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PCMS 320 Operations, Safety and Maintenance Manual - Ver-Mac

1. and e That the equipment has been used in a manner considered normal usage Signalisation Ver Mac does not warrant any of its equipment or parts thereof against depreciation or damage caused by normal wear lack of reasonable and proper maintenance failure to follow operating instructions misuse lack of proper protection during storage collision or accident Under no circumstances shall this Warranty extend to 1 Any Ver Mac equipment or part thereof which has been modified repaired or altered in any way in any establishment other than Signalisation Ver Mac s own factory 2 Any Ver Mac equipment or part thereof which has been modified repaired or altered in any way without the express written consent of Signalisation Ver Mac 3 Any and all other components of Ver Mac products which are warranted separately by the respective manufacturers of said components 4 Any and all replacement parts not supplied by Signalisation Ver Mac 5 Repair to or replacement of any equipment or component parts where the loss or damage is caused by or arises from natural calamities or unforeseeable events Operations Safety amp Maintenance V 2 0 Ver Mac 2011 Repair and or replacement Repair or replacement of any equipment or component part shown to be defective shall always be at the discretion of Signalisation Ver Mac and shall be carried out at its factory unless agreed to otherwise by prior arrangement With Signalisation
2. Use Extreme Caution and Stand Clear Check under the PCMS Disengage the sign brake unit for leaked fluid and rotate signboard 180 The sign will come down rapidly No clicking insufficient power to pump below 10V Signboard is e Take a voltage reading raised but will e Charge battery not come down Sign has pushed through the top of cylinder Clicking you have power Use Extreme Caution and Stand Clear e Rotate the sign 180 and power switch to DOWN The sign will come down rapidly Problem with the Check for a clicking solenoid sound 64 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Appendix A Schedule of Recommended Maintenance Problem Possible Cause Check Verify the hydraulic Hydraulic Lift system amp level Battery voltage Low voltage J Regulator LVD state Unable to raise the signboard Check if you have the Hydraulic Lift syst ydraulic Lift system optional Hand pump the battery box Refer to Controller disconnect less than 10 4V Action Use Extreme Caution and Stand Clear Hydraulic Lift Release the pressure turn the hydraulic bypass valve counter clockwise U so that the fluid flows back into the reservoir The mast will come down by itself Charge batteries as per suggested maintenance manual Hydraulic Lift Verify that safety release valve is tight Insert handle into pump and start to pump Continue t
3. Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 5 Occupational Health and Safety DOs and DON Ts The constantly changing conditions at work zones are always unexpected by road users This creates an even higher degree of vulnerability for the workers and incident management responders on or near the roadway Don t take short cuts or rush to complete your task You should be aware of all work zone hazards at all times run across or dodge traffic in lanes outside the defined work zone work in a live traffic lane under adverse conditions not even for a few seconds work in a live traffic lane without the proper traffic control in place not even for a few seconds assume you are safe on the shoulder area turn your back to oncoming traffic if at all possible put yourself in an unexpected location that may surprise a driver get distracted by talking to co workers or pedestrians or when you using two way radios to communicate with other workers ensure you are very visible to road users especially at night and in low light conditions wear all the necessary personal protective equipment and safety footwear look for any oncoming traffic before opening doors and stepping out of vehicles take advantage of anything that can provide protection and warning without causing additional exposure Example work vehicles and barricades plan ahead so that you have all necessary equipment and devices and you a
4. Wheel Lug Nuts Torque Procedure 1 Use proper tools 2 Torque lug nuts in the correct order following the appropriate star pattern sequence until tight Torque star pattern sequence D 6 O g 5 hole rim 6 hole rim 26 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Tires and Rims Tire and Rim Periodic Maintenance When repacking wheel bearings make sure that all the jacks are supporting the trailer and the opposite wheel is blocked Before 3 12 Function Required Each Use Months Months Tires Tire Inflation Maintain inflation at manufacturer s Pressure specifications Check overall condition adequate Tire Condition tread cuts wear bulging etc Replace if necessary Wheels Rotate to check that wheel moves freely Inspect for cracks dents or distortion or impact damage lu Nuts and Tighten to manufacturer specified lu torque values Wheel Inspect for corrosion or wear Bearings amp Remove cup and repack with grease Grease Cups E Z Lube Inspect for leakage Replace if removed Hub Drum Inspect for abnormal wear or scoring o pe Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 27 Axles and Suspension Axles and Suspension Always use the jacks on the trailer frame Do not jack up trailer on suspension components SAFETY PRECAUTION Always wear safety shoes and instep guard protection when handling jacks Axle Periodic Maintenanc
5. If level is below the plates add enough distilled water to cover the plates before charging the battery Fully charge the battery before adding more distilled water When the battery is charged remove the vent caps and check the electrolyte levels again Add distilled water until electrolyte level is 1 8 inch 30 cm below the top Replace and tighten all vent caps Battery Charging and Testing Visual inspections of batteries are important but they do not tell you the actual condition of the batteries You need to test the batteries to determine their state of charge and overall condition Then you can determine whether or not the battery bank needs replacing Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 55 Battery Bank Check Battery Voltage Take real voltage readings when the batteries are neither charging nor discharging nothing connected and turned on Also make sure that the batteries have been resting and not charging for at least 30 minutes before taking the reading Be absolutely certain that the solar panels and the charger are disconnected before taking your reading Note e Digital Voltmeters should read as the voltage shown on the State of Charge SOC chart e Voltage readings in the 10 5 V range on a charged battery typically indicates an internal short in a battery cell State of Charge SOC Chart Discharging 12 50 12 40 12 30 12415 12 00 11 70 11 50 11 25
6. Note Hydrometer readings should not vary more than 0 05 between cells State of Charge Specific Gravity These readings are correct at 25 C 75 F Sulphation of batteries starts when specific gravity falls below 1 225 or voltage measures less than 12 4 for a 12V battery or 6 2 for a 6V battery Sulphation hardens on the battery plates It reduces and eventually destroys the power generating ability of the battery Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 57 Battery Bank 58 Note Charging with an External Charger Batteries in PCMS units are 6 volt The batteries are wired in series to create a 12V system 2 x 6V batteries linked together Additional batteries 2 x 6V are then connected in parallel to increase capacity Most battery chargers are 12 V and need to be connected correctly Most garage and consumer automotive battery chargers only offer a Bulk Charge These units have little if any voltage regulation and are fine for a quick boost to low batteries Do not leave on for long periods as you risk overcharging and damaging your batteries Refer to Suggested Charging Time table DO NOT connect your charger to a single battery as it damages the battery To use an external charger please make sure you use a minimum 30 Amp charger Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Battery Bank Charging the Batteries with the Onboard Charger 1 Loca
7. PCMS 320 Operations Safety and Maintenance Manual Australian Edition VER MAC Publication N UME PCMS 320 Operations Safety amp Maintenance Manual V2 0 1781 RUE B 2 CANA T 418 654 1 44 0517 WWW VER M This Page Intentionally Blank PCMS 320 Operations Safety amp Maintenance Manual Australian Edition VER MAC Publication N UME PCMS 320 Operations Safety amp Maintenance Manual Australian Edition V2 0 March 2012 Information contained in this manual may be modified or corrected without notice No part of the contents of this manual may be reproduced or transmitted in any form or by any means without the written permission of the publisher MMXII VER MAC Inc TECHNICAL PUBLICATIONS All rights reserved Manual Change Information Customers should note that this manual is up to date at time of issue but is not subject to automatic update For additional information concerning the latest changes to this document please consult our web site WWW Ver mac com Technical Support For help with any difficulties concerning PCMS units or this manual please contact Ver Mac Support support ver mac com We also request that you notify us of any error or omission found in our publications Operations Safety amp Maintenance V 2 0 Ver Mac 2011 List of Revisions Date Version Revision Author 2011 07 07 N OO Nyo Australia specific edition Disclaimer Failure to read and fol
8. Voltage and state of charge is an approximate not a specific number It can Note vary depending on battery type manufacturer battery quality current temp and the age of the battery The voltages shown are taken at 25 C 77 F Immediately after either charging or discharging the battery voltage may not have stabilized Because the battery is chemical in nature the voltage normally settles down about 30 minutes after charging or discharging has discontinued 56 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Battery Bank Hydrometer Test hydrometer measures the specific HOLD TUBE gravity or relative density of liquids VERTICAL In a battery it measures the proportion Dl roo voce ELECTROLYTE of the battery electrolyte sulphuric acid to the density of water Using a glass float Hydrometer TAKE READING 1 Check the electrolyte level to be AT EYE LEVEL sure that it is above the plates in all cells If it is below the plates you cannot do the test 2 Draw the acid into the hydrometer so that the float is lifted free and not touching the top or the bottom Hold the barrel upright and your eye level with the surface of the liquid Disregard the curvature of the liquid against the glass and take your reading from the bottom of the curve 3 For accurate readings apply cell temperature corrections add or Subtract 0 004 points for each 5 C 9 F variation from 25 C 77 F
9. Allow only enough slack for tight turns Twist safety chains equally from hook ends to take up slack Attach hooks from the underside to the tow vehicle Replacement Safety Chains When replacing the safety chains use safety chains rated equal to or greater than twice the maximum gross trailer weight rating GWR on the trailer nameplate Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 35 Brakes and Breakaway Systems Brakes and Breakaway System Periodic Maintenance Before 3 12 Each Use Months Months Function Required Brakes all systems Rotate and listen to the wheel to check for wear damage or corrosion Brakes Test that brakes are operational Electric Brakes ETERA Brakes CR fluid level Fill to with d Ho fluids if Field test gH XM to manufacturer s instructions Breakaway System Breakaway Check battery charge and safety switch operation System Synchronize Surge Brake Actuator RSS Inspect for rust fraying RSS Replace as necessary Make sure that the hooks are whole Safety Chains 2 not bent or rusted Lubricate lightly with grease 36 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Coupler Hitch Coupler Hitch The coupler hitch on most Ver Mac PCMS units is a pintle hook and lunette ring combo It provides a more secure coupling than a ball type trailer hitch especially over rough surfaces and on construction sites and is used
