VER-MAC PCMS Series Use and care manual

PCMS Operations,
Safety and
Maintenance Manual
List of Revisions
Date
Version
Revision
2011/07/07
1.0
Original
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.

..

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 website members section:
http://www.ver-mac.com/extranet/en/members
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Technical Support
For help with any difficulties concerning PCMS units or this manual, please contact Ver-Mac Support:
[e-mail]
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-Mac PCMS
units.
Please work safely.
We also request that you notify us of any error
or omission found in our publications.
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.
© MMXVIII Signalisation Ver-Mac Inc.
All rights reserved
Ver-Mac®is a registered trademark of Signalisation Ver-Mac Inc.

ii PCMS Operations, Safety & Maintenance V 3.0 Ver-Mac 2018
Warranty Statement
(Updated February 2016)
Our warranty applies to all equipment newly-manufactured by Signalisation Ver-Mac Inc.
subject to normal use for which the equipment and/or components were intended.
Electronic components manufactured by Signalisation Ver-Mac Inc., are warranted for a period
of twenty-four (24) months from the date of delivery to the original purchaser.
All non-electronic components manufactured by Signalisation Ver-Mac Inc., are warranted for a
period of twelve (12) months from the date of delivery to the original purchaser.
Components not manufactured by Signalisation Ver-Mac Inc. are warranted
following the terms of the component’s manufacturer.
Limitations
The warranty is contingent on the following two conditions:
Signalisation Ver-Mac Inc. does not warrant any of its equipment, or parts thereof, against any
deterioration or damage caused by normal wear, lack of reasonable and proper maintenance,
failure to follow operating instructions, misuse, lack of proper protection during storage,
collisions, accidents, natural catastrophes or unforeseen events.
The equipment has been connected 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 Signalisation Ver-Mac Inc. shall in no way exceed the initial cost of the
equipment or part upon which such liability is based.
Repair or Replacement
Repair or replacement of any equipment or defective component shall always be at the
discretion of Signalisation Ver-Mac and shall be carried out at its factory, unless otherwise
agreed by prior arrangement with Signalisation Ver-Mac.
Signalisation Ver-Mac shall not be held liable for any cost incurred by the owner in the
execution of repairs.
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, nor in the installation of replacement parts.
The end user is responsible for the cost of shipping, duties and handling related to
defective parts returned to Signalisation Ver-Mac Inc. Signalisation Ver-Mac Inc. will
assume the return cost of shipping via regular service of replacement or repaired parts.

Ver-Mac 2018 PCMS Operations, Safety & Maintenance V3.0 iii
Claim Procedure
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.
Defective equipment or component parts for repair or replacement must always 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 contract or on the invoice.
For any repair or replacement, please complete the RMA request form at the following
address:
http://www.ver-mac.com/extranet/en/rma-request

iv PCMS Operations, Safety & Maintenance V3.0 Ver-Mac 2018
Table of Contents
Table of Contents.............................................................................................................................. iv
1Overview...................................................................................................................................... 1
1.1 About your Portable Changeable Message Sign Model ......................................................... 1
1.2 Safety and Warning Information............................................................................................. 1
1.3 Maintenance.......................................................................................................................... 2
1.4 Troubleshooting..................................................................................................................... 3
1.5 About Replacement Parts...................................................................................................... 3
1.6 About Maximum Speeds........................................................................................................ 3
2Pre-towing and Work Site Inspections...................................................................................... 4
2.1 Walk-Around Inspection of PCMS Unit................................................................................... 4
2.2 Work Site Inspection (before PCMS Unit Setup).................................................................... 6
3Unit Deployment and Removal .................................................................................................. 7
3.1 Trailer Deployment................................................................................................................. 7
3.2 Setup and Adjustment of Signboard and Solar Array............................................................. 8
3.3 Ballast.................................................................................................................................... 8
3.4 Messages.............................................................................................................................. 8
3.5 Takedown of Signboard and Solar Array................................................................................ 9
3.6 Trailer Removal ..................................................................................................................... 9
4Trailer 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
5Tires 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
6Axles and Suspension.............................................................................................................. 17
6.1 Axle Periodic Maintenance................................................................................................... 17
7Brakes and Breakaway Systems ............................................................................................. 18
7.1 Electric Brakes..................................................................................................................... 18
7.2 Hydraulic Surge Brakes....................................................................................................... 19
7.3 Manual Brake on the Trailer................................................................................................. 21
7.4 No Independent Trailer Braking System............................................................................... 21
7.5 Breakaway System.............................................................................................................. 22
7.6 Safety Chains ...................................................................................................................... 23
7.7 Brakes and Breakaway System Periodic Maintenance ........................................................ 24
8Coupler/Hitch ............................................................................................................................ 25
8.1 Pintle Hook and Lunette Ring Combination.......................................................................... 25
8.2 Ball Coupler/Hitch................................................................................................................ 25

