power supply and is running on backup battery.

Sirens

Red light indicator - When illuminated, indicates that the RoadBlade system blades are up.

Red push button - Used to raise the RoadBlade system blades up Green push button - Used to lower the RoadBlade system blades down

Green light indicator - When illuminated, indicates that the RoadBlade system blades are down.

Red light indicator

Red push button

Green push button

Green light indicator

E) Emergency Operations

Activating the system

With every multiple system activation station there will be an emergency activation button. This activation but-ton is located on the top to prevent accidental activations. In the need to activate both systems simply depress the red emergency button. Once depressed all of the blades will rise up at once. This button bypasses the indi-vidual red push buttons for quick activation of the systems.

For locations with only one system, single system activation stations are used. These systems do not contain any emergency buttons. The Red Pushbutton is the only method to raise the blades.

Once the situation is in hand to clear the road, depress the individual green buttons for each system located on the front panel of the activation station.

Mushroom Push Buttons with Siren Alert - If Installed

For each location a separate mushroom push button was provided to allow personnel easier access to the emer-gency up command for the RoadBlades – depressing these buttons will also cause the warning siren to come on.

Originally these were designed to be placed above the inside of the door opening for the guard shack (current location of mushroom push button may have changed; if so locate your particular system’s placement of push button for emergency use).

When the panic button is depressed a siren will proceed to alert personnel that the blades are up and will remain on until personnel unlock the mushroom panic button.

The push button stays in the locked down position until personnel twists the top button to disengage the button.

Once the button has been released (the siren will go off but the blades will remain in the up position) and if the situation is under control, clear the road by depressing the green buttons for each system located on the front panel of the activation station to lower the blades.

( 5 )

F) Deactivating the System - Blades Stuck Up

If the system has been deployed and there is no blade movement response after the buttons have been depressed, two options can be exercised:

Option 1: Reenergize the system.

Open the pole mount box and turn off all of the breakers and disconnect the back up battery.

Wait approximately 10 seconds to allow all the power to drain out, reconnect the batteries and then turn on the breakers.

If this does not work then, Option 2: Manually disconnect the system.

See Section P) Actuator Box Removal and Replacement (Page 15).

CAUTION: DO NOT STEP ON THE TIPS OF THE BLADES. THEY WILL PUNCTURE

YOUR SHOES.

If the blades do not come down automatically, that is an indication that there is something in the way of the blades. Inspect the system for any large items such as a rock. If found, remove the rock and the blades should come down.

( 6 )

G) Operator Daily Service Requirements

The system needs to be cycled at least once a day.

Preferably during non busy traffic conditions such as late at night or after the site has been closed for the day.

Cycling the system, allows any dirt accumulation throughout the day to fall through the blades.

The addition of the rubber covers will help keep most dirt accumulation from forming in the top of the blade cavities. Continue to cycle the blades to allow the covers to throw the dirt off of the top.

If the system is not cycled for long periods of time, accumulation of dirt and debris can eventually pin the blades and keep it from operating properly.

Cycling of the system also allows the user to ensure the system is in proper condition ready to be operated when and if the moment arises.

( 7 )

H) Environmental Conditions

Environmental conditions are going to vary from location to location. In environments that have freezing weather heating elements are going to be required. They prevent the RoadBlade system from freezing and to keep water from freezing in the drain to eliminate any potential drainage back up.

In environments where freezing is not common, but heavy rain is the situation, proper drainage steps should have been incorporated during installation. Heavy rain is going to bring more dirt or sand accumulation than normal. After heavy rains a visual inspection of the inside of the trench that holds the RoadBlade modules will need to be done to ensure the system is draining properly. After inspection of the trench and it is found to be full of dirt or sand, the trench drain outlet (or catch basin basket) may need to be cleaned out.

If the system is installed between curbs - pay particular attention to the first and last module. Typically that is where most of the accumulation will occur.

( 8 )

Daily:

•Cycle the system once a day to the ensure system is working properly and remove any loose debris accumula-tion from the blades (inspect back side of blades against module housing for accumulation).

•If there is no stainless steel box installed in front of the acutator box - verify Mil Spec plugs are securely tight-ened at the actuator box.

