CENTURION SYSTEMS CLAWS Installation Manual

INSTALLATION MANUAL TRAFFIC BARRIERS Centurion Systems (Pty) Ltd www.centsys.com

from 07h00 to 18h00 GMT+2 Saturdays 08h00 to 16h30 GMT +2 Manufactures to international quality standard ISO 9001:2008 100% testing of products In-house R&D development team Centurion Systems (Pty) Ltd reserves the right to make changes to the products described in this manual without notice and without obligation to notify any persons of any such revisions or changes. Additionally, Centurion Systems (Pty) Ltd makes no representations or warranties with respect to this manual. No part of this document may be copied, stored in a retrieval system or transmitted in any form or by any means electronic, mechanical, optical or photographic, without the express prior written consent of Centurion Systems (Pty) Ltd. 1986 1990 1995 1999 Today Sales and technical support to Africa, Europe, Asia, the Americas, Australia and the Pacifi c Company Profi le

2.1. Technical Specifi cations 2.2. Product Dimensions 2.2.1. Surface Mount 2.2.2. Flush Mount Surface Mount Installations 3. Product Identifi cation 4. Tools Required 5. Introduction 5.1. Installation Confi gurations 5.1.1. Orientation of Installation 5.1.2. Spike Impact Direction 6. RHS Surface Mount - Similar Direction of Travel 6.1. Confi guring the Drive Linkage Assembly 6.2. Spike Module Assembly 6.3. Re-assembling the Ramp Plates and Linkage Cover 6.4. Integrating the SECTOR II with the CLAWS 6.5. Completing the Assembly 7. RHS Surface Mount - Opposing Direction of Travel 7.1. Confi guring the Drive Linkage Assembly 7.2. Spike Module Assembly 7.3. Re-assembling the Ramp Plates and Linkage Cover 7.4. Integrating the SECTOR II with the CLAWS 7.5. Completing the Assembly page 8 page 8 page 8 page 9 Page 9 Page 9 page 10 page 11 page 12 page 12 page 12 page 12 page 14 page 16 page 16 page 19 page 26 page 28 page 32 page 33 page 33 page 36 page 43 page 45 page 49 SAFETY FIRST IMPORTANT SAFETY INSTRUCTIONS Contents page 6

8.1. Confi guring the Drive Linkage Assembly 8.2. Spike Module Assembly 8.3. Re-assembling the Ramp Plates and Linkage Cover 8.4. Integrating the SECTOR II with the CLAWS 8.5. Completing the Assembly 9. LHS Surface mount - Opposing Direction of Travel 9.1. Confi guring the Drive Linkage Assembly 9.2. Spike Module Assembly 9.3. Re-assembling the Ramp Plates and Linkage Cover 9.4. Integrating the SECTOR II with the CLAWS 9.5. Completing the Assembly Flush Mount Installations 10. Product Identifi cation 11. Tools Required 12. Introduction 12.1. Installation Confi gurations 12.1.1. Orientation of Installation 12.1.2. Spike Impact Direction 13. RHS Flush Mount - Similar Direction of Travel 13.1. Confi guring the Drive Linkage Assembly 13.2. Spike Module Assembly 13.3. Preparing the Trench and Drainage System 13.4. Re-assembling the Ramp Plates and Linkage Cover 13.5. Integrating the SECTOR II with the CLAWS 13.6 Completing the Assembly page 51 page 51 page 54 page 61 page 63 page 67 page 69 page 69 page 72 page 79 page 81 page 85 page 87 page 88 page 89 page 90 page 90 page 90 page 91 page 93 page 93 page 96 page 103 page 105 page 106 page 110 CONTENTS

14.1. Confi guring the Drive Linkage Assembly 14.2. Spike Module Assembly 14.3. Preparing the Trench and Drainage System 14.4. Re-assembling the Ramp Plates and Linkage Cover 14.5. Integrating the SECTOR II with the CLAWS 14.6 Completing the Assembly 15. LHS Flush Mount - Similar Direction of Travel 15.1. Confi guring the Drive Linkage Assembly 15.2. Spike Module Assembly 15.3. Preparing the Trench and Drainage System 15.4. Re-assembling the Ramp Plates and Linkage Cover 15.5. Integrating the SECTOR II with the CLAWS 15.6 Completing the Assembly 16. LHS Flush Mount - Similar Direction of Travel 16.1. Confi guring the Drive Linkage Assembly 16.2. Spike Module Assembly 16.3. Preparing the Trench and Drainage System 16.4. Re-assembling the Ramp Plates and Linkage Cover 16.5. Integrating the SECTOR II with the CLAWS 16.6 Completing the Assembly 17. Wiring Diagram 18. Installation Handover Icons used in this manual This icon indicates tips and other information that could be useful during the installation. This icon denotes variations and other aspects that should be considered during installation. This icon indicates warning, caution or attention! Please take special note of critical aspects that MUST be adhered to in order to prevent injury. This icon indicates areas where mechanical crushing may occur CONTENTS page 111 page 111 page 114 page 121 page 123 page 124 page 128 page 129 page 129 page 132 page 139 page 141 page 142 page 146 page 147 page 147 page 150 page 157 page 159 page 160 page 164 page 165 page 166 CONTENTS

read all the following instructions. Incorrect installation or incorrect use of the product may cause serious harm to people and / or property. The installer, being either professional or DIY, is the last person on the site who can ensure that the operator is safely installed, and that the whole system can be operated safely. IMPORTANT SAFETY INSTRUCTIONS Warnings for the installer CAREFULLY READ AND FOLLOW ALL INSTRUCTIONS before beginning to install the product. • All installation, repair, and service work to this product must be done by a suitably qualifi ed person • Do not activate the CLAWS unless you can see them and can determine that the CLAWS are clear of people, pets, vehicles or any obstructions. • Nothing must be placed on or near the trench covers at any time. • No one must be near the trench covers at any time. Always keep people and objects away from the spikes’ area of travel • Children should be supervised to ensure that they do not play with or around the spikes and trench cover • This device is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety • Secure all easily-accessed CLAW controls in order to prevent unauthorised use • Do not in any way modify the components of the automated system • Do not install the equipment in an explosive atmosphere. The presence of fl ammable gas or fumes is a serious danger to safety • Before attempting any work on the system, cut electrical power and disconnect the batteries • The mains power supply of the automated system must be fi tted with a double pole switch with contact opening distance of 3mm or greater. Use of a 5A thermal breaker is recommended • Make sure that an earth leakage circuit breaker with a threshold of 30mA is fi tted upstream of the system • Never short-circuit the battery and do not try to recharge the batteries with power supply units other than that supplied with the product, or manufactured by Centurion Systems (Pty) Ltd SAFETY FIRST IMPORTANT SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS

of the system are suitably earthed • Safety devices must be fi tted to the installation to guard against mechanical movement risks such as crushing, dragging and shearing • It is recommended that at least one warning indicator light be fi tted to every system • Always fi t a warning sign visibly to the inside and outside of the entrance and exit • The installer must explain and demonstrate the manual operation of the system in case of an emergency, and must hand the User Guide and Safety Instructions over to the end user • Explain these safety instructions to all persons authorised to use the system, and be sure that they understand the hazards associated with the system • Do not leave packing materials (plastic, polystyrene, etc.) within reach of children as such materials are potential sources of danger • Dispose of all waste products like packaging materials, worn-out batteries, etc. according to local regulations • Always check the obstruction detection system, and safety devices for correct operation • Neither Centurion Systems (Pty) Ltd, nor its subsidiaries, accepts any liability caused by improper use of the product, or for use other than that for which the automated system was intended • This product was designed and built strictly for the use indicated in this documentation. Any other use, not expressly indicated here, could compromise the service life/operation of the product and/or be a source of danger • Everything not expressly specifi ed in these instructions is not permitted IMPORTANT SAFETY INSTRUCTIONS SAFETY FIRST SAFETY INSTRUCTIONS

Inductive Loop Detectors in preference to infrared beams. When installing the Loop detectors, positioning is very important for the safety of the vehicle • X refers to the distance required between the loops and CLAWS for free-exit • Free-exit for uni-directional traffi c, X must be greater than 500mm from the CLAWS • For bi-directional traffi c, X must also be greater than 500mm from the CLAWS X X Loop detector Loop detector CLAWS

high-volume sites. They provide a formidable deterrent to would-be criminals and due to their robust construction they are very diffi cult to defeat. Clever modular design allows the CLAWS to be ordered ex-stock and can be confi gured into a variety of diff erent lengths. The orientation of the spikes can also be easily changed depending on the direction of the traffi c fl ow. Their external limit switches allow for safe operation of the system. CLAWS are easy to install and use a standard SECTOR II controller and a standard SECTOR II gearbox, saving you time and reducing your spares inventory. They boast all-weather construction and have been designed to allow for all moving parts to be removed easily for quick and easy maintenance. CLAWS also provide onboard support for a traffi c light interface, and the Independent Drive CLAWS models have variable speed control and multiple Modes of Operation. The CLAWS Direct Drive system utilises the SECTOR II traffi c barrier’s drive mechanism. It is available in both Flush Mount and Surface Mount variants. The Flush Mount models are ideal for installations that require seamless access control for smooth-fl owing traffi c, whereas the Surface Mount models are mounted above the general surface of the roadway and create a traffi c-calming bump for a safer access control point. GENERAL DESCRIPTION SECTION 1 1. General Description 2. Product Specifi cations 2.1. Technical Specifi cations Spike Modules - Available lengths 1 metre and 1.5 metre Spikes raise / lower time As per co-installed SECTOR II Daily operations - Max 50% of co-installed SECTOR II original specifi cation Daily Operations - Mains present 50% of co-installed SECTOR II original specifi cation Anti-corrosion - Main chassis Hot dip galvanised Mild Steel Spike material 85mm Mild Steel, electroplated and powder-coated Maximum allowable axel weight 4000kg

2.2.1. Surface Mount 2.2.2. Flush Mount 405mm 524mm 2905mm 900mm 87mm 2905mm 1500mm 1000mm 385mm 485mm 2885mm 2885mm 400mm 143mm 1500mm 1000mm PRODUCT SPECIFICATIONS SECTION 2

TRAFFIC BARRIERS Centurion Systems (Pty) Ltd www.centsys.com

2 1 7 6 5 4 3 1. Boom pole 2. Spikes module assembly 3. Ramp plates 4. Trench cover plate 5. Spikes 6. Drive linkage assembly 7. SECTOR II Module Frame Linkage Frame Sandwich Plate Top Coupler Bottom Coupler 8x20 Dowel Pin CLAWS Direct Drive RHS Surface Mount - similar direction of travel illustrated PRODUCT IDENTIFICATION SECTION 3 3. Product Identifi cation

Long Drive Arm Linkage Drive Shaft Bearing Housing Hold Down Bracket Con-rod Assembly Linkage Cover Plate Linkage End Cover Module End Cover TOOLS REQUIRED SECTION 4 • 13mm,17mm, and 19mm Spanners • Ratchet • 19mm, and 24mm Sockets • Allen Key Set • Mallet • Tape Measure • Spirit Level • Torque Wrench 4. Tools Required

CLAWS Spikes driven directly from a SECTOR II Barrier by a “push -pull” linkage system. The installation described in this document is a 2.5 meter installation. For other installations, modules of 1.5 or 1.0 meters can be used to achieve diff erent widths. The installation of the CLAWS Spikes requires a minimum of two persons. 5.1. Installation Confi gurations The surface-mountable CLAWS Spikes can be installed in four diff erent confi gurations. The confi guration is dependent on two factors: • Orientation of installation • Direction of spike impact FIGURE 2. RHS CONFIGURATION FIGURE 3. LHS CONFIGURATION 5.1.1. Orientation of Installation The orientation of installation is described as the side at which the drive linkage is installed when approaching the CLAWS Spikes. In other words, when driving up to the CLAWS Spikes, in the correct direction for traffi c fl ow, and the drive is installed on the right-hand side of the vehicle, it’s deemed a right-hand installation. And when driving up to the CLAWS Spikes, in the correct direction for traffi c fl ow, and the drive is installed on the left-hand side of the vehicle, it’s deemed a left-hand installation. 5. Introduction INTRODUCTION SECTION 5

The CLAWS Spikes are designed to take a much larger or more frequent impact in one direction. The spikes can be installed to face either towards oncoming traffi c (similar) or face towards traffi c (opposing) trying to enter from the wrong direction or lane. There are four types of typical installations. Refer to Section 5, Figures 2 and 3 to determine if the installation is left- or right-hand orientated. Secondly; pay attention to the spike impact direction: • Similar direction of travel prevents vehicles from exiting whilst the boom pole is still down (Normal direction of traffi c) • Opposing direction of travel prevents vehicles entering against the fl ow of traffi c whilst the boom pole is down FIGURE 6. RHS SIMILAR DIRECTION OF TRAVEL FIGURE 4. SPIKE IMPACT DIRECTION - SIMILAR FIGURE 5. SPIKE IMPACT DIRECTION - OPPOSING Direction of travel Direction of travel Direction of normal traffi c fl ow INTRODUCTION SECTION 5