10. Bourke i 30 Region B n T x am of Sawa R A1 ZA Kalgoorlie egion Woomera Region A Istand 30 Green n Head wPer h i a Esperange wAdelaide fa Mar re ee IN Az mr DE r int 200 km Albany Mount Gambier 70 Kk Regions are marked wiih the letters Region AS EC n to AS B S ast D within 70 km CN er MP Binder oasia Region boundaries are ol Matbourne GPO m i amp mooth lings amp l in from amp smoothed Genny 49 T coastline by 50 100 150 and 200 km 2 Islands within 0 km of the coisi Region A3 De are the same Hegion as the n s pai adjacent coast Hobart 3 hi a Australia 1 i e ihe FIGURE 3 1 in part WIND REGIONS Ver Mac 2011 Operations Safety amp Maintenance V 2 0 79 Glossary Actuator a simple machine that converts hydraulic fluid pressure or electric current into motion and causes another device or equipment component to move up or down Ballast heavy material such as sand bags or ballast boots placed low on a PCMS unit trailer to improve its stability Character Display Card plastic panel of LEDs that is used to form the characters on the main PCMS message display One LED per pixel PCMS 548 Four LEDS per pixel PCMS 320 Communication Card a k a Comm Card connects the sign with the controller and coordinates the flow of data from the controller to the PCMS message display Controller a microprocessor that e monitors the current status and representation
11. Exterior Crank the signboard up a little and check main harness cables for wear Make sure the cable lies loosely on the battery boxes not squeezed between sign case and battery box not caught in anything or dragging on the ground RE Check all reflectors at top of case in place unbroken Replace as needed Check door closed and undamaged Check functioning of dashpot door closers that hold the face open Replace if broken Check condition of all rubber T latch Sign Case clamps CORTES TLS tight not cracked or loose Verify all welds at corners of sign case Check condition of rubber bungee strap not dry or brittle Replace as needed before towing Check condition of any external photocells Clean as needed Remove dust and debris Signboard Wash and rinse off accumulated Face grime in winter remove snow and ice accumulation Transport Inspect for proper support Cradles Replace cushions as needed Adjust height if necessar Check for rust and corrosion Sign Brake Lubricate lightly Adjust tension screw Under Solar Test photocell function Panels cover sensor with dark tape Check sign brightness Devices securely attached undamaged Example m Radar Check wiring and connectors Beacons secure Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 47 Signboard Signboard Interior Periodic Maintenance Before 3 12 Function Required Every Use Months Months Signboard Interior i Check for signs of
12. Mac 2011 Operations Safety amp Maintenance PCMS V 1 0 69 Tire Condition Appendix A Schedule of Recommended Maintenance Before 3 12 Each Use Months Months Item Function Required Wheels Rotate to check that wheel moves freely Inspect for cracks dents or distortion or impact damage Lug Nuts and Tighten to manufacturer specified Bolts torque values Inspect for corrosion or wear Remove cup and repack with grease E Z Lube Inspect for leakage Replace if removed Hub Drum Inspect for abnormal wear or scoring ue gt Di CJ b Q 2 a u amp Grease Cups Axles Visually check camber upward bend Inspect for rust loss of arch or leaves sandwiched together Replace any sagging or broken springs Visually inspect U bolt connections for bending elongation of bolt holes excess wear Inspect welds for integrity Brakes all systems Axle Beam Suspension Parts Rotate and listen to the wheel to check for wear damage or corrosion Brakes Test that brakes are operational Adjust brakes Brake Lines Inspect for cracks leaks kinks Electric Brakes Brakes Carry out full maintenance procedure Trailer Brake Inspect wiring me spots fraying N Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Appendix A Schedule of Recommended Maintenance Before c 12 Each Use Months Months Item Fu
13. and tighten the nut In high wind areas or unusually windy conditions the sign brake may not be Note enough to prevent the signboard from turning Under these circumstances it may be advisable to increase the tension on the band Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 45 Signboard Photocells Dust and grime accumulation can obstruct the correct functioning of external photocells Photocells detect the ambient light conditions and the brightness of the sign display adjusts in consequence External photocells are located on the junction box underneath the solar panels or on the left outside side wall of the sign case Radar Device speed radar device is attached directly to the underside of the sign case Sign Display Before putting your PCMS into operation it can be a good idea to run a pixel text and verify that all display cards for the signboard are functioning Accessing the pixel test varies depending on the software that controls the signboard Unit software Steps Quickstep Login gt F4 Utilities F3 Brightness gt F5 Test Signore Login 4 Setup 4 Tests 1 Chessboard Login Toggle Menu Option Pixel Test Chessboard 46 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Signboard Signboard Exterior Periodic Maintenance Before 3 12 Every Use Months Months Function Required Signboard
14. connecting the trailer to the tow vehicle If Separation occurs the breakaway cable pulls tight and automatically applies the trailer brakes according to the trailer breaking system On trailers with a hydraulic breaking system the breakaway cable serves to activate the actuator to apply the trailer brakes 1 Note The breakaway cable attached to the tow vehicle is normally shorter than the safety chains but must never be taut e Always connect breakaway cable to towing vehicle e Make sure breakaway cable has a direct free pull You can test the breakaway system by pulling the breakaway cable Your trailer brakes should immediately activate and lock up the wheels To disengage the breakaway system replace the breakaway cable in the switch Replacement Breakaway Cable Replacement breakaway cable must be slack enough to prevent accidental activation of the breakaway mechanism 34 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Brakes and Breakaway Systems Safety Chains N Do not let safety chains drag on ground Safety chains can prevent a runaway trailer in case the coupler or vehicle hitch fails Crossed safety chains can prevent the trailer coupler from striking the ground if uncoupling occurs Make sure that the safety chains have enough slack to turn but do not drag on the ground ote Always use safety chains when towing Proper Rigging of Safety Chains Cross safety chains under coupling
15. normal conditions e Where equipment is operated under severe conditions very dusty extreme heat or cold etc affected items require more frequent servicing 68 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Appendix A Schedule of Recommended Maintenance Before 3 12 Each Use Months Months Item Function Required Trailer Structure Wash underneath to remove build up of Body l l corrosive material road salt gravel Frame Welds Check for cracks and or failures eee All Links and i Inspect for cracks or impact damage Replace as needed Jacks Tubular Swivel Extend jack as far as possible and 4 lubricate entire outside length of inner ram with SAE 30 heavy oil Grease each jack grease fitting at top of outer ram Lights amp Reflectors Brake Lights Pee Check connections wires plugs etc L R i i ioni Test all lights in turn for functioning Clearance Replace any burned out light bulbs Lights i d Tail Lights Check condition Reflectors Replace any broken missing or cracked reflectors Hardware amp Fasteners Double check all nuts and bolts for Nuts and Bolts tightness and condition Lubricate lightl Make sure that all safety and locking pins are in place and solid Tires Tire Inflation Maintain inflation at manufacturer s Pressure specifications Check overall condition adequate tread cuts wear bulging etc Replace if necessary Ver
16. of Ball and Coupler Place coupler over the trailer ball on the tow vehicle Raise the locking lever so that the coupler can drop fully onto the hitch ball Press the locking lever down on the coupler to ensure the hitch ball fits Snugly in the coupler with no play between the hitch ball and the coupler If there is play tighten the adjustment nut until no play is present To adjust coupler to ball raise the locking lever push up on the channel lock and turn nut to tighten or loosen the coupler Make sure that ball and tongue has adequate capacity for the trailer and all Safety or locking cotter pins are in place and in good condition Note 38 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Coupler Hitch Coupler Hitch Periodic Maintenance Before 3 12 Function Required Each Use Months months Coupler Hitch Pintle Hook amp Check capacity Draw Bar Inspect for wear Inspect for rust Coupler and Clean and lubricate ball socket and Ball clamp lightly with grease Ball and Tongue Check capacity Verify that all are in place and Safety Pins properly inserted Replace weak or missing pins Lubrication of the coupler hitch stops corrosion and helps prevent binding during turns It keeps moving parts inside the coupler operating smoothly A film of clean heavy weight grease on the ball reduces friction between the coupler and hitch ball Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 39
17. red LED on back of cards check harness try additional card If no voltage check harness continuity Check harness continuity If OFF verify that there is 12V to the communication card Tighten all wiring connections If there is voltage try replacement communication card If the problem persists check wiring between cards and communication card If ON run the Pixel test to check all the display cards Make sure that every display card lights properly and in sequence If Pixel test runs and stops e Check for loose connections on the card that the test stops on and also on the card before There should be current and data feed into each card Ver Mac 2011 Appendix A Schedule of Recommended Maintenance Problem Possible Cause Check Action Test the functioning all photocells with flashlight Photocells inside and e Too strong replace outside the signcase photocell Too weak clean to Status Photocell l remove all buildup Brightness of display External source of light or shadow Correct situation Example causing a false relocate signboard Ambient light reading Open signcase and check wires for Tighten all connections photocell inside case Power supply to Power ON the sign and PPly Signboard turned OFF i signboard restart touchscreen Open control box and check modem is Reconnect and tighten Loose wiring to photocell Communication powered on difficult or Ensure antenna is impossible Check cellula
18. water infiltration BENT Sign Case Floor Check drainage holes are unblocked Run Chessboard test and visually check all pixels are operational Check there is no corrosion on the cards Display Cards Check all hoods are secured above each pixel Check all display cards are screwed in place Check harness cable Make sure it is not loose frayed or worn Check cables between cards Make sure connections are inserted correctl Check the Communication Card Relay Bracket for water damage and corrosion and connection Check the GPS for water damage and corrosion and connection Check photocell functionality on communication card Photocell Test functioning cover sensor with dark tape Check sign brightness Red light ON on communications card in the interior of sign case indicates a problem with electronics Contact Ver Mac Support for assistance Note 48 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Solar Array Solar Array Solar Panels Never attempt to work on solar array in wet or damp conditions Electrical current is always present Solar panels can produce an electrical shock or burn unless care is taken Solar panels are a live electrical power source Current and power increase with light intensity Panels continue to produce nearly full voltage even in overcast conditions They produce DC voltage even when not connected to an electrical circuit Solar panels have no ON OFF switch Be