Weekly:

•Visually inspect the RoadBlade (and arm if installed) looking for dirt build up at the blades or at the bottom of the trench.

•Verify mounting screws that hold the modules to the trench have not vibrated free.

•Verify the adjustment nuts on each blade is tight. The previous shaft that has the ball end should be visible, if not, this possibly is an indication the adjustment nut is lose.

•If traffic arms are installed: – verify nuts are securely tightened that holds the aluminum swing arm to the pivot bracket.

Monthly:

•Inspect the interior of the pole mount box.

Record activation cycles for future references.

•Verify the back up battery is connected.

•Lubricate connecting pins that hold the blades to main shaft – if needed.

Yearly:

•Replace backup batteries.

•Hose out the bottom of trench and drain outlet – local environmental conditions will dictate if this process needs to be done more frequently. Initial weekly inspections will determine frequency depending on various locations and their environment.

•Inspect catch basin debris basket and bottom of basin (if installed) - local environmental conditions will dictate if this process needs to be done more frequently. Initial weekly inspections will determine frequency depend-ing on various locations and their environment.

Every 150,000 activations

•Replace motor in activation box – brushes on the motor will start to go bad around 200,000 activations.

I) Preventive Maintenance Plan and Schedule

( 9 )

J) Lubrication Data

Spray corrosive preventive compound such as WD-40 may be needed periodically for a system that has been in the road for extended lengths of time and excessive squeaking occurs during activation and deactivation.

When this occurs - raise the blades up and then wash down with water (depending on your local environment will dictate wether a hose or pressure washer may be needed). The dirt or debris between the pin and blade will break free eliminating the squeaking.

If squeaking still occurs - use spray lubricant (for example WD-40) on the outer housing of the adjustment nut.

The adjustment nut slides on the bottom of the through hole and may cause the system to squeak. See Section P) Parts Identfication for description of adjustment nut.

The adjustment nut may be rubbing against the module causing the squeak.

( 10 )

K) Troubleshooting Guides and Diagnostic Techniques

The system will not cycle (open or close):

Are the Mil Spec plugs connected?

Make sure the AC breakers are turned on inside the pole mount box.

Verify the backup battery is connected.

Did you lose AC power and completely drained the backup battery?

The main stop/go light is not working (If Installed):

Is the main power turned off?

If so the stop/go light only works on 110 Volts AC. Once AC power has been restored the lights should be working again.

The blades do not go straight up.

See section N) Adjusting the Roadblade System (Page 13)

The blades do not go down flush.

During the adjustment, did you over adjust one module in the string before starting the adjust-ment from the control box?

If so, simply loosen the 2” adjustment nut on the module before the problem module.

See section N) Adjusting the RoadBlade System (Page 13)

The system is acting sluggish.

Is main power to the system off?

If so, the backup battery may need recharged or replaced.

Is there any debris in the path of the moving blades?

If so, remove the debris.

This can be caused by an over torqued clutch that is protecting the motor.

The first module or another module in the system may be over tightened, or foriegn objects or debris most likely may be obstructing blade travel.

See section M) Maintenance and repair procedures

( 11 )

L) Maintenance and Repair Procedures

Under section “I) Preventive maintenance plan and schedule”, maintenance issues are broken down by four sec-tions and their tasks:

1) Daily

2) Weekly

3) Monthly

4) Yearly

Operator Level Maintenance which is simple operation checks and troubleshooting, general periodic mainte-nance, inspection and cleaning of system, to replacement of simple components. Operator level maintenance would fall in the daily and weekly cycle.

Depot/Contractor Level Maintenance includes maintenance beyond the operator level, such as periodic mainte-nance, components repair, and major repairs. Depot/contractor level maintenance would fall in the Monthly and Yearly cycle.

NOTE: Operator maintenance could be extended to the monthly cycle if the customer wants to maintain a more hands on control of the system. Recording of activation cycles is critically important for an accurate estimate as to when items need replaced.

( 12 )

M) Adjusting the RoadBlade System

( 13 )

All RoadBlade units are aligned and tuned for proper blade operation in the manufacturing facility. Due to variances of different locations and road surfaces, some minor adjustments may be needed prior to installa-tion of the next module. If adjustments are not made after installation, the system may not function properly.