FIGURE 9. LHS OPPOSED DIRECTION OF TRAVEL FIGURE 8. LHS SIMILAR DIRECTION OF TRAVEL Direction of normal traffi c fl ow Direction of normal traffi c fl ow Direction of normal traffi c fl ow INTRODUCTION SECTION 5

Similar 6.1.1. Stripping the drive linkage assembly FIGURE 10 FIGURE 12 FIGURE 14 FIGURE 11 FIGURE 13 FIGURE 15 STEP 1 STEP 3 STEP 5 STEP 2 STEP 4 STEP 6 M6x20 screw M8x25 screw Linkage end cover Drive linkage assembly Bearing Housing Bearing Housing Bolt Linkage frame Bearing shaft assembly Washer Linkage cover plate RHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 6 6. RHS Surface Mount - Similar Direction of Travel

FIGURE 16 Left-hand Side Orientation Grub Screw Grease nipple Grease nipple Grease nipple Bearing housing Bearing housing Remove Short Drive Arm 68mm 77.5mm Right-hand Side Orientation RHS Installations LHS Installations Linkage frame Bearing shaft assembly FIGURE 17 FIGURE 19 FIGURE 18 FIGURE 20 STEP 7 STEP 9 STEP 8 STEP 10 The grease nipples on the bearing housings must face up (Section 6, Figures 19 and 20). Take note of the orientation of the Linkage Frame, the Bearing Shaft Assembly, and the Drive Linkage Arm (Section 6, Figure 20). RHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 6

Section 6, Figure 21. 1. The drive arm must point towards the longer side of the drive linkage assembly (1.5x) 2. The notch must be at the bottom of the shaft (6 o’clock) 3. The bolt head must face the bottom and the nut on top 4. The angle of the bolt and nut must be as shown (11 o’clock) STEP 11 Replace the bearing housing bolts once everything is in the correct orientation. Hand-tighten for the time being. FIGURE 21 VIEW A 11 o’ clock 1.5X 1.5X X X 6 o’ clock 1 3 4 2 RHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 6

the drive linkage assembly without fastening the bolts. Check that the linkage cover plate is in the correct position and that there is ample clearance for the drive arm (Section 6, Figure 22). Linkage cover plate 6.2. Spike Module Assembly 6.2.1. Preparing the Spike Module assembly(ies) for installation Spring Washer Spring Washer M8x20 screw M8x20 screw Ramp plate Trench cover Ramp plate FIGURE 23 FIGURE 25 FIGURE 24 FIGURE 26 STEP 1 STEP 3 STEP 2 STEP 4 VIEW A RHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 6

Take note of the orientation of the sandwich plate to the linkage unit before fi xing them to the spike module assembly (Section 6, Figure 27). Sandwich plate Linkage unit M12 Nut M12x25 bolt Spike module To assist with the alignment and adjustment of the shafts, loosen (but do not remove) the bolts on all of the bearing housings. STEP 3 Using six M12x25 bolts, fi x one spike module to another (Section 6, Figure 29). FIGURE 29 Ensure that the shafts align throughout the assembly Bearing housing M12x25 Bolt Spike Module M12 Nut STEP 1 STEP 2 FIGURE 27 FIGURE 28 RHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 6

as an uneven surface could result in an uneven binding of the spike shafts. This will result in premature failure. 6.2.3. Bolting down the assembly to the ground FIGURE 30 M12 Rawl-bolts or Chem-bolts 6.2.4. Assembling the shaft couplings The coupler is used to connect and align the shafts together. It is essential that the coupler is assembled correctly; failing to do so will result in slipping of the spikes which is undesirable. FIGURE 32 FIGURE 31. SHAFT COUPLER Dowel pin Bottom coupler Shaft Top coupler Cap screws RHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 6

to aid in the fi tment of all the shaft couplings. Dowel pin Bottom coupler Groove STEP 5 Repeat this coupling process for additional spike modules. Once all shafts have been coupled, check that they move freely. STEP 1 STEP 3 STEP 2 STEP 4 FIGURE 33 FIGURE 35 FIGURE 34 FIGURE 36 Top coupler Shaft Bottom coupler Dowel pin Groove in shafts Bottom coupler Cap screws Dowel pin Top coupler 60Nm 60Nm Tighten Grub Screws STEP 6 STEP 7 FIGURE 37 FIGURE 38 RHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 6

Far end of the assembly Drive linkage end of the assembly 20mm PVC Conduit The length of the PVC conduit will be relative to the length of the spike modules and drive linkage unit combined. Ensure that a further 110mm is added to this to account for the modules and coupling (Refer to Section 6, Figure 40). FIGURE 40 19mm 91mm Sandwich plate 20mm PVC conduit 20mm PVC conduit RHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 6

PVC access elbow 37x25mm PVC Coupler 37x25mm PVC Coupler Use an appropriate PVC adhesive to bond all conduit lengths, access elbows and couplers to one another. Please ensure that the moving mechanical parts do not rub against the conduit or cables. FIGURE 46. PROXIMITY SENSOR FIGURE 45. PROXIMITY SENSOR Star washer Proximity coupler Proximity coupler Proximity sensor bush Proximity sensor bush Star washer and Hex nut Threaded shaft Hex Nut Threaded shaft Prox s Star w and He STEP 2 STEP 4 STEP 3 STEP 5 FIGURE 41 FIGURE 43 FIGURE 42 FIGURE 44 RHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 6

Proximity coupler Threaded shaft Proximity sensor bush Proximity sensor assembly 37x25mm PVC Coupler FIGURE 49 Far end of the assembly Drive linkage end of the assembly There should be ample cable left over on the drive linkage end, as the wiring will need to be routed up the SECTOR II at a later stage. M8 x10mm Grub screw Proximity sensor Proximity sensor Proximity sensor bush 37x25mm PVC Coupler STEP 6 STEP 7 STEP 8 FIGURE 48 FIGURE 50 FIGURE 51 RHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 6

Ramp plates Trench plate covers Ramp plates Spring Washer M8x20 screw Take notice of the slot orientation in the trench cover plates before it is placed back into position. The spike must rest on the straight edge of the slot when it is in its upright position. Leave out the four M8 screws and Spring Washers on the far end of the assembly as the module end cover will be assembled later. Spring Washer M8x20 screw Drive linkage cover plate STEP 1 STEP 4 STEP 5 STEP 2 STEP 3 FIGURE 52 FIGURE 55 FIGURE 56 FIGURE 53 FIGURE 54 RHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 6