19. Adjusting the brakes is important As brake shoes wear down the clearance increases and the actuating mechanism must travel further to effectively apply the brakes At a certain point the mechanism is no longer effective Every 5 years approximately check the brake drum and apply a thin layer of zinc grease 76 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Appendix C Safety Warning and Instructions Decals Appendix C Safety Warning and Instructions Decals This appendix contains representations of the safety warning and instructions decals supplied on Ver Mac PCMS Australian units from factory Please refer to these representations and their corresponding numbers if ordering replacements Never put a PCMS unit into operation on a work site with known defects or missing instructions or decals Always replace any safety and instruction decals that are damaged dirty or illegible in any way PART NO9 Sticker AVOID SPILLING OR SPLASHING BATTERY ELECTROLYTE SULPHURIC ACID BEFORE WORKING WITH A BATTERY REMOVE ALL METALLIC PERSONAL EFFECTS RINGS WATCHES NECKLACES AND ANYTHING WHICH MAY FALL FROM POCKETS OF CLOTHING ALWAYS WEAR APPROVED EYE PROTECTION AND PROTECTIVE CLOTHING GLOVES AND APRONS AVOID TOUCHING YOUR EYES WHILE WORKING HEAR BATTERIES TOP UP ELECTROLYTE IN BATTERY CELLS ONLY TO THE CORRECT LEVEL AS RECOMMENDED WASH YOUR HANDS WHEN DONE Location in battery co
20. All Cables Visually check cabling for signs of ee damage Verify condition Controller clean undamaged Devices a Peripherals Check for proper functioning ee Manual amp Check condition Stickers complete clean and readable Weatherproof Inspect for tight seal Seal Replace as needed Optional ENS Check that all connections for peripheral Example devices are firmly attached Data Loggers Bluetooth Ver Mac 2011 Operations Safety amp Maintenance PCMS V 1 0 75 All Connections Appendix B Full Brake Maintenance Appendix B Full Brake Maintenance Full Brake Maintenance Hydraulic and Electric Systems This procedure is for trailers with either electric or hydraulic braking systems AS a minimum requirement full brake maintenance should be carried out once a year These components are an option on Ver Mac PCMS Please check that your PCMS has this component before proceeding IMPORTANT Annual Brake Maintenance Procedure 1 Park your trailer on asphalt or cement and stabilize Inspect all wheel and brake lines for leaks and cracks 2 Undo the lug nuts remove the wheel and the drum cover 3 Wash brake pads with brake cleaner if necessary Replace as needed Check brake shoes Replace if worn 4 Repack hub drums and check for grease leaking on brake shoes Check fluid in actuator hydraulic Change if dirty Lightly lubricate moving parts of brake coupler e ectric Adjust brakes
21. Mast The mast on the PCMS unit has the signboard and the solar panels attached On most units a hydraulic pump system that is connected to the batteries in the battery box raises and lowers the mast However some smaller units rely on a manual hand winch to raise and lower the mast Mast Periodic Maintenance Function Required Before E l4 q Each Use Months Months Mast Check for leaks hydraulic fluid on the ground under the mast Raise mast to full height and check Nylatron runners and screws Clean any build up Adjust for snug fit on mast Check main bolt top of mast is tight we Check all metal parts for rust and corrosion Lubricate lightly Hydraulic Lift System for Mast For safety during transport Ver Mac disconnects power to the hydraulic pump Make sure the power feed is connected to the battery terminals inside the battery compartment Note 40 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Mast Raising and Lowering the Mast A R Note Before raising or lowering the mast open battery box and check that the hydraulic bypass valve is tight 1 To raise mast open control box and flip switch to Sign Up The mast rises automatically 2 To lower mast reverse the procedure The hydraulic system used to raise and lower the mast does not require any regularly scheduled maintenance beyond periodic checking of the fluid Maintenance Procedure Check the hydraulic flui
22. Ver Mac e Signalisation Ver Mac shall not be held liable for any and all costs incurred by the owner in the carrying out of authorized repairs e Signalisation Ver Mac shall not be held liable for reimbursement of any indirect or incidental expenses incurred in either the removal of defective equipment or component s nor in the installation of replacement parts Claim procedure e In order to make a claim under the terms of this warranty the owner of the equipment must first establish that the equipment has been installed maintained and operated within the normal limits of its intended usage e Defective equipment or component parts for repair or replacement must always be returned to Signalisation Ver Mac along with an RMA number obtained beforehand from Customer Service at Signalisation Ver Mac Do not return equipment or component parts without prior authorization and the requisite RMA Ver Mac 2011 Operations Safety amp Maintenance V 2 0 V Vi This Page Intentionally Blank Operations Safety amp Maintenance V 2 0 Ver Mac 2011 Table of Contents Overview Introduction Safety and Warning Information Maintenance Replacement Parts Optional Devices Occupational Health amp Safety Night Time Operations DOs and DON Ts PCMS 320 Product Host Control System Pre Towing and Work Site Inspections Walk Around Inspection of PCMS Unit Work Site Inspection Unit Deployment and Removal Trailer Deploymen
23. actical further away from the live traffic lane Be very careful if you attempt to maneuver the unit trailer into position for setting up SAFETY PRECAUTION PCMS unit trailer are heavy Do not attempt to move a PCMS unit trailer on you own Use a trailer mover or seek assistance I Position the trailer as close as possible to the location with the tow vehicle 2 Setone 1 jack in position and block the trailer wheels before you start to disconnect the coupler from the tow vehicle hitch 3 Unplug the power connection to the tow vehicle and store plug in the holder optional Unhook the breakaway cable if your trailer is equipped with brakes 5 Detach the safety chains 6 Check the ground conditions and install a the jacks Make sure the wheels are off the ground and trailer is level Add blocks under the jack pads as needed 12 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Unit Deployment and Removal Setup and Adjustment of Signboard and Solar Array Always turn the solar panels so they face of due south In the southern hemisphere due north Use a compass Please keep in mind that large metal objects can affect the calibration of a compass and stand away from any metal 7 8 Turn on sign Power ON Off switch and program message Ver Mac 2011 object when you take the coordinates Raise the mast Up Down switch or manual hand winch Make sure the sign clears all other equipment on t
24. afety amp Maintenance PCMS V 2 0 Ver Mac 2011 Occupational Health and Safety Occupational Health amp Safety The hazards of working close to constant and speedy traffic flows are not easily managed Inattentive driving is one of the most common hazards that road workers face but speeding is another danger You should always be vigilant and aware of work zone conditions Smooth slippery greasy or wet conditions can increase the risk of falls slips and personal injury as well as unpredictable driver and vehicle hazard Preventive measures such as protective barriers and sufficient clearance from live traffic and on the road shoulder personal protective equipment and safety apparel high reflectivity vest gloves safety footwear are aids to ensure that you are visible and protected at all times Final responsibility lies with you to take every precaution and to be attentive to traffic at all times SAFETY PRECAUTION Do not expose yourself to a life threatening situation Protect yourself at all times Night Time Operations At night poor visibility inadequate lighting worker fatigue and driver condition contribute to increase hazards for road users and workers Because there is less traffic drivers tend to drive faster through work zones at night SAFETY PRECAUTION NIGHT OPERATIONS Make sure you are e visible to the road users e wearing the proper retroreflective apparel e inside the lighted work zone
25. afety switch fixed to the trailer tongue This switch automatically applies full power to the brakes if ever the trailer detaches from the tow vehicle during driving The safety switch is connected to the 12V battery system for the PCMS and linked to the tow vehicle by the breakaway cable In a breakaway situation the cable pulls the plunger out of the safety switch and so completes the electrical circuit allowing the battery to power the electric brakes and bring the trailer to a stop Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 29 Brakes and Breakaway Systems N Do not use trailer breakaway system as a parking brake Testing the Brakes Note Testing the trailer braking system is always a two person operation Testing Procedure Deploy the jacks and raise wheels off the ground Check the condition of the wiring electrical connectors especially the main trailer connector magnets and battery Make sure the emergency battery in the battery box is fully charged 12 6V Pull on the emergency breakaway cable while your partner vigorously spins the trailer wheel to see if it stops the wheels If the brakes fail to apply check wiring continuity the trailer circuit breaker or fuse ground connections and magnets Maintenance Do not get grease or oil on the brake linings drums or magnets electric system Full Maintenance Procedure Inspect all wiring secure attached in position Check connection
26. and Breakaway Systems No Independent Trailer Braking System If the trailer has no independent braking system the trailer relies exclusively on the application of the brakes on the tow vehicle to apply braking force to the trailer For safe and effective braking operations it is crucia that the weight of the trailer does not exceed the gross vehicle weight rating GVWR of the tow vehicle The tow vehicle GVWR is generally found on a label inside the door frame of the vehicle The trailer GWR is on the trailer name plate at the front of the trailer Proper synchronization of trailer brakes with tow vehicle brakes is essential to safety and overall handling Allow for additional distance in braking and stopping of the tow vehicle In a breakaway situation the safety chains may prevent the trailer from breaking away completely from the tow vehicle The trailer will not stop of its own accord Be sure you stay within the weight ratings of both your PCMS trailer and tow vehicle Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 33 Brakes and Breakaway Systems Breakaway System Note This component is an option on Ver Mac PCMS Please check that your PCMS has this component before proceeding Avoid accidental activation of breakaway mechanism Do not coil breakaway cable around coupler or safety chains All PCMS trailers with an electric braking system or a hydraulic breaking system have a breakaway cable
27. care Regular maintenance means e less likelihood of equipment failure and down time for repairs e greater operating reliability e improved safety of personnel and public As with all mechanical equipment routine maintenance is best practice to preserve the life of the PCMS unit and to ensure that it is running safely and properly Because PCMS units are generally stationary for relatively long periods of time in tough worksite environments maintenance tasks focus mainly on prevention and removal of rust and corrosion Maintenance tasks are recommended at least once a year Thorough maintenance is especially recommended before the PCMS unit goes into long term storage or after hard use c N EM Note Lack of maintenance can invalidate any and all guarantee provisions Before you start any of the maintenance procedures in this manual please have in hand the 1 model and identification number of your PCMS unit braking system hydraulic electric or none on the unit trailer type of hitch coupler pintle lunette ring or ball type on the unit trailer type of hoist hydraulic lift or reversible hand winch to raise the mast peripheral devices attached to the PCMS unit PCMS unit components not manufactured by Ver Mac Ou BR C MN For detailed information on the maintenance requirements of any PCMS Note component assembled by but not manufactured by Signalisation Ver Mac please consult the relevant manufa
