UB 40 and 60 Slide presentation

UB 40 & UB 60 : 

UB 40 & UB 60 Under Bridge Inspection Vehicle Operator Training

Training Agenda – Two Day : 

Training Agenda – Two Day Day One 8 am – 12 pm ? Classroom Instruction Noon – 1 pm ? ***LUNCH*** 1 pm – 4 pm ? Equipment Familiarization (Shop) Day Two 8 – 8:30 am ? Meet at Columbus Unit Building (16 Acres), Drive to Bridge Site 8:30 am – Noon ? Operator’s Demonstration & Workshop on Site (US 31 Bridge over Flatrock River) Noon – 1 pm ? ***Lunch*** 1 pm – 4 pm ? Operator’s Demo & Workshop on Site Cont.d) Please be on time to each session; those that are not will be wasting valuable hands-on training for others.

Course Objective : 

Course Objective Read, and be familiar with the contents of the Operation and Maintenance Manual. Know the location and function of all the controls on the unit. Know and observe the posted capacity of the unit. Know how to conduct a thorough pre-operation inspection of the unit and what to look for at each checkpoint. Know the operating sequence of the unit, including the holding valve testing.

Safety Items : 

Safety Items

Personal Fall Arrest System : 

Personal Fall Arrest System Worker tied to fixed object Harness, not belt Lanyard, lifeline, deceleration device Never use to hoist workers or objects Inspect before every use Cuts, tears, abrasions, stitches coming out Cracks or burrs No Alterations Approriate labels Parts move freely

Manufacturers Warnings : 

Manufacturers Warnings WARNING! This Unit is equipped with a LIMIT SYSTEM override feature. It is to be used to retrieve booms and personnel from under the bridge in an EMERGENCY situation ONLY (electrical malfunction). Never move booms & turntables outside the normal operational envelope under outside the normal operational envelope under ANY circumstance! The unit’s LIMIT SYSTEM is overridden when this handle is depressed. Instability of unit and overloading of components can occur from improper use of the override system. WARNING! This unit(s) is a complicated device that requires skill and alertness from the operators in order to obtain the maximum usefulness from this machine(s). In order to operate this machine(s) you must be trained in safe an proper operating procedures. WARNING! This unit is not insulated! DO NOT exceed the minimum safe approach distance to energized power lines and parts as stated in the American National Standards Institute standard for Vehicle-Mounted Bride Inspection and Maintenance Devices (ANSI/SIA A92.8). Before the commencement of operation near electrical power lines, the person responsible for the operation of the job shall notify the owners of the electrical power lines or their authorized representatives, provide them with all pertinent information and request their cooperation in minimizing risk associated with operating in proximity to such lines.

Safety Warnings & Placards : 

Safety Warnings & Placards

Safety Procedures : 

Safety Procedures Know the location and function of ALL controls on the unit. You should be able to go immediately to whatever control is required.

Safety Procedures : 

Safety Procedures Operators should demonstrate a complete cycle of operation with emphasis on the boom holding valve tests. Remember that the controls should be handled smoothly.

Safety Procedures : 

Safety Procedures Using a personal fall arrest system is required in all bridge access machines. If a mishap causes platform tipping, you won’t be taking a fall.

Safety Procedures : 

Make a careful inspection before putting the unit into use. Use a checklist and don’t allow yourself to be distracted. Safety Procedures

Safety Procedures : 

Use smooth “feathering” movements on the controls. Jerky, sudden stops and starts are hard on the equipment and upsetting to persons in the platform. Safety Procedures

Safety Procedures : 

Be sure to look in the direction the platform is moving when maneuvering under the bridge structure. Safety Procedures

Safety Procedures : 

The operating instruction booklet should always be with the unit and available for ready reference. Safety Procedures

Safety Procedures : 

Make sure the boom assembly is tied down before taking the vehicle on the highway. Safety Procedures

Safety Procedures : 

Unauthorized alterations of the unit will void the warranty and possibly cause structural failure. Use the equipment as it was designed to be used. Safety Procedures

INDOT Added Safety Precautions : 

INDOT Added Safety Precautions Communication Devices Spotter Hand Signals Camera (UB 60 Only)

Slide 19: 

1 2 3 4

Unit Controls : 

Unit Controls Typical bridge access machine and its control stations

Controls in the Cab : 

Controls in the Cab Similar Controls Different Year Truck Chassis

Controls in the Cab : 

Controls in the Cab UB 60 Cab Control Station UB 40 Cab Control Station

UB 60 In-Cab Control Panels : 

UB 60 In-Cab Control Panels Unit power switch PTO switch Two – Speed switch Strobe light switch Engine Kill switch Engine Kill light Axle lock indicator lights Tag axle control panel

Controls in the Cab : 

Controls in the Cab UB 60 Cab Control Station UB 40 Cab Control Station

UB 40 In-Cab Control Panels : 

UB 40 In-Cab Control Panels Unit power switch PTO switch Strobe light switches Engine Kill switch Engine Kill light Throttle Pulley