Make sure that there is clearance for the drive arm to swing through. If this plate is assembled back-to-front the drive arm won’t swing through and you will need to turn the plate around (Refer back to Section 6, Figure 22). M6x20 screw Module end cover Spring Washer M8x20 screw STEP 6 STEP 8 STEP 10 STEP 7 STEP 9 FIGURE 57 FIGURE 59 FIGURE 61 FIGURE 58 FIGURE 60 RHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 6

Refer to Section 3.3 of the SECTOR II Installation manual for instructions on fi tting and leveling the boom pole. SECTOR II Drive linkage cover plate 110mm Drive linkage end cover SECTOR II M12x60 Hex Bolt Heavy duty washer Hold down bracket Drive linkage assembly Lift the spikes by hand to get them just under the level of the trench plate, which pushes the linkage arm back, allowing you to move the unit into its correct position; 110mm from the front edge of the Linkage Cover Plate. (Section 6, Figure 64). 6.4. Integrating the SECTOR II with the CLAWS 6.4.1. Placing the SECTOR II into position Drive linkage unit SECTOR II SECTOR II Drive linkage end cover Drive linkage frame Drive linkage cover plate Y Y STEP 1 STEP 3 STEP 2 STEP 4 FIGURE 62 FIGURE 64 FIGURE 63 FIGURE 65 RHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 6

occur; use the drive arm to move the spikes up and down. Apply Lock-tite 243 to all the internal threads and torque both the M16x40 and M16x110 bolts to 40Nm (Steps 3 and 4) 6.4.3. Inserting the Con-rod SECTOR II Con-rod STEP 1 STEP 3 STEP 2 STEP 4 FIGURE 66 FIGURE 68 FIGURE 67 FIGURE 69 RHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 6

the spikes. Con-rod 6.4.4. Adjusting the CLAWS spikes The CLAWS spikes will raise during this procedure! Con-rod top nut Con-rod base nut STEP 1 STEP 2 STEP 3 FIGURE 70 FIGURE 71 FIGURE 72 RHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 6

are below the top plate (Section 6, Figures 75 and 76). Optimum Position: Spikes are below the trench plate and the boom pole is in the vertical position. Optimum Position: Spikes are above the trench plate and the boom pole is in the horizontal position. VIEW A VIEW A VIEW A Spike Spike Trench plate Trench plate VIEW A FIGURE 73 With one person holding the barrier pole in the lowered position, adjust the spikes so that the spikes just touch the trench plate (Section 6, Figure 73). Con-rod top nut Spike Con-rod base nut Trench Plate STEP 4 FIGURE 74 RHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 6

6.5.1. Fitting the relay enclosure and its bracket SECTOR II Conrod Relay enclosure bracket Front brace plate Front brace plate Screws SECTOR II Relay enclosure bracket SECTOR II Relay enclosure bracket Relay enclosure Front brace plate Route the excess wire from the proximity sensor, and wire it to the relay by referring to the wiring diagram (Section 17). Complete the installation of the SECTOR II as per its full installation manual, and proceed to ‘Section 18 - Installation Handover’ STEP 1 STEP 3 STEP 2 FIGURE 77 FIGURE 79 FIGURE 78 RHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 6

Drive linkage assembly Bearing Housing Bearing Housing Bolt Linkage frame Bearing shaft assembly Washer Linkage cover plate FIGURE 1 FIGURE 3 FIGURE 5 FIGURE 2 FIGURE 4 FIGURE 6 STEP 1 STEP 3 STEP 5 STEP 2 STEP 4 STEP 6 7.1. Confi guring the Drive Linkage Assembly for Right-hand Similar 7.1.1. Stripping the drive linkage assembly 7. RHS Surface Mount - Opposing Direction of Travel RHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 7

Left-hand Side Orientation 68mm 77.5mm Right-hand Side Orientation RHS Installations LHS Installations Linkage frame Bearing shaft assembly The grease nipples on the bearing housings must face up (Section 7, Figures 10 and 11). Take note of the orientation of the Linkage frame, the Bearing Shaft Assembly, and the Drive linkage arm (Section 7, Figure 11). Grub Screw Grease nipple Bearing housing Bearing housing Remove Short Drive Arm FIGURE 7 FIGURE 8 FIGURE 10 FIGURE 9 FIGURE 11 STEP 7 STEP 9 STEP 8 STEP 10 RHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 7

Section 7, Figure 12. 1 VIEW A 1 o’ clock 1.5X X 6 o’ clock 3 4 2 1. The drive arm must point towards the longer side of the drive linkage assembly (1.5x) 2. The notch must be at the bottom of the shaft (6 o’clock) 3. The bolt head must face the bottom and the nut on top 4. The angle of the bolt and nut must be as shown (1 o’clock) STEP 11 Replace the bearing housing bolts once everything is in the correct orientation. Hand-tighten for the time being. FIGURE 12 RHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 7

the drive linkage assembly without fastening the bolts. Check that the linkage cover plate is in the correct position and that there is ample clearance for the drive arm (Section 7, Figure 13). Linkage cover plate 7.2. Spike Module Assembly 7.2.1. Preparing the Spike Module assembly(ies) for installation Spring Washer Spring Washer M8x20 screw M8x20 screw Ramp plate Trench cover Ramp plate FIGURE 13 FIGURE 14 FIGURE 16 FIGURE 15 FIGURE 17 STEP 1 STEP 3 STEP 2 STEP 4 VIEW A RHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 7

Take note of the orientation of the sandwich plate to the linkage unit before fi xing them to the spike module assembly (Section 7, Figure 18). Sandwich plate Linkage unit M12 Nut M12x25 bolt Spike module To assist with the alignment and adjustment of the shafts, loosen (but do not remove) the bolts on all of the bearing housings. STEP 3 Using six M12x25 bolts, fi x one spike module to another (Section 7, Figure 20). Ensure that the shafts align throughout the assembly Bearing housing M12 Nut Spike Module M12x25 Bolt FIGURE 20 STEP 1 STEP 2 FIGURE 18 FIGURE 19 RHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 7

as an uneven surface could result in an uneven binding of the spike shafts. This will result in premature failure. 7.2.3. Bolting down the assembly to the ground M12 Rawl-bolts or Chem-bolts 7.2.4. Assembling the shaft couplings The coupler is used to connect and align the shafts together. It is essential that the coupler is assembled correctly; failing to do so will result in slipping of the spikes which is undesirable. Dowel pin Bottom coupler Shaft Top coupler Cap screws FIGURE 21 FIGURE 23 FIGURE 22. SHAFT COUPLER RHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 7

to aid in the fi tment of all the shaft couplings. Dowel pin Bottom coupler Groove STEP 5 Repeat this coupling process for additional spike modules. Once all shafts have been coupled, check that they move freely. Tighten Grub Screws STEP 1 STEP 3 STEP 6 STEP 2 STEP 4 STEP 7 FIGURE 24 FIGURE 26 FIGURE 28 FIGURE 25 FIGURE 27 FIGURE 29 Top coupler Shaft Bottom coupler Dowel pin Groove in shafts Bottom coupler Cap screws Dowel pin Top coupler 60Nm 60Nm RHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 7