28. cturer s own Maintenance manual Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 3 Overview Replacement Parts Maintenance routines are much the same for all PCMS units but replacement parts can vary according to the model of PCMS and any trailer component options that the client specifies Example braking system e To know what the correct replacement part is please check the PCMS Parts Manual for your PCMS unit or contact Ver Mac Support e Before calling Ver Mac for assistance please identify the trailer by its Vehicle Identification Number VIN The VIN is shown on the trailer nameplate on the front of the trailer near the controller cabinet Optional Devices Equipment needs change according to worksites and improvements in technology Most PCMS units that leave the Ver Mac factory have any optional devices that the client specifies already attached to the unit and connected The complete PCMS unit is ready to go into operation upon delivery Upgrades and information about new compatible devices is always available on the Ver Mac website When ordering an optional device after your initial purchase please ensure that you specify not only the serial number of the PCMS unit to receive the device but also any hardware or installation kit Contact Ver Mac Support to ensure you obtain all the relevant details as to placement of the device on the PCMS unit and how to connect to the software 4 Operations S
29. d in the reservoir is approximately 34 full Add Dexron II ATF hydraulic fluid as necessary to maintain level Replace the cap on the reservoir tightly to prevent loss or contamination of the hydraulic fluid Lowering the Mast with Hydraulic Bypass Valve Turning the hydraulic bypass valve too quickly may cause the sudden and rapid descent of the signboard To avoid possible injury make sure you are well clear and out of the way If the hydraulic system fails to function gradually turn the hydraulic bypass valve counterclockwise to release the pressure so the fluid flows back into the reservoir and lowers the mast Once the mast is down retighten the hydraulic bypass valve Ote This procedure only lowers the mast It does not enable you to raise the mast Raising the Mast with Optional Manual Hand Pump 1 Open battery box and check that the safety release valve is tight 2 Remove the handle from its holder in the battery box and insert it into the pump 3 Commence pumping and continue until mast rises to full height Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 41 Mast Reversible Hand Winch System for Mast IMPORTANT This component is an option on Ver Mac ae Please check that your PCMS has this component before proceeding Manual hand winches require your physical strength to crank and raise and lower the mast When working with a manual winch stay alert watch what you are doing and use comm
30. e Before 3 12 tem Function Required Each Use Months Months Axles Visually check camber Inspect for rust loss of arch or leaves sandwiched together Replace any sagging or broken Visually inspect U bolt connections Suspension for bending elongation of bolt Parts holes excess wear o Hangers Inspect welds for integrity 28 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Brakes and Breakaway Systems Brakes and Breakaway Systems Proper braking is critical to the safe towing of any PCMS unit trailer Ver Mac PCMS unit trailers can have e an electric brake system braking activated by an electrical connection to the brake pedal of the tow vehicle or e a hydraulic surge system braking activated by a special trailer coupler actuator with no control from the towing vehicle Or e no independent trailer braking system lightweight trailer models only N Adding extra weight to trailer can adversely affect braking and steering Electric Brakes IMPORTANT This component is an option on Ver Mac PCMS Please check that your PCMS has this component before proceeding An electric brake system operates in conjunction with drum brakes on the trailer wheels Under normal conditions the tow vehicle supplies the power to the trailer s electric brakes The amount of braking applied to the towing vehicle regulates the process All trailers with an electric braking system have a s
31. e PCMS V 2 0 Ver Mac 2011 Tires and Rims Trailer Tire Wear Diagnostic Chart Variations in tire pressure can adversely affect handling and stability of the unit trailer Wear Pattern Over inflated tire X amp l 1 I i Center Wear i ins A i Under inflated tire Edge Wear Side Wear Loss of camber or overloading l Out of balance AY Cupping Replacement Tires and Rims Action Adjust pressure Adjust pressure Make sure load does not exceed axle rating Realign load or axle Check bearing adjustment and balance tires Changes in wheel size can seriously affect trailer stability and safety Signalisation Ver Mac recommends a replacement tire that is the same size ply and brand as the tire originally installed on the unit trailer Signalisation Ver Mac recommends a replacement rim that is the same size and brand as the rim that was originally installed on the unit trailer Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 25 Tires and Rims Lug Nuts on Wheel N Failure to torque wheel lug nuts to the specifications of the wheel manufacturer can provoke loss of wheel s Proper torque is essential to prevent wobble and potential loss of wheel s Over or under torqued lug nuts can cause the wheel to separate from the wheel mounting Always check and re torque wheel lug nuts before towing Note Keep lug nuts un lubricated at all times
32. e marker and clearance lights Marker lights enhance the visibility of the trailer at night They are positioned on the sides of the trailer frame amber toward the front and red to the rear As well three 3 red clearance lights are in the center of the back bar on trailers wider than 80 203cm So Check that the plug on the tow vehicle matches the trailer wiring end plug on the trailer Always test all trailer lights before towing Make sure wiring is properly installed and secured to trailer to prevent it from hanging and catching on any road debris Replacement Light Bulbs Make sure that any replacement light bulbs are 12V DC Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 21 Trailers Trailer Light and Reflector Periodic Maintenance Before c 12 Item Function Required Each Use Months Months Lights amp Reflectors Brake Lights Turn Signals Check connections wires and plugs Test all lights in turn for functioning Replace any burned out light bulbs L R Clearance Lights Tail Lights Check condition Reflectors Replace any broken missing or cracked reflectors 22 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Trailers PCMS Unit Hardware and Fasteners Loose or incorrect hardware and fasteners can cause damage to equipment and personal injury Replacement Hardware and Fasteners If you need to replace any hardware make sure the replacement part i
33. ection part of your pre towing routine and have the defects fixed BEFORE going on the road 8 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Pre Towing and Work Site Inspections Walk Around Checklist DANGER Never crawl under a trailer supported by the jacks alone Walk Around Checklist obvious physical damage flat tires broken or cracked reflectors 2 Test and check that stop brake lights function correctly flashers left and right function correctly tail lights function correctly all marker lights function correctly 4 If trailer is attached to towing vehicle verify that coupler is attached correctly snug on ball coupler is locked to hitch amp safety pin inserted safety chains are crossed amp hooked from underside breakaway chain are attached to both safety switch amp tow vehicle all jacks are retracted amp are in the horizontal position trailer wiring is connected to the tow vehicle 5 Before taking the unit on the road field test 0 L INH the surge brake system is operational Failure to maintain hydraulic fluid in surge brake actuator at an adequate level can lead to brake failure Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 Pre Towing and Work Site Inspections Work Site Inspection Note This should be completed before PCMS setup Site location and conditions affect the effectiveness of portable message Signs in a work zone A wo
34. ection so that the power cable does not become tangled in the rotate and tilt mechanism Care and Cleaning of Solar Panels While solar panels generally require little maintenance beyond thorough cleaning lack of maintenance eventually affects the batteries and the performance of the PCMS unit Cleaning Procedure for Solar Panels 1 Remove all accumulated dust and debris in winter any heavy snow 2 Use mild detergent to remove any oil or grease deposits 3 Rinse surface thoroughly Be sure to remove all dirt and detergent residue Note Do not rely exclusively on the rain to clean the panel Replacement Solar Panels Replacement solar panels for the solar array must be the same wattage and ideally from the same manufacturer as the rest of the array 50 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Solar Array Solar Array Periodic Maintenance Before c 12 Item Function Required Every Use Months Months Solar panels Tilt and clean upper glass surface using plenty of water In winter remove excess snow or ice build up as soon as possible Sunlight usually melts any light snow or ice Support Structure Check for a loose Panel Frame Frame ML ail Check for rust and corrosion Pivoting Jack Lubricate inner ram and turn mechanism Check for rust and corrosion Lubricate lightly Panel Brake EUR Make sure cotter safety pin is in position Screw Transport Inspect for proper support C
35. enance Check battery fluid level every three months in temperate climates every 30 days during the summer and in hot climates Check that the clips holding the cables on the battery terminals are tight and that cables themselves are not frayed or broken Clean any dirty battery terminals and the insides of cable clamps with a post and clamp cleaner Spray the clamps with a battery terminal protector Remove any fluid or residue build up on the tops of the batteries Use a 50 50 solution of baking soda and water Rinse with clean water Never over tighten the battery terminals This can result in broken battery posts post meltdown and or fire 54 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Battery Bank Battery Fluid Level Maintaining the fluid level in the battery cells is the most effective way of optimizing the service life of the battery bank Fill the batteries after extended charging Be sure to check the electrolyte level after charging Keep below the bottom of the fill well in the cell cover Never fill or overfill the battery cells When the battery charges the electrolyte can overflow causing corrosion and other damage a E Note In warm climates and during the summer check the battery fluid levels every 30 days Battery Fluid Procedure Remove the vent caps Look inside and check the electrolyte levels Minimum level required for charging the battery is at the top of the plates
36. ents the handle from spinning rapidly backwards if ever your hand slips off the winch handle while lowering the mast Note The winch brake is not fully locked until you hear at least two 2 clicks of the ratchet Only then do you release the handle Replacement Winch Cable Always replace winch cable with one that is identical in diameter and load limit Replacement Procedure for Winch Cable 1 Unwind the cable from the drum Remove completely and dispose of it 2 Insert the new cable on the drum making sure you insert it correctly Secure it tightly Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 43 Mast Reversible Hand Winch Periodic Maintenance Before c 12 Function Required Every Use Months Months Hand Winch Inspect for dirt buildup breaks frays Make sure that the cable is pulling Straight off the winch Clean and lubricate auto type grease Ratchet Parts ale EL Remove handle retainer assembly handle and brake disc cover and Brake Disc inspect for wear Replace if less than 1 16 thick or cracked or broken Brake Ratchet wiles operation Mechanism turn handle clockwise to reel cable in and listen for clicking sound Remove handle and retainer Brake Ratchet assembly handle and disc cover Parts Inspect for wear and unsafe condition Check that winch is properly installed on mast Check welds If winch brake disc mechanism operates intermittently or erratically yo