Ver-Mac 2018 PCMS Operations, Safety & Maintenance V3.0 v
8.3 Coupler/Hitch Periodic Maintenance.....................................................................................26
9Mast Maintenance......................................................................................................................27
9.1 Mast Periodic Maintenance...................................................................................................27
9.2 Hydraulic Lift System for Mast ..............................................................................................27
9.3 Reversible Hand Winch System for Mast..............................................................................28
10 Signboard...............................................................................................................................31
10.1 Sign Brake............................................................................................................................31
10.2 Photocells.............................................................................................................................31
10.3 Radar Device........................................................................................................................32
10.4 Sign Display..........................................................................................................................32
10.5 Signboard Exterior Periodic Maintenance.............................................................................32
10.6 Signboard Interior Periodic Maintenance ..............................................................................34
11 Solar Array..............................................................................................................................35
11.1 Solar Panels.........................................................................................................................35
11.2 Orientation and Tilt ...............................................................................................................35
11.3 Care and Cleaning of Solar Panels.......................................................................................36
11.4 Replacement Solar Panels ...................................................................................................36
11.5 Solar Array Periodic Maintenance.........................................................................................36
12 Battery Bank...........................................................................................................................38
12.1 First Aid Procedures.............................................................................................................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 A –Full Brake Maintenance..................................................................................50
14.1 Full Brake Maintenance (Hydraulic and Electric Systems)....................................................50
15 Appendix B –Safety Warning and Instructions Stickers ....................................................51
16 Appendix C –Setup and Takedown for a Telescopic Camera............................................53
16.1 Trailer Deployment ...............................................................................................................53
16.2 .Solar Panels and Camera Setup..........................................................................................53
16.3 Sign Case Setup...................................................................................................................53
16.4 Sign Case Takedown............................................................................................................54
16.5 Solar Panels and Camera Takedown....................................................................................54
16.6 Positioning Unit for Transport ...............................................................................................54
16.7 Safety Stickers for the Camera Option..................................................................................55

Overview Give us your thoughts
Ver-Mac 2018 PCMS Operations, Safety & Maintenance V3.0 1
1 Overview
This manual is intended to guide owners and operators in the safe operation and
maintenance of Ver-Mac trailer-mounted PCMS units.
The maintenance procedures and schedules described in this manual apply to Ver-Mac
manufactured PCMS units in general.
It is important to know that PCMS units:
Differ from one model to another.
Contain component parts from manufacturers other than Ver-Mac.
Vary according to optional additional components and devices that may have been
added to the unit.
May have been customized according to the original purchaser’s specifications.
Please make sure that all personnel have read and understood this manual before putting
your PCMS unit into operation.
NOTE
Installation, operation and maintenance of PCMS units, as well as any necessary
repair work, should only be carried out by qualified person.
1.1 About your Portable Changeable Message Sign Model
This manual covers operation, safety and maintenance for all trailer-mounted models of our Portable
Changeable Message Sign. You will 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
48x80
HD, Mini, full matrix
PCMS-548
Yes
No
45x80
30x56
Small, full matrix
PCMS-320
Yes
No
63x98
30x48
Mid-size, color, full matrix
PCMS-320RT
Yes
No
66x104
30x48
Mid-size, full matrix
PCMS-320RC
No
Yes
64x105
30x48
Mid-size, full matrix
PCMS-320RC RT
No
Yes
64x105
30x48
Mid-size, color, full matrix
PCMS-1210
Yes
No
71x133
8 characters/line
Full size, 3-line display
PCMS-1210QS
No
No
71x133
8 characters/line
Same as 1210 plus handheld
controller
PCMS-1500
Yes
No
83x133
30x48
Full size, full matrix, older
PCMS-1500LP
Yes
No
76x131
28x48
Full size, full matrix, newer
PCMS-1500C
Yes
No
83x145
30x56
Extended size, full matrix
1.2 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.

Overview Give us your thoughts
2 PCMS Operations, Safety & Maintenance V3.0 Ver-Mac 2018
A chapter at the end of this manual contains illustrations and parts numbers for all the
decals in use on Ver-Mac PCMS units.
In addition, safety and warning decals are displayed on the PCMS units themselves for
the express purpose of alerting personnel to potential hazards.
DANGER
Indicates a high level of risk for serious personal injury.
WARNING
Indicates a moderate level of risk for personal injury and potential
for damage to equipment.
CAUTION
Indicates a potentially unsafe practice and risk for minor personal
injury.
NOTE
Refers to an important feature that the operator should be aware of for maximum
operating efficiency of the equipment or to help in completing a procedure.
1.3 Maintenance
Maintenance is a guide to equipment 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 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.
NOTE
Lack of maintenance can invalidate any and all guarantee provisions.
Before undertaking any of the maintenance procedures in this manual please list the
following:
1. Model of the PCMS unit.
2. Braking system (hydraulic, electric or none) on the trailer.
3. Type of hitch/coupler (pintle/lunette ring or ball-type) on the trailer.