Far end of the assembly Drive linkage end of the assembly 20mm PVC Conduit The length of the PVC conduit will be relative to the length of the spike modules and drive linkage unit combined. Ensure that a further 110mm is added to this to account for the modules and coupling (Refer to Section 7, Figure 31). 19mm 91mm Sandwich plate 20mm PVC conduit 20mm PVC conduit FIGURE 30 FIGURE 31 RHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 7

20mm PVC conduit 60mm 20mm PVC conduit PVC access elbow 37x25mm PVC Coupler 37x25mm PVC Coupler Linkage Frame Use an appropriate PVC adhesive to bond all conduit lengths, access elbows and couplers to one another. Please ensure that the moving mechanical parts do not rub against the conduit or cables. Star washer Proximity coupler Proximity coupler Proximity sensor bush Proximity sensor bush Star washer and Hex nut Threaded shaft Hex Nut Threaded shaft Prox s Star w and He FIGURE 37. PROXIMITY SENSOR FIGURE 36. PROXIMITY SENSOR STEP 2 STEP 4 STEP 3 STEP 5 FIGURE 32 FIGURE 34 FIGURE 33 FIGURE 35 RHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 7

of the assembly There should be ample cable left over on the drive linkage end, as the wiring will need to be routed up the SECTOR II at a later stage. M8 x10mm Grub screw Proximity sensor Proximity sensor Proximity sensor bush 37x25mm PVC Coupler FIGURE 38. PROXIMITY SENSOR FIGURE 40 STEP 6 STEP 7 STEP 8 FIGURE 39 FIGURE 41 FIGURE 42 RHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 7

Ramp plates Trench plate covers Ramp plates Spring Washer M8x20 screw Take notice of the slot orientation in the trench cover plates before it is placed back into position. The spike must rest on the straight edge of the slot when it is in its upright position. Leave out the four M8 screws and Spring Washers on the far end of the assembly as the module end cover will be assembled later. Spring Washer M8x20 screw Drive linkage cover plate STEP 1 STEP 4 STEP 5 STEP 2 STEP 3 FIGURE 43 FIGURE 46 FIGURE 47 FIGURE 44 FIGURE 45 RHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 7

Make sure that there is clearance for the drive arm to swing through. If this plate is assembled back-to-front the drive arm won’t swing through and you will need to turn the plate around (Refer back top Section 7, Figure 13). M6x20 screw Module end cover Spring Washer M8x20 screw STEP 6 STEP 8 STEP 10 STEP 7 STEP 9 FIGURE 48 FIGURE 50 FIGURE 52 FIGURE 49 FIGURE 51 RHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 7

Refer to Section 3.3 of the SECTOR II Installation manual for instructions on fi tting and leveling to boom pole. SECTOR II Drive linkage cover plate Drive linkage end cover SECTOR II M12x60 Hex Bolt Heavy duty washer Hold down bracket Drive linkage assembly Lift the spikes by hand to get them just under the level of the trench plate, which pushes the linkage arm back, allowing you to move the unit into its correct position; 80mm from the front edge of the Linkage Cover Plate. (Section 7, Figure 55). 7.4. Integrating the SECTOR II with the CLAWS 7.4.1. Placing the SECTOR II into position Drive linkage unit SECTOR II SECTOR II Drive linkage end cover Drive linkage frame Drive linkage cover plate Y Y STEP 1 STEP 3 STEP 2 STEP 4 FIGURE 53 FIGURE 55 FIGURE 54 FIGURE 56 RHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 7

M16x110 bolts to 40Nm (Steps 3 and 4) 7.4.3. Inserting the Con-rod SECTOR II Con-rod Do not place any body parts near the spikes as serious injury could occur; use the drive arm to move the spikes up and down. STEP 1 STEP 3 STEP 2 STEP 4 FIGURE 57 FIGURE 59 FIGURE 58 FIGURE 60 RHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 7

The CLAWS spikes will raise during this procedure! Turning the Con-rod clockwise or anti-closwise will raise or lower the spikes. Con-rod top nut Con-rod base nut Con-rod STEP 1 STEP 2 STEP 3 FIGURE 61 FIGURE 62 FIGURE 63 RHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 7

that the spikes just touch the trench plate (Section 7, Figure 64). To ensure correct adjustment, raise the barrier pole and check that the spikes are below the top plate (Section 7, Figures 66 and 67). VIEW A VIEW A VIEW A Spike Spike Trench plate Optimum Position: Spikes are below the trench plate and the boom pole is in the vertical position. VIEW A Trench plate Optimum Position: Spikes are above the trench plate and the boom pole is in the horizontal position. FIGURE 66 FIGURE 67 FIGURE 64 STEP 4 FIGURE 65 Spike Trench Plate RHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 7

7.5.1. Fitting the relay enclosure and its bracket SECTOR II Relay enclosure bracket Front brace plate Front brace plate Screws SECTOR II Relay enclosure bracket SECTOR II Relay enclosure bracket Relay enclosure Front brace plate Route the excess wire from the proximity sensor, and wire it to the relay by referring to the wiring diagram (Section 16). Complete the installation of the SECTOR II as per its full installation manual, and proceed to ‘Section 17 - Installation Handover’ STEP 1 STEP 3 STEP 2 FIGURE 68 FIGURE 70 FIGURE 69 RHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 7

Similar 8.1.1. Stripping the drive linkage assembly M6x20 screw M8x25 screw Linkage end cover Drive linkage assembly Bearing Housing Bearing Housing Bolt Linkage frame Bearing shaft assembly Washer Linkage cover plate FIGURE1 FIGURE 3 FIGURE 5 FIGURE 2 FIGURE 4 FIGURE 6 STEP 1 STEP 3 STEP 5 STEP 2 STEP 4 STEP 6 8. LHS Surface Mount - Similar Direction of Travel LHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 8

FIGURE 7 Left-hand Side Orientation 68mm 77.5mm Right-hand Side Orientation RHS Installations LHS Installations Grub Screw Grease nipple Grease nipple Grease nipple Bearing housing Bearing housing Remove Long Drive Arm Linkage frame Bearing shaft assembly FIGURE 8 FIGURE 10 FIGURE 9 FIGURE 11 STEP 7 STEP 9 STEP 8 STEP 10 The grease nipples on the bearing housings must face up (Section 8, Figures 10 and 11). Take note of the orientation of the Linkage frame, the Bearing Shaft Assembly, and the Drive linkage arm (Section 8, Figure 11). LHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 8