37. fore commencing any maintenance on the electrical connections on the unit e disconnect power supply at junction boxes e disconnect red solar regulator lead Even when you have taken every precaution be aware that the solar panels continue to generate current Note Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 49 Solar Array Orientation and Tilt Correct orientation and tilt angle to horizon of the solar array is most important For optimum power generation solar panels need to face the midday sun at an angle roughly equal to the latitude of your location The rotation mechanism and pivoting jack enable you to orient and tilt the solar array Proper Orientation and Tilt Procedure Release the solar panel handbrake upward thrust and make sure solar cable is out of the way Pull down and turn handle on the pivoting jack until panels are facing up into the sky at approximately 45 or the angle that you require Using the handles above the panel brake turn the solar array and orient it toward the South in southern hemisphere towards North Pull down on panel brake and lock the panels into position At the same time make sure the metal L clamp is gripping the rotation plate firmly Tighten the adjustment screw use Phillips head screwdriver if the panel brake appears loose To prepare the solar array for transportation reverse the procedure Make sure you turn the panels in the opposite dir
38. ghtness Photocell Solar panels Tilt and clean upper glass surface using plenty of water In winter remove excess snow or ice build up as soon as possible Sunlight usually Bus any light snow or Support Structure Check for rust and corrosion Lubricate Pivoting Jack i l inner ram and turn mechanism Check for rust and corrosion Lubricate lightly Panel Brake Make sure cotter safety pin is in position Make sure cotter safety pin is in position e Screw Transport Inspect for proper support Cradles Replace cushions as needed Electrical Junction Open and use a volt meter to test and Boxes monitor output Cables or Wiring Verify connection to communications card inside sign case 74 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Appendix A Schedule of Recommended Maintenance Before c 12 Item Function Required Each Use Months Months Batteries Inspect outside of battery damage cracking and leaking fluid Replace any leaking battery nmediatel Inspect water level Fill as needed Test with voltmeter Battery Bank fully charged 12 7 V or higher Charge as needed Test with Hydrometer Check specific gravity does not vary more than 0 05 units between cells Inspect terminals for corrosion tightness of connections Clean as necessar Inspect for damage water infiltration EMEN Boxes Check that cover closes and locks securely Controller Cabinet
39. ging and Testing Battery Bank Periodic Maintenance Controller Cabinet Solar Regulator Controller Cabinet Periodic Maintenance Troubleshooting Appendix A Schedule of Recommended Maintenance viii Operations Safety amp Maintenance PCMS V 2 0 29 29 31 33 34 35 36 37 37 38 39 40 40 40 42 45 45 46 46 46 47 48 49 49 50 50 50 51 52 53 54 55 55 60 61 61 63 64 68 Ver Mac 2011 Appendix B Full Brake Maintenance Full Brake Maintenance Hydraulic and Electric Systems Appendix C Safety Warning and Instructions Decals Appendix D Australian Regions and Terrain Categories Glossary Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 76 76 77 79 80 Overview Introduction This manual is intended to guide Australian owners and operators in the safe operation and maintenance of Ver Mac PCMS 320 units The maintenance procedures and schedules described in this manual are specific to Ver Mac PCMS 320 models for the Australian market Ver Mac PCMS units can and do e differ from one model to another e contain component parts from manufacturers other than Ver Mac e vary according to optional additional components and devices that may have been added to the unit and e may have been customized according to the original purchaser s specifications c Q Note Installation operation and maintenance of PCMS units as well as any necessary re
40. hazardous items are caught before they degenerate and the trailer requires a major overhaul Always carry out a general maintenance check of the trailer and unit components before towing and setting up the PCMS unit at a work site Repair replace or correct any obvious deficiencies DANGER Never crawl under the trailer unless it is resting on jack stands with additional support under the trailer tongue Improperly supported PCMS trailers may fall unexpectedly resulting in serious injury or death Do not lift or support trailer on any part of the axle or the suspension system Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 17 Trailers Safety and Instructions Decals As of 2012 all Ver Mac PCMS trailers display safety and instructions decals prominently on certain parts of the units 1 If your PCMS unit is an older model and has no decals please contact Ver Mac Note Support to receive decals and information concerning their placement on the PCMS unit All operators and personnel working on the units need to be aware of and pay close attention to all such indications e Make sure that all decals are whole clean and visible e Replacement decals are available from Ver Mac or your Ver Mac distributor Please see Appendix C Safety Warning and Instruction Decals for more information Piggyback Towing Piggyback towing can pose a threat to public safety Before towing PCMS units piggyback plea
41. he trailer Turn the signboard display to face the oncoming traffic Fine tune the orientation with the site viewer Lock the signboard in position with sign hand brake Lower the signboard so you can access the solar panel tilt and rotate system Make sure the sign casing does not collide with surrounding objects Wind the tilt arm adjustment knob until the solar array is at a 45 degree angle You now have enough clearance to rotate the solar panel Release the solar panel hand brake and rotate the solar panels with the two rotation handles on the mast Lock solar panel hand brake to keep the solar array in position You can adjust the solar panel handbrake for a firmer grip as needed Raise the signboard fully Until and unless you program a new message the signboard displays the last message that ran on the PCMS Operations Safety amp Maintenance PCMS V 2 0 13 Trailers 14 Wind Loading Never use large loose items for ballast as they can become dangerous projectiles if the signboard is hit In certain locations and under specific conditions turbulence or extreme weather conditions you may need to add ballast to stabilize the PCMS trailer To avoid creating an additional potential hazard the ballast used to stabilize the PCMS unit should be secured Where it is necessary to add weight to the PCMS unit for stability you can place foot plate extenders on the leveling jacks and add sand bags ballast boots or
42. ign hand brake and turn the signboard until it is in position above the transportation cradle Unlock the solar panel brake and rotate the array to the transportation position Make sure the support bar on the back of the array is above the rubber bumpers Wind the tilt arm adjustment knob until the solar panels are tight against the sign case for transport Lock the solar panel handbrake Trailer Removal Be very careful when attempting to maneuver trailer into position to attach it to tow vehicle Make sure power is OFF signboard and solar panels down and in their respective transportation cradles and the sign brake engaged Back tow vehicle as close as possible to the trailer Lower jacks till wheels are on the ground Block the wheels and swivel all but one jack into horizontal travelling position Attach the coupler hitch securely to ball on tow vehicle snug on the ball Cross the safety chains under the hitch and attach the hooks to the tow vehicle from the underside Attach breakaway cable to tow vehicle if the trailer is equipped with brakes Make sure it is not taut not around the ball or caught in the chains Connect power plug to the tow vehicle having first removed it from the optional holder if available Do the Walk around check before driving off Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Trailers PCMS Maintenance Trailers general maintenance check ensures that potentially
43. ill mast is fully extended Recharge the batteries Power supply loose DE i Check all connections Tighten all connections wiring Check LED indicators Low voltage on solar regulator in Cabinet Tap anywhere on screen and wait for the startup sequence 1 Open controller cabinet and check for low voltage disconnect Check fuse J2 on solar regulator Touchscreen controller in sleep mode Sign ON Touchscreen Controller not Controller is working operational but has no power Ver Mac 2011 Log in again Check power systems and continuity on all cables between touchscreen and batteries Operations Safety amp Maintenance PCMS V 1 0 65 Troubleshooting Problem Possible Cause No message or message not activated Relay Bracket Sign ON Touchscreen Controller working No display Communications card One or more characters in message does not display Display card is damaged or there is a faulty connection to a card 66 Operations Safety amp Maintenance PCMS V 2 0 Preview screen Check that the green and yellow LEDS on the back of each display card Check voltage on relay bracket Check harness between display cards and relay bracket Check that the green and yellow LEDs on communication card are flickering Run the Pixel Tests to locate the defective or damaged card s Action If no message on Preview check the program and restart the message If
44. in place of a ball coupler Some PCMS units are fitted with an optional 2 ball coupler Pintle Hook and Lunette Ring Combination Verify that the retaining pin for the pintle hook ts properly locked to avoid accidental release of the pintle hook and the trailer A 72 mm 3 I D round metal lunette ring is fixed horizontally on the trailer The pintle hook is a vertical ring that opens and has a jaw that attaches to a tow vehicle Verify that pintle hook and draw bar on the tow vehicle have adequate Note capacity for the trailer and all safety or locking cotter pins are in place and in good condition Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 3 Coupler Hitch Ball Coupler Hitch This component is an option on Ver Mac PCMS Please check that your PCMS has this component before proceeding IMPORTANT b Make sure that the trailer ball is completely engaged in the coupler When you attach the trailer to the tow vehicle make sure it is hitched securely e Usethe trailer jacks to lower the coupler onto the ball e Make sure the coupler is in the loose position and that the clamp in the coupler has dropped open The trailer tongue should be snug on the ball when locked You have the proper adjustment when the coupler is as tight as possible on the ball and you can still open and close the locking lever If adjustment nut is too tight handle does not lock Proper Rigging
45. ive or incorrectly connected Solar array disconnected Batteries incorrectly connected No solar voltage reading on the Standby controller Over voltage from batteries greater Example 12V batteries in series than 15 15V Defective solar regulator U101 Q102 Battery voltage around e 14 45V at 25 C OK e 13 70V at 25 C e 12 95V at 50 C No solar voltage reading on the Serial communication defective or controller incorrectly connected Standby One or more solar panels may be Controller displays solar voltage incorrectly connected Example 20 00V but no solar current Defective solar regulator U101 Solar regulator is OK but there is not enough sunlight Check orientation of the solar array Solar current entering current is less than the battery current ROUROING CHErEMt Solar regulator is OK but the system is drawing too much current Solar current entering current is greater than the battery current OK outgoing current LVD Low Voltage Disconnect Battery voltage too low Defective jumper switch or wire in J5 Fuse F2 blown F1 replacement fuse System OFF and no LEDs lit on regulator Ground disconnected Check J2 2 ON 2 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Controller Cabinet Controller Cabinet Periodic Maintenance Before c 12 Function Required Each Use Months Months Controller Cabinet AII Connections All Cable