Important - before making any adjustments make sure the numerical sequence is correct.

For example:

To adjust the third module, the adjustment on module #2 needs to be set properly in order the blades to be activated to an approximate 90 degree angle after the adjustments have been made. The jam nut needs to be retightened and the remaining installation can be completed.

*NOTE* Because all modules are preset at the manufacturing facility, if any major adjustments are made, all succeeding modules will need to be adjusted. Making adjustments to one module effects the tension on the remaining modules.

For example:

If module #3 is adjusted, then #’s 4, 5, 6, etc. may have to be modified due to the tension being adjusted on module #3.

To adjust the blades:

A. Raise the blades in their full up (active) position.

B. Locate the 2” adjustment nut and adjust it using the 7/16” open-end wrench until the necessary adjustment is made.

C. Once the proper adjustments are made, use the 7/16” open wrench on the 2” long nut and the other 7/16” open-end wrench on the jam nut.

D. Tighten the jam nut until it is firm against the 2” adjustment nut. When the blades are in the up position, grab a blade and move it back and forth. There should be some “give” in each blade. This ensures that the activation motor has traveled to its full forward motion and therefore is activating properly. If necessary, proceed using the previous steps to adjust other modules that are out of alignment.

* Do not adjust blades so that they are tight and have no movement.

Note: Adjustments made on one module will affect the modules that follow it. Therefore it is recommended that blade adjustments start at the module closest to the actuator box and proceed toward the end as modules are added.

#2 Adjustment

Jam Nut #2 #3

N) Blade Maintenance and Removal

( 14 )

The blades should move up and down in a manner that when you release the main shaft the blades should snap down - if they do, the particular module is operating correctly. If for any reason the blades do not snap down, use a spray lubricant in each of the following locations for each individual blade.

Repeat until all the modules for the system you have are complete.

Blade Maintenance

(A)

(B)

(B)

(A)

Spray the lubricant at the location where the blade inserts into the main module (A) and where the pin holds the blade to the main shaft (B).

Removing and replacing a broken blade:

Raise the blades up. With a screwdriver, push the “C” clip off the 3/16” retaining pin that holds the blade to the main shaft. Remove the 3/16” blade retaining pin from the main shaft.

With the T-handle Hex Key unscrew the 4 mounting screws that hold the retaining plate against the blade’s ro-tating arm. Insert a replacement blade. Replace the retaining plate and screw the 4 mounting screws back in.

Raise the blade and align the oval slot with the hole in the main shaft. Insert the 3/16” retaining pin though the holes. Reattach the “C” clip to prevent the 3/16” retaining pin from becoming lose.

O) Actuator Box Removal and Replacement

( 15 )

First, unbolt the 1/4-20 hex head bolts from the junction box lid directly behind the actuator box. Remove the lid to access the two mil spec plugs behind the actuator box.

Unscrew the two mil spec plugs from the actuator box.

Grab the handle below the mil spec plugs.

Junction box lid

Mil Spec plugs

Pull handle

Actuator box

O) Actuator Box Removal and Replacement - Cont’d

( 16 )

With your other hand, grab the bottom of the actuator box and slide it away from the modules.

To connect the actuator box:

Simply reverse the previous procedures.

Slide the actuator box towards the fi rst module until the connection blocks slide under the two ball screws on the module. Swing the end of the actuator box down towards the rail. Connect the appropri-ate MIL SPEC plugs located at the back of the actuator box. The actuator box is now ready to activate the RoadBlade system.

The middle connection adjustment nut should be recessed or almost in line with the two rounded mount-ing blocks. If the adjustment nut is past (forward of) the blocks, connect the MIL SPEC plugs to the actuator box and cycle the system to the passive mode to allow the motor inside the box to bring the adjustment nut back in line with the blocks.

Lift the actuator box up using the pull handle at the back of the actuator box.

While doing this the main shaft will disconnect from the fi rst blade module shaft. Rotate the box up until the face of the actuator box touches the mod-ule.

