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VER-MAC PCMS Series, Operation, Safety And Maintenance Manual

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Appendix A 

– Full Brake MaintenanceGive us your thoughts 

 

50 

PCMS Operations, Safety & Maintenance V3.0 

Ver-Mac 2018 

14 

Appendix A – Full Brake Maintenance  

14.1 

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. 

 

  

NOTE

 

These components are an option on Ver-Mac PCMS. Please check that your 
PCMS has this component 

before

 proceeding. 

 

 

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 (

electric

) 

5. 

Adjust brakes 

 

 

  

NOTE

 

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. 

 

  

NOTE

 

Every 5 years approximately, check the brake drum and apply a thin layer of zinc 
grease. 

 

 

 

Summary of Contents for PCMS Series

Page 1: ...nal 2014 04 1 1 New warranty statement 2014 11 1 2 Suggested recharging times added 2015 03 1 3 Outrigger maintenance added 2015 01 2 0 SmartDocs started hitches maintenance updated 2016 10 2 1 New template added info on sealed batteries 2017 07 3 0 RC models 2018 02 3 1 Added appendix for telescopic camera ...

Page 2: ... ...

Page 3: ...com Disclaimer Failure to read and follow the instructions and procedures contained in this manual could result in failure of the equipment 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 guarantees This manual contains a complete list of all scheduled maintenance intervals for all Ver M...

Page 4: ...d to a power source of the correct voltage and amperage Exclusions Under no circumstances shall this warranty extend to Any of our products which have been modified repaired or altered in any way in any establishment other than the Signalisation Ver Mac Inc factory without authorization from Signalisation Ver Mac Inc Replacement parts not supplied by Signalisation Ver Mac Inc The obligations of Si...

Page 5: ...s be returned to Signalisation Ver Mac Inc along with an RMA number obtained beforehand from Customer Service at Signalisation Ver Mac Inc End User Responsibilities The end user is responsible for the appropriate choice of product for its proper usage and the results obtained by this product This warranty applies only to products that have been paid in full according to the terms stipulated in the...

Page 6: ... 3 6 Trailer Removal 9 4 Trailer Maintenance 10 4 1 Safety and Instructions Stickers 10 4 2 Pre Maintenance Procedure 10 4 3 Trailer Structure 11 4 4 Jacks 11 4 5 Trailer Lights and Reflectors 12 4 6 PCMS Unit Hardware and Fasteners 13 5 Tires and Rims 14 5 1 Trailer Tire Wear Diagnostic Chart 14 5 2 Replacement Tires and Rims 15 5 3 Lug Nuts on Wheel 15 5 4 Tire and Rim Periodic Maintenance 16 6 ...

Page 7: ...ocedures 39 12 2 Deep cycle Battery Maintenance 40 12 3 Sealed Battery Maintenance 43 12 4 Suggested Recharging Times 43 12 5 Charging with an External Charger 44 12 6 Charging the Batteries with the Onboard Charger 45 12 7 Replacement Batteries 45 12 8 Battery Bank Periodic Maintenance 46 13 Controller Cabinet 47 13 1 Solar Regulator 47 13 2 Controller Cabinet Periodic Maintenance 49 14 Appendix ...

Page 8: ......

Page 9: ...ill find your model in the controller box or on the vehicle identification number VIN plate In JamLogic our fleet management software you will need to enter pixel numbers rather than a model Here is a table describing the various models Model Controller Box Wi Fi Display size in Display Resolution HxW pixels Particularity PCMS 4880 Yes No 36x56 48x80 HD Mini full matrix PCMS 4880RC No Yes 36x56 48...

Page 10: ...ipment care Regular maintenance means Less likelihood of equipment failure and down time for repairs Greater reliability of operating 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 p...

Page 11: ...odels To know the correct replacement part See the PCMS Parts Manual for your unit or contact Ver Mac Support for further information Before calling Ver Mac for assistance please make sure you have the identification number of your PCMS in hand o Vehicle Identification Number VIN is on the tongue of the trailer o Serial number is on the PCMS panel or in the control box 1 6 About Maximum Speeds Ver...

Page 12: ... 2 1 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 of your PCMS unit Before moving the unit to the worksite Before removing the unit from a work site Periodically during long term storage of the unit Make the walk around inspection ...

Page 13: ...y batteries fully charged 12 6V signboard solar panels in cradles sign hand brake solar panel brake locked if there is an adjustable hitch and there were changes to it make sure that all bolts are tightened at 203 N m 150 ft lbf Replace worn bolts 4 If trailer is attached to towing vehicle verify coupler attached correctly snug on ball coupler locked to hitch safety pin inserted safety chains cros...