46. ller for display as message on the signboard or to trigger a warning message to display Solar array a linked assembly of two or more solar panels plus the electrical connections to the battery bank Solar regulator limits the rate at which electric current is added to or drawn from the batteries Work Zone an area of a highway with construction maintenance or utility work activities Ver Mac 2011 Operations Safety amp Maintenance V 2 0 81 VER MAC MANAGING TRAFFIC MOVING PEOPLE MMXI VER MAC Inc TECHNICAL PUBLICATIONS All rights reserved
47. low the instructions and procedures contained in this manual could result in failure of the equipment property damage and serious injury The owner is responsible for the proper use and maintenance of the equipment Failure to properly maintain equipment can also void all warranted guarantees See the Appendix A of this manual for all scheduled maintenance intervals Please work safely Ver Mac 2011 Operations Safety amp Maintenance V 2 0 iii Warranty Statement Updated August 2011 Signalisation Ver Mac warrants all their newly manufactured traffic control equipment to be free from defects in material and workmanship This warranty applies only to Ver Mac manufactured components e All non electronic components manufactured by Signalisation Ver Mac are warranted for a period of twelve 12 months from the date of delivery to the original purchaser e Electronic components manufactured by Signalisation Ver Mac are warranted for a period of twenty four 24 months from the date of delivery to the original purchaser Limitations and Exclusions Coverage under this warranty is limited to components manufactured by Signalisation Ver Mac and maintained and operated within the limits of the normal usage for which the component was designed In the case of electronic components this warranty is contingent upon the following two conditions e That the equipment has been connected to a power source of the correct voltage and amperage
48. move handle retainer assembly Brake Disc handle and brake disc cover and inspect for wear Replace if less than 1 16 thick or cracked or broken Brake Ratchet SEC OP arion turn handle clockwise to reel cable in Mechanism nr and listen for clicking sound Brake Ratchet Remove handle and retainer assembly handle and disc cover Inspect for wear Parts ae and unsafe condition Check that winch is properly installed on mast Check welds Signboard Exterior Clean and wet with oil auto type 10W 30 Crank the signboard up a little and check main harness cables for wear Make sure the cable lies loosely on the battery boxes not squeezed between in Check all reflectors at top of case in place unbroken Replace as needed Check door closed and undamaged Check functioning of dashpot door po closers that hold the face open Replace if broken Check condition of all rubber T latch clamps tight not cracked or loose Verify all welds at corners of sign case 72 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Appendix A Schedule of Recommended Maintenance Before 3 12 Item Function Required Each Use Months Months Check condition of rubber bungee strap not dry or brittle Replace as needed before towing Check condition of any external photocells Clean as needed Remove dust and debris Wash and rinse off accumulated grime in winter remove snow and ice acc
49. mpartment Ver Mac 2011 Operations Safety amp Maintenance V 2 0 77 Appendix C Safety Warning and Instructions Decals PART N 9 Sticker LEAD ACID BATTERIES 7 CORROSIVE LIQUIDS ELECTROLYTE E 9836 ENERGIZED E CIRCA GATE NO SMOKING ALWAYS USE EATREME CAUTION WHEN HANDLING LEAD ACID BATTERIES KEEP BATTERY ACID AWAY FROM SKIN AND EYES NEVER SMOKE OR ALLOW 4 SFARK OR FLAME IM VICINITY OF A BATTERY Location in Location in battery compartment compartment E 8144 Keep hands and fingers clear of the drum and cable when operating Do Not attempt to guide cable by hand Location Directly above the winch handle on metal winch reel Support bracket 78 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Glossary Appendix D Australian Regions and Terrain Categories This map is for reference purposes only taken from AS NZS 1170 2 2002 Christmas Island Region B Re Qgpon B Australian Territory only 11 McDonnel Creek Moreton Cocos Islands Region C Region C Mareeba Region C Bees Borroloola es iet Kununurra West Moreland Aurkeatown 2o bar athe EON TOR 4 a Rockhampton Onslow Alice Springs Millstream Bundaberg Region D Y ZA sires f l C em 25 Carnarvon id z zi Region B gui eee Gascoyne Junction Region A4 A risb na r s ASI Si Teuwonebs c Es Kyogie E Corindi Morlolk glands 21 o ullewa 4 Region B
50. nction Required Hydraulic Brakes Check fluid level Fill to with DOT 3 braking fluids if low Field test according to manufacturer s instructions Breakaway System Check battery charge and safety switch bu Synchronize Surge Brake Actuator Ld Inspect for rust Ld as necessary Make sure that the hooks are whole not Safety Chains b 2 ent or rusted Lubricate lightly with grease Coupler Hitch Pintle Hook amp Check capacity Draw Bar Inspect for wear Inspect for rust Coupler and Clean and lubricate ball socket and Ball clamp lightly with grease Ball and Tongue Check capacity Verify that all are in place and properly t t Mast inserted Check for leaks hydraulic fluid on the ground under the mast Replace weak or missing pins Raise mast to full height and check Nylatron runners and screws Clean any build up Adjust for snug fit on mast Safety Pins Ver Mac 2011 Operations Safety amp Maintenance PCMS V 1 0 71 Appendix A Schedule of Recommended Maintenance 12 Months 3 Months Before Each Use Item Function Required E Check main bolt top of mast is tight Check all metal parts for rust and corrosion Lubricate lightl Hand Winch Inspect for dirt buildup breaks frays Make sure that the cable is pulling straight off the winch Clean and lubricate auto type grease All Shafts Bushings and Ratchet Parts Re
51. need to check the brakes to be sure they fully release when the tow vehicle is in motion and apply properly and evenly when the tow vehicle is braking Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 31 Brakes and Breakaway Systems 32 Testing Hydraulic Brakes Deploy the jacks and raise wheels off the ground Activate the brake actuator with the breakaway cable and hold for approx 10 seconds while your partner vigorously spins the trailer wheel The wheel should come to an abrupt stop Check both sides to confirm good hydraulic performance of the braking system When you release the pressure on the master cylinder the wheel Should rotate freely A slight drag of the shoe and drum is normal Even if the brakes apply normally the only way to know if the brakes are adjusted properly is to test drive the trailer behind a vehicle Hydraulic Surge Brake Maintenance Failure to properly and adequately grease and maintain the actuator could weaken it and may cause it to fail Full Maintenance Procedure Check the brake fluid and change if sediment or water contamination Check all lines and fittings for corrosion or leaks Replace as necessary Remove the brake drums and clean inside the brakes Check brake pads shoes and related parts Replace as necessary Pack the wheel bearings with grease before the drum is installed Adjust and test the brakes Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Brakes
52. odem thus allowing remote control of all Sign functions Both the Touchscreen Controller and JamLogic 2 are NTCIP compatible and compatible with and operational under Windows XP In addition users can communicate with the signboard on site using a portable computer connected directly to the PCMS unit through an RS 232 port For greater detail concerning the Product Host Control System please refer to the current User manual for the Touchscreen Controller available on the Ver Mac website or JamLogic 2 online help or as a pdf version on the Ver Mac website Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 7 Pre Towing and Work Site Inspections Pre Towing and Work Site Inspections These preliminary inspections help to ensure that e the installation site is suitable e the structure of the PCMS unit is solid e the unit components are all well secured e the braking and lighting systems are operational Walk Around Inspection of PCMS Unit The walk around inspection aims to catch any obviously out of place conditions that could potentially affect safety and unit operations Always carry out a walk around inspection e before moving the PCMS unit to the worksite e before removing the PCMS unit from a work site e periodically during long term storage of the PCMS unit A walk around inspection only covers items that you can check without getting under the trailer Note Make the walk around insp
53. of the current message that is displayed on the sign e performs diagnostics testing of various system components including pixels power system and sensors e activates messages and schedules stored in the memory e configures display parameters including display size and colors e configures communications port settings and NTCIP options Hydraulic bypass valve a safety mechanism that enables you to relieve the pressure in the hydraulic pump by draining hydraulic fluid back into the pump cylinder Mode Charging the batteries describes the operating state that the battery charger has switched to during the charging process Modem small printed circuit board card that you insert in controller to obtain wireless access to the PCMS and its data 80 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Glossary Portable Changeable Message Sign PCMS a traffic control device capable of displaying one or more messages Messages on a PCMS can be changed e manually on site local controller e remotely via modem e automatically according to a predetermined and activated Schedule PCMS unit the entire equipment assembly solar array signboard trailer structural electrical and electronic components battery bank and controller It also includes any peripheral devices attached on the frame or components Radar directional Doppler radar that captures the speed of an approaching vehicle and communicates this to the contro
54. on sense Proper footing and balance enables better control of the winch in unexpected situations Do not over reach Maintain proper footing and balance all the time Do not stand on trailer to raise or lower mast Loose clothing and long hair can be caught in moving parts Raising Mast 1 Disengage the locking pin on the mast 2 Slowly and evenly turn the crank handle clockwise and raise the mast to its full height This action produces an audible clicking sound from inside the winch mechanism 3 Release the handle slowly to lock the mast in position 4 Make sure the locking pin on the mast is fully inserted and locking the mast in position Keep hands and fingers clear of the drum and cable area of the winch when operating Do not attempt to guide cable by hand Never continue turning the handle counter clockwise if the cable does not keep moving out This disengages the winch brake mechanism and can create an unsafe or hazardous condition 42 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Mast Lowering Mast 1 Disengage the locking pin on the mast 2 Slowly and evenly turn crank handle counter clockwiseo and lower the mast until the signboard is resting in the transportation cradle 3 Reverse the movement and turn crank handle clockwise approx 20 cm 8 This action locks the mast in position 4 Pull and turn the locking pin on the mast to the locked position The winch brake prev