Q) Parts Identification

( 18 )

2 - Ball Connectors

RB 0008-A

10 - Retaining Plates

RB 0102

20 - Mounting Screws

RB 0101

1 - Jam Nut

RB 0109

2 - Lock Down Screws

RB 0106

5 - Clevis Pins with “C” Clip Assembly

RB 0105

1 - Adjustment Nut

RB 0007

5 - Blades

RB 0104

1 - Main Shaft Spring

RB 0108

1 - Main Module Body

RB 0103

Main Shaft

RB 0005

1 - Large “C” Clip

RB 0107

(19 )

1 - Rubber Cover Hold Down Bar

RB 3158

1 - Rubber Cover

RB 3157

( 20 )

( 21 )

R)Manufacturer Information

( 25 )

RoadBlade Manufacturer:

PMG, Inc.

170 North 17th Street Wheeling, WV 26003

Phone: 304-277-4057 Fax: 304-277-4085 Email: pmg@roadblade.com www.roadblade.com

S) Warranty Information

( 26 )

TERMS AND CONDITIONS OF MANUFACTURER’S WARRANTY

The terms and conditions of warranty described in this writing constitute the complete and exclusive warranty agreement between the original buyer and PMG, Inc. (“PMG”) or a PMG Authorized Distributor or Dealer re-garding the PMG ROADBLADE branded product that the original buyer has purchased. No change to the terms and conditions of this Manufacturer’s Warranty is valid unless it is made in writing and signed by an authorized officer of PMG. PMG reserves the right to amend or change this warranty from time to time.

Limited Warranty

The warranty described in this writing shall be the sole and exclusive warranty granted by PMG and shall be the sole and exclusive remedy available to the original buyer. Subject to the limitations, exclusions and disclaimers in this warranty, PMG warrants to the original buyer that the RoadBlade and all accessories (col-lectively or individually referred to as “Product”, as appropriate) purchased from PMG or a PMG Authorized

Distributor or Dealer conforms to PMG specifications and will be free from defects in material or workmanship for a period of one year from the time of original purchase.

U) Warranty Information

( 27 )

The suitability of the Product for a specific purpose or application must be determined by the customer and is not warranted by PMG.

If the Product is found to be defective in material or workmanship during the warranty period, then PMG, at its option, will promptly repair or replace the Product at no charge to the original buyer. PMG reserves the right to make all decisions, in its discretion, regarding whether a claim qualifies as eligible warranty work. Correction of defects, in the manner described in this warranty, shall constitute complete fulfillment of all liabilities and responsibilities of PMG or its Authorized Distributor or Dealer to the original buyer with regard to the Product and full satisfaction of all claims, whether based on contract, negligence, strict liability or otherwise.

Warranty Exclusion

This Limited Warranty covers normal use, and neither PMG and its Authorized Distributor or Dealer warrants or is responsible for:

I. Damage or failure caused by accident, abuse, misuse, mishandling, misapplication or other external causes;

II. Damage or failure caused by power surge or a disaster such as fire, flood, wind, earthquake, lightning or other acts of nature;

III. Damage or failure caused by unauthorized attachments, tampering, alterations or modifications, or ser vice other than by PMG or its Authorized Agent; or

IV. Damage caused by failure to carry out proper maintenance as outlined in the Product’s User Manual.

U) Warranty Information

( 28 )

Further, this warranty will be VOID if the Product has been open or tampered with or if the warranty seal has been broken.

Disclaimer of Implied Warranties

THE WARRANTY EXPRESSED IN THIS DOCUMENT IS THE ONLY STATEMENT OF THE LEGAL

RESPONSIBILITIES OF PMG AND ITS AUTHORIZED DISTRIBUTORS AND DEALERS, AND PMG

AND ITS AUTHORIZED DISTRIBUTORS AND DEALERS DISCLAIM ALL IMPLIED WARRANTIES,

INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PUR-

POSE. In no event shall PMG or its authorized distributors or dealers be liable for indirect, special, incidental or consequential damages. (Some states do not allow limitations, and so such limitations may not apply to all buyers.) No distributor or dealer of PMG Products and no representative or employee has the authority to make any other warranty, expressed or implied, oral or written, that is binding on PMG.

PMG\warranty.agr