Section 8, Figure 12. 1. The drive arm must point towards the longer side of the drive linkage assembly (1.5x) 2. The notch must be at the bottom of the shaft (6 o’clock) 3. The bolt head must face the bottom and the nut on top 4. The angle of the bolt and nut must be as shown (1 o’clock) STEP 11 Replace the bearing housing bolts once everything is in the correct orientation. Hand-tighten for the time being. FIGURE 12 VIEW A 1 o’ clock 1.5X X 6 o’ clock 1 3 4 2 LHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 8

the drive linkage assembly without fastening the bolts. Check that the linkage cover plate is in the correct position and that there is ample clearance for the drive arm (Section 8, Figure 13). Linkage cover plate Linkage cover plate 8.2. Spike Module Assembly 8.2.1. Preparing the Spike Module assembly(ies) for installation Spring Washer Spring Washer M8x20 screw M8x20 screw Ramp plate Trench cover Ramp plate FIGURE 13 FIGURE 14 FIGURE 16 FIGURE 15 FIGURE 17 STEP 1 STEP 3 STEP 2 STEP 4 VIEW A LHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 8

Take note of the orientation of the sandwich plate to the linkage unit before fi xing them to the spike module assembly (Section 8, Figure 18). Sandwich plate Linkage unit M12 Nut M12x25 bolt Spike module To assist with the alignment and adjustment of the shafts, loosen (but do not remove) the bolts on all of the bearing housings. Step 3 Using six M12x25 bolts, fi x one spike module to another (Section 8, Figure 20). Ensure that the shafts align throughout the assembly Bearing housing M12x25 Bolt Spike Module M12 Nut FIGURE 20 STEP 1 STEP 2 FIGURE 18 FIGURE 19 LHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 8

as an uneven surface could result in an uneven binding of the spike shafts. This will result in premature failure. 8.2.3. Bolting down the assembly to the ground M12 Rawl-bolts or Chem-bolts 8.2.4. Assembling the shaft couplings The coupler is used to connect and align the shafts together. It is essential that the coupler is assembled correctly; failing to do so will result in slipping of the spikes which is undesirable. Dowel pin Bottom coupler Shaft Top coupler Cap screws FIGURE 21 FIGURE 23 FIGURE 22. SHAFT COUPLER LHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 8

Place the spikes into the down position (and the drive arm pointing upwards) to aid in the fi tment of all the shaft couplings. STEP 5 Repeat this coupling process for additional spike modules. Once all shafts have been coupled, check that they move freely. STEP 1 STEP 3 STEP 6 STEP 2 STEP 4 STEP 7 FIGURE 24 FIGURE 26 FIGURE 28 FIGURE 25 FIGURE 27 FIGURE 29 Top coupler Shaft Bottom coupler Dowel pin Groove in shafts Bottom coupler Cap screws Dowel pin Top coupler 60Nm 60Nm LHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 8

Far end of the assembly Drive linkage end of the assembly 20mm PVC Conduit The length of the PVC conduit will be relative to the length of the spike modules and drive linkage unit combined. Ensure that a further 110mm is added to this to account for the modules and coupling (Refer to Section 8, Figure 31). 19mm 91mm Sandwich plate 20mm PVC conduit 20mm PVC conduit FIGURE 30 STEP 1 FIGURE 31 LHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 8

PVC access elbow 37x25mm PVC Coupler 37x25mm PVC Coupler Use an appropriate PVC adhesive to bond all conduit lengths, access elbows and couplers to one another. Star washer Proximity coupler Proximity coupler Proximity sensor bush Proximity sensor bush Star washer and Hex nut Threaded shaft Hex Nut Threaded shaft Prox s Star w and He Please ensure that the moving mechanical parts do not rub against the conduit or cables. FIGURE 37. PROXIMITY SENSOR FIGURE 36. PROXIMITY SENSOR STEP 2 STEP 4 STEP 3 STEP 5 FIGURE 32 FIGURE 34 FIGURE 33 FIGURE 35 LHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 8

of the assembly There should be ample cable left over on the drive linkage end, as the wiring will need to be routed up the SECTOR II at a later stage. M8 x10mm Grub screw Proximity sensor Proximity sensor Proximity sensor bush 37x25mm PVC Coupler FIGURE 38. PROXIMITY SENSOR FIGURE 40 STEP 6 STEP 7 STEP 8 FIGURE 39 FIGURE 41 FIGURE 42 LHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 8

Ramp plates Trench plate covers Ramp plates Spring Washer M8x20 screw Take notice of the slot orientation in the trench cover plates before it is placed back into position. The spike must rest on the straight edge of the slot when it is in its upright position. Leave out the four M8 screws and Spring Washers on the far end of the assembly as the module end cover will be assembled later. Spring Washer M8x20 screw Drive linkage cover plate STEP 1 STEP 4 STEP 5 STEP 2 STEP 3 FIGURE 43 FIGURE 46 FIGURE 47 FIGURE 44 FIGURE 45 LHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 8

Make sure that there is clearance for the drive arm to swing through. If this plate is assembled back-to-front the drive arm won’t swing through and you will need to turn the plate around (Refer back to Section 8, Figure 13). M6x20 screw STEP 6 STEP 8 STEP 10 STEP 7 STEP 9 FIGURE 48 FIGURE 50 FIGURE 52 FIGURE 49 FIGURE 51 Module end cover Spring Washer M8x20 screw LHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 8

8.4.1. Placing the SECTOR II into position Drive linkage unit SECTOR II SECTOR II Drive linkage end cover Drive linkage frame Drive linkage cover plate 8.4.2. Fitting and leveling the SECTOR II boom pole Refer to Section 3.3 of the SECTOR II Installation manual for instructions on fi tting and leveling to boom pole. Lift the spikes by hand to get them just under the level of the trench plate, which pushes the linkage arm back, allowing you to move the unit into its correct position; 110mm from the front edge of the Linkage Cover Plate. (Section 8, Figure 55). STEP 1 STEP 3 STEP 2 STEP 4 FIGURE 53 FIGURE 55 FIGURE 54 FIGURE 56 LHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 8

occur; use the drive arm to move the spikes up and down. Apply Lock-tite 243 to all the internal threads and torque both the M16x40 and M16x110 bolts to 40Nm (Steps 3 and 4) 8.4.3. Inserting the Con-rod SECTOR II Con-rod STEP 1 STEP 3 STEP 2 STEP 4 FIGURE 57 FIGURE 59 FIGURE 58 FIGURE 60 LHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 8