55. or failures ee o Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 19 Trailers Jacks Four 2 000 Ib tubular top wind swivel jacks attached at the four corners of trailer frame support the PCMS unit when it is not attached to a tow vehicle Use of the jacks allows you to safely raise and keep the trailer wheels off the ground while the PCMS unit is in operation on worksites or during long term storage SAFETY PRECAUTION Wear safety shoes and instep guard protection when handling jacks because jacks may slip or parts may fall Jacks may fall causing damage or injury Unexpected tilting of trailer can cause injury and damage Always fully retract amp swivel jack to horizontal position before towing trailer Do not attempt to raise mast or position solar panels and signboard unless all jacks are securely in position Jacks Periodic Maintenance Before 3 12 Item Function Required Each Use Months Months Jacks Tubular Extend jack as far as possible and Swivel lubricate entire outside length of inner 4 ram with SAE 30 heavy oil Grease each jack grease fitting at top of outer ram 20 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Trailers Trailer Lights and Reflectors Trailer lights perform a valuable and necessary function but they occasionally breakdown or malfunction All Ver Mac trailers come equipped with e brake lights e tail lights e turn signals left and right
56. other ballast material to each corner of the trailer The ballast should be kept to the minimum amount needed and placed no higher than 330 mm 13 in above the road surface SAFETY PRECAUTION Never tow a PCMS unit with ballast on the trailer Ballast calculation 1 You can deploy the PCMS 320 outriggers extended without the addition of ballast in the regions shown in the table PCMS 320 with no added ballast A NO W NO B NO C NO D NO 2 You can deploy the PCMS 320 in more regions if you add extra weight to the trailer to increase its wind resistance If you add 225 kg to the PCMS 320 you can use the unit in e Region A terrain category 1 e Region W terrain category 3 Region B terrain category 2 e Region C terrain category 4 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Unit Deployment and Removal If you add 335 kg you can also use the unit in e Region W terrain category 2 e Region B terrain category 1 e Region C terrain category 3 Weight kg to add to PCMS 320 for deployment in other regions Terrain category To know the region and terrain category that applies to the proposed location of your PCMS unit please refer to the map in Appendix D of this manual or the decal on the PCMS unit Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 Trailers 16 Takedown of Signboard and Solar Array 4 5 Shut off the signboard Power ON OFF switch Unlock s
57. pair work should only be carried out by qualified persons Please make sure that all personnel have read and understood this manual before putting your PCMS unit into operation Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 1 Overview Safety and Warning Information Basic safety precautions and procedures as well as important points to remember during operation of the PCMS unit appear throughout this manual DANGER WARNING and CAUTION indications as well as Notices are posted in appropriate locations in this manual In addition safety and warning decals are displayed on the actual PCMS units for the express purpose of alerting personnel to potential hazards Appendix C of this manual contains illustrations and parts numbers for all the decals in use on Ver Mac PCMS 320 units for Australia DANGER Indicates a high level of risk for serious personal injury SY Indicates a moderate level of risk for personal injury and potential for damage to equipment Indicates a potentially unsafe practice and risk for minor personal injury SAFETY PRECAUTION Indicates an advisable safety precaution to follow Refers to an important feature that the operator should be aware of for Note maximum operating efficiency of the equipment or to help in completing a procedure A M 2 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Overview Maintenance Maintenance is a guide to equipment
58. plugs at the tow vehicle end and at the trailer end for corrosion Spray with penetrating fluid or WD 40 If electrical system is not working properly check the electrical ground Remove the brake drums and clean inside the brakes Check magnets brake pads shoes and related components Replace as necessary Pack wheel bearings with grease before the drum is installed Adjust and test the brakes Test drive the trailer behind a vehicle to confirm that brakes function 30 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Brakes and Breakaway Systems Hydraulic Surge Brakes This component is an option on Ver Mac PCMS Please check that your IMPORTANT PCMS has this component before proceeding In a hydraulic surge brake system an actuator responds to the braking Signal from the tow vehicle and activates the trailer brakes The braking process is automatic If separation of trailer and tow vehicle occurs the breakaway cable pulls tight and triggers the actuator to apply the trailer brakes When you replace components in the hydraulic braking system or if there is a leak you also have to bleed the brakes Note Only qualified and experienced personnel should bleed brakes For details on how to bleed the brakes refer to the manufacturer s manual for the braking system Note Testing the trailer braking system is always a two person operation Testing the Brakes For safe driving you
59. r signal connected correctly check strength continuity of antenna cable Check link light is illuminated on the modems Check with cell provider and ensure account is active Poor communication No input from Check connecting connection between battery or solar wires at regulator and Tighten all connections array the regulator and the the controller controller Remove all accumulated Solar panels are dirty buildup dirt snow grime Clean thoroughly Power supply seems to be inadequate Note If one battery Work through battery does not hold a checklist charge it will drain all Replace any bad battery the batteries Batteries 1 Clean and tighten all terminals Ver Mac 2011 Operations Safety amp Maintenance PCMS V 1 0 67 Appendix A Schedule of Recommended Maintenance Appendix A Schedule of Recommended Maintenance The general condition of the PCMS unit structure must be sound at all times with all unit components well secured and braking and lighting systems operational This applies whether the PCMS unit is installed at a work site or being towed or in storage Regular maintenance and routine inspections ensure your signboard unit is in good operating condition and help to prevent costly and time consuming repairs The preventive maintenance schedules on the following pages are recommended e Service intervals shown in the recommended maintenance schedules have been established for operation under
60. radles Replace cushions as needed Electrical Junction Open and use a volt meter to test Boxes and monitor output Cables or Wiring Verify connection to communications card inside sign case Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 51 Battery Bank Battery Bank deep cycle battery generally requires only preventive maintenance e maintaining electrolyte levels e tightening any loose terminals e removing corrosion e maintaining the correct state of charge while in storage Regular battery maintenance and correct charging procedures can prolong battery life Batteries can weigh 30 to 60 Ib 14 to 27 kg Practice safe lifting and carrying procedures to prevent back injuries Use a battery carrier to lift a battery or place hands at opposite corners 52 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Battery Bank First Aid Procedures First Aid Procedure Battery Electrolyte sulphuric acid Flush immediately and thoroughly with water any area of your body that is contacted by battery acid Eye contact gt Immediately flush the contaminated eye s with clean lukewarm gently flowing water for at least 30 minutes by the clock while holding the eyelid s open If irritation persists repeat flushing Neutral saline solution may be used as soon as it is available DO NOT INTERRUPT FLUSHING If needs be keep emergency vehicle waiting Be careful not
61. re aware of the traffic conditions work on the same side of the road as any work vehicle and warning beacon whenever possible avoid hours and locations with high traffic volume Plan ahead for better traffic conditions Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 PCMS 320 PCMS 320 The PCMS unit model 320 corresponds to Australian Type B and Type C specifications The PCMS 320 has an overall length of 3641 mm and an overall width of 1984 mm The trailer has a very low profile with a maximum travelling height of 2824 mm Operating height is 3813 mm to the top of the mast and 4653 mm to the top of the integrated solar panel The ground clearance is 305 mm The weight of the PCMS 548 without any optional equipment is approximately 1014 kg with a tongue weight of 126 kg With optional equipment the total weight is below 1500 kg and the tongue weight is less than 150 kg The sign display resolution is 30 x 48 pixels 5 x 8 4 LEDs per pixel Product Host Control System The Touchscreen controller located on the control panel inside the controller cabinet provides onsite direct control of all functions of the PCMS unit local programming operation and monitoring The touchscreen also enables users to select and set the fallback response default message to power or communication malfunction or failure JamLogic 2 is Ver Mac s proprietary software system It communicates with the PCMS unit via wireless based m
62. ries in good condition normally stay charged for months as batteries get older and do more charge discharge cycles capacity gradually reduces If any battery loses more than half its capacity in a month it is probably time to replace your entire battery bank Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 59 Battery Bank Battery Bank Periodic Maintenance Before c 12 Function Required Each Use Months Months Batteries Inspect outside of battery damage cracking and leaking fluid Replace any leaking battery immediatel Inspect water level Fill as needed Test with voltmeter Battery Bank fully charged 12 7 V or higher Charge as needed Test with Hydrometer Check specific gravity does not vary more than 0 05 units between cells Inspect terminals for corrosion tightness of connections Clean as necessary Inspect for damage water infiltration BEN Check that cover closes and locks securely 60 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Controller Cabinet Controller Cabinet The heavy duty lockable metal control box contains all the connections for the mechanical and display functions of the signboard The controller devices for on site programming are located inside the box as well as is the solar regulator Checking the connections generally requires you to open the control box and lift the panel covering the various connections Solar Regulator Solar regulators req
63. rk site inspection enables you to take every precaution to avoid all hazards in the work area prior to installation and operation of the unit DANGER Be safe Stay alert and pay close attention to the surrounding traffic at all times Site Verification Check List 1 Verify site location is on the verge behind the shoulder is open and level as possible with good road base Support is clear of side streets entryways and wheelchair users lines overpasses etc E maximum exposure to direct sunlight 0o no shadows from nearby structures no light towers in close proximity Note Even a small amount of shading reduces solar panel output significantly 10 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Unit Deployment and Removal Unit Deployment and Removal When you are working at the roadside you must always remain alert to your Surroundings and the traffic behavior DANGER Be safe Stay alert and pay close attention to the Surrounding traffic at all times SAFETY PRECAUTION Make sure your PCMS unit is delineated with traffic control devices or shielded with a barrier or barricade When the PCMS is not in use it should be removed or faced away from the view of oncoming traffic Note Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 11 Trailers Trailer Deployment Trailer mounted PCMS units should be placed on the shoulder of the roadway or if pr