Page 14: ...he 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 as open and level as possible good road base support no overhead hazards or obstructions electric lines overpasses etc 2 Verify conditions for solar array maximum exposure to direct sunlight no sha...

Page 15: ...ver trailer into position for setting up 1 Position the trailer as close as possible to the location with the tow vehicle 2 Set one 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 optional holder if available 4 Unhook breakaway cable if trailer is equipped wi...

Page 16: ... 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 so stand away from any metal object when taking coordinates 7 Raise the signboard fully 8 Turn on sign Power ON Off switch and controller 3 3 Ballast WARNING Never use large loose items for ballast as they can become dangero...

Page 17: ... maneuver trailer into position to attach it to tow vehicle 1 Make sure power is OFF signboard and solar panels down and in their respective transportation cradles and the sign brake engaged 2 Back tow vehicle as close as possible to the trailer 3 Lower jacks till wheels are on the ground 4 Block the wheels and swivel all but one jack into horizontal travelling position 5 Attach the coupler hitch ...

Page 18: ...arts of the units NOTE If your PCMS unit is an older model and has no decals please contact Ver Mac 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 Make sure that all decals are whole clean and visible Replacement decals are available from Ver M...

Page 19: ... lb tubular swivel jacks attached at each corners of trailer frame support the PCMS unit when it is not attached to a tow vehicle These work in combination with four optional adjustable outriggers stabilizer bars to support the 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 ...

Page 20: ...n but they occasionally breakdown or malfunction All Ver Mac trailers come equipped with brake lights tail lights turn signals left and right 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 o...

Page 21: ...4 6 PCMS Unit Hardware and Fasteners WARNING Loose or incorrect hardware and fasteners can cause damage to equipment and personal injury 4 6 1 Replacement Hardware and Fasteners If you need to replace any hardware make sure the replacement part is of equal size grade and type See Parts Specifications in the User manual for the particular model of PCMS unit 4 6 2 Hardware and Fastener Periodic Main...

Page 22: ...the Class III trailers Tire Safety Checklist Check that tires are inflated to specified pressure 32 psi especially before towing Make sure the tire valves have valve caps and are not touching rubbing the rim or wheel Inspect tires for signs of wear cracks or impact damage Remove any foreign objects wedged in tread bits of glass etc Tighten wheel bolts at 90 120 ft lb 122 167 N m 5 1 Trailer Tire W...

Page 23: ...n the unit trailer 5 3 Lug Nuts on Wheel WARNING 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 lu...

Page 24: ...lation Pressure Maintain inflation at manufacturer s specifications Tire Condition Check overall condition adequate tread cuts wear bulging etc Replace if necessary Wheels Wheels Rotate to check that wheel moves freely Inspect for cracks dents or distortion or impact damage Lug Nuts and Bolts Tighten to manufacturer specified torque values Wheel Bearings Grease Cups Inspect for corrosion or wear R...

Page 25: ...spension components 6 1 Axle Periodic Maintenance Item Function Required Before Each Use 3 Months 12 Months Axles Axle Beam Visually check camber upward bend Springs Inspect for rust loss of arch or leaves sandwiched together Replace any sagging or broken springs Suspension Parts Visually inspect U bolt connections for bending elongation of bolt holes excess wear Hangers Inspect welds for integrit...

Page 26: ...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 safety...

Page 27: ...ttached in position 2 Check connection plugs at the tow vehicle end and at the trailer end for corrosion Spray with penetrating fluid or WD 40 3 If electrical system is not working properly check the electrical ground 4 Remove the brake drums and clean inside the brakes Check magnets brake pads shoes and related components Replace as necessary 5 Pack wheel bearings with grease before the drum is i...

Page 28: ...he trailer wheel The wheel should come to an abrupt stop 3 Check both sides to confirm good hydraulic performance of the braking system 4 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 vehi...

Page 29: ... brake handle you must first loosen the screw that is perpendicular to the knob If the brakes are still too loose you can adjust the cable by loosening the clamp on the right side wheel and moving the cable to get it tighter Break cable clamp 7 4 No Independent Trailer Braking System If the trailer has no independent braking system the trailer relies exclusively on the application of the brakes on...

Page 30: ...ains All PCMS trailers with an electric braking system or a hydraulic breaking system have a breakaway cable 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 ...

Page 31: ... occurs Make sure that the safety chains have enough slack to turn but do not drag on the ground NOTE Always use safety chains when towing 7 6 1 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 Proper Rigging of Safety Chains 1 Cross safety chains under coupling 2 A...