The CLAWS spikes will raise during this procedure! Con-rod top nut Con-rod base nut Turning the Con-rod clockwise or anti-closwise will raise or lower the spikes. Con-rod STEP 1 STEP 2 STEP 3 FIGURE 61 FIGURE 62 FIGURE 63 LHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 8

are below the top plate (Section 8, Figures 66 and 67). VIEW A VIEW A VIEW A Spike Spike Trench plate Optimum Position: Spikes are below the trench plate and the boom pole is in the vertical position. VIEW A Trench plate VIEW A Optimum Position: Spikes are above the trench plate and the boom pole is in the horizontal position. With one person holding the barrier pole in the lowered position, adjust the spikes so that the spikes just touch the trench plate (Section 8, Figure 64). FIGURE 66 FIGURE 67 FIGURE 64 STEP 4 FIGURE 65 Spike Trench Plate LHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 8

8.5.1. Fitting the relay enclosure and its bracket Front brace plate Screws SECTOR II Relay enclosure bracket SECTOR II Relay enclosure bracket Relay enclosure Front brace plate STEP 1 STEP 3 STEP 2 FIGURE 68 FIGURE 70 FIGURE 69 Route the excess wire from the proximity sensor, and wire it to the relay by referring to the wiring diagram (Section 16). Complete the installation of the SECTOR II as per its full installation manual, and proceed to ‘Section 17 - Installation Handover’ SECTOR II Relay enclosure bracket Front brace plate LHS SURFACE MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 8

Similar 9.1.1. Stripping the drive linkage assembly M6x20 screw M8x25 screw Linkage end cover Drive linkage assembly Bearing Housing Bearing Housing Bolt Linkage frame Bearing shaft assembly Washer Linkage cover plate FIGURE 1 FIGURE 3 FIGURE 5 FIGURE 2 FIGURE 4 FIGURE 6 STEP 1 STEP 3 STEP 5 STEP 2 STEP 4 STEP 6 9. LHS Surface Mount - Opposing Direction of Travel LHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 9

Left-hand Side Orientation 68mm 77.5mm Right-hand Side Orientation RHS Installations LHS Installations Linkage frame Bearing shaft assembly The grease nipples on the bearing housings must face up (Section 9, Figures 10 and 11). Take note of the orientation of the Linkage frame, the Bearing Shaft Assembly, and the Drive linkage arm (Section 9, Figure 11). Grub Screw Grease nipple Bearing housing Bearing housing Remove Long Drive Arm FIGURE 7 FIGURE 8 FIGURE 10 FIGURE 9 FIGURE 11 STEP 7 STEP 9 STEP 8 STEP 10 LHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 9

Section 9, Figure 12. 1 3 4 2 VIEW A 11 o’ clock 1.5X X 6 o’ clock 1. The drive arm must point towards the longer side of the drive linkage assembly (1.5x) 2. The notch must be at the bottom of the shaft (6 o’clock) 3. The bolt head must face the bottom and the nut on top 4. The angle of the bolt and nut must be as shown (11’clock) STEP 11 Replace the bearing housing bolts once everything is in the correct orientation. Hand-tighten for the time being. FIGURE 12 1.5X LHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 9

the drive linkage assembly without fastening the bolts. Check that the linkage cover plate is in the correct position and that there is ample clearance for the drive arm (Section 9, Figure 13). Linkage cover plate VIEW A Linkage cover plate 9.2. Spike Module Assembly 9.2.1. Preparing the Spike Module assembly(ies) for installation Spring Washer Spring Washer M8x20 screw M8x20 screw Ramp plate Trench cover Ramp plate FIGURE 13 FIGURE 14 FIGURE 16 FIGURE 15 FIGURE 17 STEP 1 STEP 3 STEP 2 STEP 4 LHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 9

Take note of the orientation of the sandwich plate to the linkage unit before fi xing them to the spike module assembly (Section 9, Figure 18). Sandwich plate Linkage unit Spike module To assist with the alignment and adjustment of the shafts, loosen (but do not remove) the bolts on all of the bearing housings. STEP 3 Using six M12x25 bolts, fi x one spike module to another (Section 9, Figure 20). Ensure that the shafts align throughout the assembly Bearing housing M12 Nut Spike Module M12x25 Bolt FIGURE 20 STEP 1 STEP 2 FIGURE 18 FIGURE 19 LHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 9

as an uneven surface could result in an uneven binding of the spike shafts. This will result in premature failure. 9.2.3. Bolting down the assembly to the ground M12 Rawl-bolts or Chem-bolts 9.2.4. Assembling the shaft couplings The coupler is used to connect and align the shafts together. It is essential that the coupler is assembled correctly; failing to do so will result in slipping of the spikes which is undesirable. Dowel pin Bottom coupler Shaft Top coupler Cap screws FIGURE 21 FIGURE 23 FIGURE 22. SHAFT COUPLER LHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 9

to aid in the fi tment of all the shaft couplings. Dowel pin Bottom coupler Groove STEP 5 Repeat this coupling process for additional spike modules. Once all shafts have been coupled, check that they move freely. Tighten Grub screws STEP 1 STEP 3 STEP 6 STEP 2 STEP 4 STEP 7 FIGURE 24 FIGURE 26 FIGURE 28 FIGURE 25 FIGURE 27 FIGURE 29 Top coupler Shaft Bottom coupler Dowel pin Groove in shafts Bottom coupler Cap screws Dowel pin Top coupler 60Nm 60Nm LHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 9

The length of the PVC conduit will be relative to the length of the spike modules and drive linkage unit combined. Ensure that a further 110mm is added to this to account for the modules and coupling (Refer to Section 9, Figure 31). 19mm 91mm Sandwich plate 20mm PVC conduit 20mm PVC conduit Far end of the assembly Drive linkage end of the assembly 20mm PVC Conduit FIGURE 30 FIGURE 31 LHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 9

20mm PVC conduit 37x25mm PVC Coupler Use an appropriate PVC adhesive to bond all conduit lengths, access elbows and couplers to one another. Please ensure that the moving mechanical parts do not rub against the conduit or cables. 20mm PVC conduit 37x25mm PVC Coupler Linkage Frame 20mm PVC conduit 60mm Star washer Proximity coupler Proximity coupler Proximity sensor bush Proximity sensor bush Star washer and Hex nut Threaded shaft Hex Nut Threaded shaft Prox s Star w and He FIGURE 37. PROXIMITY SENSOR FIGURE 36. PROXIMITY SENSOR STEP 2 STEP 4 STEP 3 STEP 5 FIGURE 32 FIGURE 34 FIGURE 33 FIGURE 35 LHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 9

of the assembly Proximity coupler Threaded shaft Proximity sensor bush Proximity sensor assembly 37x25mm PVC Coupler There should be ample cable left over on the drive linkage end, as the wiring will need to be routed up the SECTOR II at a later stage. Proximity sensor Proximity sensor bush 37x25mm PVC Coupler M8 x10mm Grub screw Proximity sensor FIGURE 38. PROXIMITY SENSOR FIGURE 40 STEP 6 STEP 7 STEP 8 FIGURE 39 FIGURE 41 FIGURE 42 LHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 9