64. s of equal size grade and type See Parts Specifications in the User manual for the particular model of PCMS unit Hardware and Fastener Periodic Maintenance Before c 12 Function Required Each Use Months Months Hardware amp Fasteners Nuts and Double check all nuts and bolts for Make sure that all safety and locking pins are in place and solid Replace any missing tightness and condition Lubricate lightl Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 23 Tires and Rims Tires and Rims Each trailer has rims installed that are designed for stability requirements Trailer stability is based on trailer width tire pressure and load capacity Size changes may result in an unsafe condition regarding stability The size of the trailer tires and also the rims fitted on the PCMS unit varies according to the gross axle weight rating GAWR e GAWR 3500 Ib ST205 75D15 5 hole rim and 6ply trailer tires for the Class II trailers e GAWR 5000 Ib ST225 75R15 6 hole rim and 6ply trailer tires for the Class III trailers Tire Safety Checklist Check that tires are inflated to specified pressure 32 psi especially before towinc Inspect tires for signs of wear cracks or impact damage Remove any foreign objects wedged in tread bits of glass stones or nails Make sure that the tire valves have valve caps and are not touching or rubbing the rim or wheel 24 Operations Safety amp Maintenanc
65. s Visually check cabling for signs of e damage Verify condition Controller clean undamaged Devices mE Peripherals Check for proper functioning MNT Manual amp Check condition Stickers complete clean and readable Weatherproof Inspect for tight seal Seal Replace as needed Optional Devices Check that all connections for Example peripheral devices are firmly attached Data Loggers Bluetooth Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 63 Troubleshooting Troubleshooting This chapter is intended as a first step in diagnosing your PCMS problem yourself Ver Mac support will be in a much better position to help you if you have managed to perform some basic troubleshooting procedures before you contact them Troubleshooting is not intended to be a complete guide to all possible problems It contains information on how to resolve some of the common difficulties that operators may experience when using Ver Mac s PCMS units Problem Possible Cause Action Check e cable for damage or e Replace cable if needed breaks e winch brake e Carry out winch brake operation inspection Make sure positive lead is connected to positive Hydraulic pump not battery terminal connected e back of pump Check pump with switch ON switch for voltage Check wiring e solenoid Change solenoid Manual winch is blocked or damaged Unable to raise or lower the signboard e connection of pump to battery
66. se check with your local authorities to Note see if this procedure is legal in your state or province Ver Mac does not recommend this practice under any circumstance 18 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Trailers Pre Maintenance Procedure Never work under a trailer resting on jacks only The trailer could slip off the jack or the jack could fail Before you start any work on the unit trailer carry out the necessary procedure to stabilize the trailer Pre Maintenance Stabilization Procedure Lower signboard and solar panels into their respective transportation cradles Lower all jacks until trailer wheels are resting fully on the ground Chock the wheels tightly and reposition the jacks so trailer is as level as possible Add another jack on the trailer tongue for additional support Trailer Structure Ver Mac produces two 2 different classes of trailer Class II rated to 3 500 Ibs 1 588 kg and Class III rated to 5 000 Ibs 2 268 kg Trailers can vary in shape and also in the size of the steel beams making up the frame Trailer Structure Periodic Maintenance Function Required Before 3 to q Each Use Months Months Trailer Structure Wash underneath to remove any build Body up of corrosive material road salt gravel All Links and Pivot Points Lubricate to prevent rusting Inspect for cracks or impact damage Replace as needed Frame Welds Check for cracks and
67. t Setup and Adjustment of Signboard and Solar Array Wind Loading Ballast calculation Takedown of Signboard and Solar Array Trailer Removal PCMS Maintenance Trailers Safety and Instructions Decals Piggyback Towing Pre Maintenance Procedure Trailer Structure Jacks Trailer Lights and Reflectors PCMS Unit Hardware and Fasteners Tires and Rims Trailer Tire Wear Diagnostic Chart Replacement Tires and Rims Lug Nuts on Wheel Tire and Rim Periodic Maintenance Axles and Suspension Axle Periodic Maintenance Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 BbAUNH mz o Ui Ul NN 17 18 18 19 19 20 21 23 24 25 25 26 27 28 28 Vil Brakes and Breakaway Systems Electric Brakes Hydraulic Surge Brakes No Independent Trailer Braking System Breakaway System Safety Chains Brakes and Breakaway System Periodic Maintenance Coupler Hitch Pintle Hook and Lunette Ring Combination Ball Coupler Hitch Coupler Hitch Periodic Maintenance Mast Mast Periodic Maintenance Hydraulic Lift System for Mast Reversible Hand Winch System for Mast Signboard Sign Brake Photocells Radar Device Sign Display Signboard Exterior Periodic Maintenance Signboard Interior Periodic Maintenance Solar Array Solar Panels Orientation and Tilt Care and Cleaning of Solar Panels Replacement Solar Panels Solar Array Periodic Maintenance Battery Bank First Aid Procedures Battery Maintenance Battery Fluid Level Battery Char
68. te the charger on unit The charger is normally located within the control unit Open the lid of the control unit and lift the white or black face The optional charger should be located inside 2 Locate the AC outlet for the charger Some installations will have the power cord wired into the charger Other installations will be wired to an external weather resistant power connector 3 Connect the AC outlet to an extension lead Connect other end of the lead into an 110V power socket 4 Change the charger switch to the ON position This switch is generally located inside the control box on the black or white face 5 Charge for the recommended time as specified in the Suggested Recharging Time tables The LED Indicator on the IQ4 shows the charging state and the battery charge status 6 Disconnect the extension and turn charger switch OFF This ensures the charger is powered off The IQ4 module allows the charger to charge in Bulk and Absorption modes for a 24 hour period only This time limit is to prevent damage to the batteries from overcharging As a result when the battery level is too low the charger may not be able to fully recharge the battery pack in a single 24 hour period When the 24 hour time limit is up the IQ4 LED small green light stays ON continuously and the IQ4 needs to be reset For full details see Battery Charging Procedures on the Support section of the Ver Mac web site Replacement Batteries Although batte
69. to rinse contaminated water into the unaffected eye or onto the face First aiders should avoid direct contact Wear chemical protective gloves if necessary Quickly transport the person affected to an emergency care facility Skin splashed with acid gt As quickly as possible flush the contaminated area with Ver Mac 2011 lukewarm gently flowing water for at least 30 minutes by the clock If irritation persists repeat flushing DO NOT INTERRUPT FLUSHING If necessary keep emergency vehicle waiting Under running water remove contaminated clothing shoes and leather goods e g watchbands belts Transport the person affected to an emergency care facility immediately Discard all contaminated clothing shoes and leather goods Operations Safety amp Maintenance PCMS V 2 0 53 Battery Bank Battery Maintenance Lead acid batteries contain sulphuric acid Sulphuric acid can destroy clothing and burn the eyes and skin Use extreme caution when handling batteries or electrolyte Wear gloves protective clothing and goggles Never smoke or allow a spark or flame in the vicinity of a battery Loss of capacity and leakage are the main things that can go wrong with batteries Check your batteries on a regular basis to be sure they are getting charged The quickest way to ruin lead acid batteries is to discharge them deeply and leave them stand uncharged for an extended period of time Battery Periodic Maint
70. u need to carry out a winch brake disc inspection as per the manufacturer s manual Note During reassembly make sure that all parts are installed correctly 44 Operations Safety amp Maintenance PCMS V 2 0 Ver Mac 2011 Signboard Signboard The exterior face of the signboard should be cleaned periodically to maintain optimum visibility of the display Care and Cleaning Procedure for Signboard Face Use plenty of water to minimize scratching of the surface by any abrasive dust and debris accumulation Use mild detergent to remove any accumulated oil or grease deposits Rinse surface thoroughly to completely remove the dirt and detergent residue Ammonia based detergents or petroleum based solvents can damage the Note polycarbonate face Lexan of sign and should not be used to clean the sign face Sign Brake Always make sure that the sign brake is engaged before towing Disengage the sign brake before lowering or raising the sign The sign brake is a heavy duty band brake attached on the mast below the signboard It holds the signboard in position e To engage the sign brake pull handle until brake locks in a horizontal position parallel to the bottom of the sign e To disengage the sign break reverse the movement e To apply or adjust the tension on the band adjust the small knob on the end of the brake with a screwdriver If this is not enough use the proper size socket wrench
71. uire very little maintenance All you need to do is regularly check the wired in connections to see that they are tight and corrosion free Note Before starting test make sure the solar array is in full sunlight Definition LED status Explanation e Solar regulator recharges the batteries with the maximum current available from the Green LED L3 flashin zur panels Bulk Mode 2x sec 9 e Regulator stays in Bulk mode as long as battery voltage is less than the charge limit e Once battery voltage reaches charge limit regulator moves into Float mode e Solar regulator maintains battery voltage o i Float Mode Yellow LED L2 flashing AP PTOX AP AZS Celie e If unable to maintain battery voltage regulator returns to Bulk mode e Solar regulator does not charge the batteries Standby Mode Green LED L3 flashing e Standby mode usually means too little solar 1x sec panels voltage output less than Battery voltage 1volt e Battery voltage is too low 10 4V at 25 Celsius so solar regulator disconnected LVD l i the output Load and extinguished signboard low Voltage Red LED L1 flashing display Disconnect e LVD condition stops when the batteries are sufficiently recharged 12 6V at 25 Celsius eos Le ane ES eons e Indicates a regulator hardware defect Defect simultaneously Ver Mac 2011 Operations Safety amp Maintenance PCMS V 2 0 61 Controller Cabinet Mode Condition Possible cause Serial communication defect
72. umulation Transport Inspect for proper support Cradles Replace cushions as needed Adjust height if necessar Check for rust and corrosion Sign Brake Lubricate lightly Adjust tension screw Check and clean photocell s Sign Case Outside Signboard Face Photocells Under Solar Test photocell function Panels cover sensor with dark tape Check sign brightness Inspect support securely attached undamaged Peripheral Devices Example Check wiring and connectors secure Signboard Interior Check for signs of water infiltration Sign Case Floor Check drainage holes are unblocked Run Chessboard test and visually check all pixels are operational Check there is no corrosion on the cards Display Cards Check all hoods are secured above each pixel Check all display cards are screwed in place Check harness cable Make sure it is not loose frayed or worn Check cables between cards Make sure connections are inserted correctly Check the Communication Card Relay Bracket for water damage and corrosion and connection Ver Mac 2011 Operations Safety amp Maintenance PCMS V 1 0 Appendix A Schedule of Recommended Maintenance Before 3 12 Each Use Months Months Item Function Required Check the GPS for water damage and corrosion and connection Check photocell functionality on communication card Test functioning cover sensor with dark tape Check sign bri

PCMS 320 Operations, Safety and Maintenance Manual - Ver-Mac

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