Page 32: ... kinks Electric Brakes Brakes Carry out full maintenance procedure Trailer Brake Inspect wiring for bare spots fraying etc Hydraulic Brakes Brakes Carry out full maintenance procedure Surge Brake Actuator Check fluid level Fill to with DOT 3 braking fluids if low Bleed brakes if necessary Field test according to manufacturer s instructions Breakaway System Breakaway System Check battery charge and...

Page 33: ...ns and has a jaw that attaches to a tow vehicle NOTE Verify that pintle hook and draw bar on the tow vehicle have adequate capacity for the trailer and all safety or locking cotter pins are in place and in good condition 8 2 Ball Coupler Hitch NOTE This component is an option on Ver Mac PCMS Please check that your PCMS has this component before proceeding CAUTION Make sure that the trailer ball is...

Page 34: ... Months 12 months Coupler Hitch Pintle Hook Draw Bar Check capacity Lunette Ring Inspect for wear Replace when badly worn Coupler and Ball Inspect for rust Clean and lubricate ball socket and clamp lightly with grease Ball and Tongue Check capacity Safety Pins Verify that all are in place and properly inserted Replace weak or missing pins Adjustable Hitch Make sure bolts are tightened at 150 ft lb...

Page 35: ... on mast Check main bolt top of mast is tight Check bolts at the bottom of the mast are tightened at 64 ft lb 86 8 N m Check all metal parts for rust and corrosion Lubricate lightly Frame Welds Check for cracks and or failures 9 2 Hydraulic Lift System for Mast NOTE For safety during transport Ver Mac disconnects power to the hydraulic pump Make sure the power feed is connected to the battery term...

Page 36: ...wn retighten the hydraulic bypass valve NOTE This procedure only lowers the mast It does not enable you to raise the mast 9 2 3 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 9 3 Rever...

Page 37: ... out This disengages the winch brake mechanism and can create an unsafe or hazardous condition 9 3 2 Lowering Mast 1 Disengage the locking pin on the mast 2 Slowly and evenly turn crank handle counter clockwise 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...

Page 38: ...s Bushings and Ratchet Parts Clean and wet with oil auto type 10W 30 Brake Disc Remove handle retainer assembly handle and brake disc cover and inspect for wear Replace if less than 1 16 thick or cracked or broken Brake Ratchet Mechanism Check operation turn handle clockwise to reel cable in and listen for clicking sound Brake Ratchet Parts Remove handle and retainer assembly handle and disc cover...

Page 39: ...sign brake is a heavy duty band brake attached on the mast below the signboard It holds the signboard in position To engage the sign brake pull handle until brake locks in a horizontal position parallel to the bottom of the sign To disengage the sign brake reverse the movement 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...

Page 40: ...ignboard Exterior Periodic Maintenance Item Function Required Before Every Use 3 Months 12 Months Signboard Exterior Main Harness 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 Sign Case Outside Check all reflectors at top of ...

Page 41: ...ellosolve Transport Cradles Inspect for proper support Replace cushions as needed Adjust height if necessary Sign Brake Check for rust and corrosion Lubricate lightly Adjust tension screw Photocells Under Solar Panels Check and clean photocell s Test photocell function cover sensor with dark tape Check sign brightness Peripheral Devices Example Radar Beacons Inspect support securely attached undam...

Page 42: ...ecured above each pixel Check all display cards are screwed in place Wiring Check harness cable Make sure it is not loose frayed or worn Check cables between cards Make sure connections are inserted correctly Electronics Check the Communication Card Relay Bracket for water damage and corrosion and connection Check the GPS for water damage and corrosion and connection Photocell Check photocell func...

Page 43: ...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 1 Release the solar panel handbrake upward thrust and make sure solar cable is out of the way 2 Pu...

Page 44: ...anels Replacement solar panels for the solar array must be the same wattage and ideally from the same manufacturer as the rest of the array 11 5 Solar Array Periodic Maintenance Item Function Required Before Every Use 3 Months 12 Months Solar panels Glass Surface Tilt and clean upper glass surface using plenty of water In winter remove excess snow or ice build up as soon as possible Sunlight usual...

Page 45: ... V3 0 37 Item Function Required Before Every Use 3 Months 12 Months Electrical Junction Boxes Open and use a volt meter to test and monitor output Connectors Check for tightness Cables or Wiring Check for wear frays breakages Verify connection to communications card inside sign case ...

Page 46: ...aintenance follows You will also find in this chapter general information on battery charges time of charging and use of the smart charger For sealed batteries there is a section to determine their state of charge CAUTION Batteries can weigh 30 to 60 lb 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 oppos...