Controls in Platform : 

Controls in Platform UB 60 Controls @ Platform UB 40 Controls @ Platform

UB 60 Platform Controls : 

UB 60 Platform Controls Power on/off switch Controls activation footswitch B1 control stick T1 control stick B2 control stick Intercom system T2 control stick B3 control stick Tele-Boom (B3) control stick High/Low range switch Engine Kill button B4 control stick Eye hooks / Tie-Offs

Controls in Platform : 

Controls in Platform UB 60 Controls @ Platform UB 40 Controls @ Platform

UB 40 Platform Controls : 

UB 40 Platform Controls Power on/off switch Controls activation footswitch B1 control stick T1 control stick B2 control stick Eye Hooks / Tie-Off T2 control stick B3 control stick Tele-Boom control stick High/low range switch Engine Kill button Aux. Eng. Restart Intercom System

Controls at Turntable : 

Controls at Turntable UB 60 Controls @ Turntable (T1) UB 40 Controls @ Turntable (T1)

Slide 31: 

Auxiliary Engine Controls Override valve lever Boom Controls Limit Switch LED Map Slope Meter

Controls at Turntable : 

Controls at Turntable UB 60 Controls @ Turntable (T1) UB 40 Controls @ Turntable (T1)

Slide 33: 

Boom Controls Platform/Ground Selector Valve Slope Meter Limit Switch LED Map

Pre-Operation Inspection : 

Pre-Operation Inspection NEW Form Under Bridge Inspection Equipment UB40 & UB60 Daily Inspection Form Operations Check and Holding Valve Test UB 60 UB 40 Holding Valve Test Components & Explanation

*NEW* Joined Inspection Form : 

*NEW* Joined Inspection Form Inspection Form Used For: Pre-Operation Before Each Shift or Each Day Signed Original must be bound and kept in Cab Frequent Inspection Annual Inspection

Operations Check & Holding Valve Test: : 

Operations Check & Holding Valve Test: This operations check MUST be preformed by qualified personnel prior to operating the unit. The parking brake set, truck running, PTO engaged and truck engine selected to the high idle. “Working at the T-1 Location”. WARNING: Any Drift in Booms during Holding Valve Test should result in immediate out-of-service

Components & Explanation : 

Components & Explanation Refer to Page 6 & 7 of Pre-Operation Inspection Form

Slide 38: 

Unit is parked at the bridge site, axle locks are engaged. Preview of Operations Step 1

Slide 39: 

Boom 4 is lowered to allow boarding of the platform. Step 2

Slide 40: 

After boarding the platform raise boom 4 to a position slightly higher than the bottom of boom 3. Step 3

Slide 41: 

Boom 1 has been raised sufficiently for the boom assembly to clear the boom rests (not high enough to cause interference with leveling linkage rods). Begin rotating turntable 2 clockwise. Step 4

Slide 42: 

Turntable 2 is being rotated clockwise and turntable 1 is rotated counter-clockwise. This will place boom 1 perpendicular to bridge rail and booms 2 and 3 parallel to rail. Step 5

Slide 43: 

Boom 1 is now fully perpendicular to rail and booms 2 and 3 are parallel to bridge rail. Step 6

Slide 44: 

Begin to open booms 2 and 3. Step 7

Slide 45: 

Booms 2 and 3 have now been operated to “open” sufficiently to enable platform to be positioned under the bridge deck. Step 8

Slide 46: 

Turntable 2 is being rotated clockwise to bring to position booms 3 and 4 to the desired position under the bridge. Step 9

Slide 47: 

Turntable 2 has been rotated clockwise to position boom 3 under the bridge. Boom 3 has been extended to reach work location. Boom 4 (if installed) may now be raised or lowered as desired. Step 10

Post Inspection : 

Post Inspection Storage Manufacturers Maintenance Periods Lubrication Procedures Documentation

Storage : 

Storage Operate equipment weekly Coat Steel with grease or oil Fluid should be topped off Rubber or Neoprene parts covered with UV resistant covering Electrical parts should be covered or protected from moisture Prevent ponding of water or moisture

Maintenance Periods : 

Maintenance Periods Every 40 Hours = compares to weekly interval Every 150 Hours = compares to monthly interval Every 200 Hours = compares to 3 month interval Every 500 Hours = compares to 6-month interval ***INDOT may have different standards, yet best mechanical judgment should be used*** Regularly scheduled cleaning, adjustments, replacements, and lubrication prolongs the life of the equipment and helps to prevent breakdowns. Every 1,000 Hours = compares to annual interval Every 2,000 Hours = compares to 2-year interval Every 5,000 Hours = compares to 5-year interval Every 10,000 Hours = compares to 10-year interval

Lubrication : 

Lubrication Guide is reference for Normal conditions and Use Lubricant status should be checked periodically Excess Lube should be wiped away to reduce staining, debris build-up, and increase visibility during Pre-Op inspection

Documentation : 

Documentation Pre-Operation Forms Record Hours of Operation in Field Log Document and attach Supporting Material to Maintenance Log