Page 47: ...G If needs be keep emergency vehicle waiting Be careful not 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 As quickly as possible flush the contaminated area with lukewarm gently flowing water for at ...

Page 48: ...he 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 Maintenance 1 Check battery fluid level every three months in temperate climates every 30 days during the summer and in hot ...

Page 49: ...attery before adding more distilled water 3 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 12 2 2 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 t...

Page 50: ...s chemical in nature the voltage normally settles down about 30 minutes after charging or discharging has discontinued 12 2 2 2 Hydrometer Test A hydrometer measures the specific gravity or relative density of liquids In a battery it measures the proportion of the battery electrolyte sulphuric acid to the density of water Using a glass float Hydrometer 1 Check the electrolyte level to be sure that...

Page 51: ...r inside 2 Put the trailer in full operation mode at the highest brightness and let it in operation for at least five 5 minutes but no more than 15 minutes 3 From the terminal strip inside the plastic battery box measure the voltage a Put the positive lead on any of the screws that has a cable identified 12 V b Put the negative lead on any of the screws that has a cable identified GND 4 Use Table ...

Page 52: ...ger in well ventilated areas only If one battery has to be replaced replace them all because they do not recharge at the same rate 12 5 Charging with an External Charger NOTE 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 charger...

Page 53: ...cified 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 NOTE 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 overchargin...

Page 54: ...cking and leaking fluid Replace any leaking battery immediately Inspect water level Fill as needed Test with voltmeter 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 Boxes Inspect for damage water infiltration Check that cover clo...

Page 55: ...all 3 possible models Definition LED status Explanation Bulk Mode Green LED L3 flashing 2x sec Solar regulator recharges the batteries with the maximum current available from the solar panels Regulator stays in Bulk mode as long as battery voltage is less than the charge limit Once battery voltage reaches charge limit regulator moves into Float mode Float Mode Yellow LED L2 flashing Solar regulato...

Page 56: ...ial communication defective or incorrectly connected Bulk Controller displays solar voltage Example 20 00V but no solar current One or more solar panels may be incorrectly connected Defective solar regulator U101 Bulk Solar current entering current is less than the battery current outgoing current Solar regulator is OK but there is not enough sunlight Check orientation of the solar array Solar reg...

Page 57: ...ition Check for proper functioning All Cables Visually check cabling for signs of damage Controller Devices Verify condition clean undamaged Check for proper functioning Peripherals Check for proper functioning Manual Stickers Check condition complete clean and readable Weatherproof Seal Inspect for tight seal Replace as needed Optional Devices Example Data Loggers Bluetooth Check that all connect...

Page 58: ...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 co...

Page 59: ...nd 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 Sticker 1 E 9361 Location Near one of the jacks 2 E 9835 Location Outside the battery boxes 3 E 9836 Location Outside the battery boxes 4 ...

Page 60: ... Give us your thoughts 52 PCMS Operations Safety Maintenance V3 0 Ver Mac 2018 PART Sticker 5 E 9473 Location Near the winch or up switch if hydraulic 6 E 9793 Location Near door latch 7 E 3499 Location On rear of trailer 8 E 7730 Location On the bumper ...

Page 61: ...ts brakes 5 Disconnect hitch assembly from vehicle by raising 6 Front jacks lower rear jacks if necessary 7 Undo safety chains 8 Adjust jacks to make sure trailer is leveled 16 2 Solar Panels and Camera Setup WARNING Follow this procedure step by step to prevent damage to the camera If not done in proper order the solar panels and the camera could collide 1 Disengage solar panels brake 2 Fully rai...

Page 62: ... switch in control cabinet 3 Lower sign case until at eye level 4 Disengage sign case brake 5 Align the sign case in transport position 6 Engage sign case brake 7 Fully lower the sign case on cradles 8 Lock pin 1 16 5 Solar Panels and Camera Takedown WARNING Follow this procedure step by step to prevent damage to the camera If not done in proper order the solar panels and the camera could collide ...

Page 63: ...RT Sticker 1 E 8144 Location Near the winch 2 E 9473 Location Near the winch 3 E 9017 Location Near tilt and rotate mechanism near winch 4 E 9796 Location Near the winch 5 E 9802 Location Near the trailer mast pin 6 E 3499 Location Near the winch ...

Page 64: ...kedown for a Telescopic Camera Give us your thoughts 56 PCMS Operations Safety Maintenance V3 0 Ver Mac 2018 PART Sticker 7 E 8152 Location Inside the controller box on door 8 E 8153 Location Inside the controller box on door ...

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