Take notice of the slot orientation in the trench cover plates before it is placed back into position. The spike must rest on the straight edge of the slot when it is in its upright position. Leave out the four M8 screws and Spring Washers on the far end of the assembly as the module end cover will be assembled later. Trench plate covers STEP 1 STEP 4 STEP 5 STEP 2 STEP 3 FIGURE 43 FIGURE 46 FIGURE 47 FIGURE 44 FIGURE 45 LHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 9

Make sure that there is clearance for the drive arm to swing through. If this plate is assembled back-to-front the drive arm won’t swing through and you will need to turn the plate around (Refer back top Section 9, Figure 13). STEP 6 STEP 8 STEP 10 STEP 7 STEP 9 FIGURE 48 FIGURE 50 FIGURE 52 FIGURE 49 FIGURE 51 LHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 9

Refer to Section 3.3 of the SECTOR II Installation manual for instructions on fi tting and leveling to boom pole. SECTOR II Drive linkage cover plate Drive linkage end cover Lift the spikes by hand to get them just under the level of the trench plate, which pushes the linkage arm back, allowing you to move the unit into its correct position; 80mm from the front edge of the Linkage Cover Plate. (Section 9, Figure 55). SECTOR II M12x60 Hex Bolt Heavy duty washer Hold down bracket Drive linkage assembly 9.4. Integrating the SECTOR II with the CLAWS 9.4.1. Placing the SECTOR II into position Place the SECTOR II on top of the drive linkage unit. Drive linkage unit SECTOR II SECTOR II Drive linkage end cover Drive linkage frame Drive linkage cover plate Y Y STEP 1 STEP 3 STEP 2 STEP 4 FIGURE 53 FIGURE 55 FIGURE 54 FIGURE 56 LHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 9

M16x110 bolts to 40Nm (Steps 3 and 4) 9.4.3. Inserting the Con-rod SECTOR II Con-rod Do not place any body parts near the spikes as serious injury could occur; use the drive arm to move the spikes up and down. STEP 1 STEP 3 STEP 2 STEP 4 FIGURE 57 FIGURE 59 FIGURE 58 FIGURE 60 LHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 9

The CLAWS spikes will raise during this procedure! Turning the Con-rod clockwise or anti-closwise will raise or lower the spikes. Con-rod top nut Con-rod base nut Con-rod STEP 1 STEP 2 STEP 3 FIGURE 61 FIGURE 62 FIGURE 63 LHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 9

that the spikes just touch the trench plate (Section 9, Figure 71). To ensure correct adjustment, raise the barrier pole and check that the spikes are below the top plate (Section 9, Figures 66 and 67). VIEW A VIEW A VIEW A Spike Spike Trench plate Optimum Position: Spikes are below the trench plate and the boom pole is in the vertical position. VIEW A Trench plate Optimum Position: Spikes are above the trench plate and the boom pole is in the horizontal position. FIGURE 66 FIGURE 67 FIGURE 64 STEP 4 FIGURE 65 Spike Trench Plate LHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 9

9.5.1. Fitting the relay enclosure and its bracket Front brace plate Screws SECTOR II Relay enclosure bracket SECTOR II Relay enclosure bracket Relay enclosure Front brace plate Route the excess wire from the proximity sensor, and wire it to the relay by referring to the wiring diagram (Section 16). Complete the installation of the SECTOR II as per its full installation manual, and proceed to ‘Section 17 - Installation Handover’ STEP 1 STEP 3 STEP 2 FIGURE 68 FIGURE 70 FIGURE 69 SECTOR II Relay enclosure bracket Front brace plate LHS SURFACE MOUNT - OPPOSING DIRECTION OF TRAVEL SECTION 9

TRAFFIC BARRIERS Centurion Systems (Pty) Ltd www.centsys.com

2 1 6 5 4 3 1. Boom pole 2. Spikes module assembly 3. Trench cover plate 4. Spikes 5. Drive linkage assembly 6. SECTOR II Module Frame Linkage Frame Sandwich Plate Top Coupler Bottom Coupler 8x20 Dowel Pin CLAWS Direct drive fl ush mount - similar direction of travel illustrated PRODUCT IDENTIFICATION SECTION 10 10. Product Identifi cation

• Ratchet • 19mm, and 24mm Sockets • Allen Key Set • Mallet • Tape Measure • Spirit Level • Torque Wrench • Permanent marker • Spade • Pick • Trough • Fish line • 50mm hole saw • Electric Drill Short Drive Arm Long Drive Arm Linkage Drive Shaft Bearing Housing Hold Down Bracket Con-rod Assembly Linkage Cover Plate Linkage End Cover Module End Cover SECTION 10 FLUSH MOUNT INSTALLATIONS - TOOLS REQUIRED TOOLS REQUIRED SECTION 11 11. Tools Required

CLAWS Spikes driven directly from a SECTOR II Barrier by a “push-pull” linkage system. The installation described in this document is a 2.5 meter installation which utilises modules of 1.5 and 1.0 meters. The installation of the CLAWS Spikes requires a minimum of two persons. 12.1. Installation Confi gurations The fl ush-mountable CLAWS Spikes can be installed in four diff erent confi gurations. The confi guration is dependent on two factors: • Orientation of installation • Direction of spike impact FIGURE 2. RHS CONFIGURATION FIGURE 3. LHS CONFIGURATION 12.1.1. Orientation of Installation The orientation of installation is described as the side at which the drive linkage is installed when approaching the CLAWS Spikes. In other words, when driving up to the CLAWS Spikes, in the correct direction for traffi c fl ow, and the drive is installed on the right-hand side of the vehicle, it’s deemed a right-hand installation. And when driving up to the CLAWS Spikes, in the correct direction for traffi c fl ow, and the drive is installed on the left-hand side of the vehicle, it’s deemed a left-hand installation. INTRODUCTION SECTION 12 12. Introduction

The CLAWS Spikes are designed to take a much larger impact in one direction. Thus, the CLAWS Spikes can be installed to take larger or more frequent impact in one direction. In other words the spikes can be installed to face either towards oncoming traffi c (similar) or face towards traffi c (opposing) trying to enter from the wrong direction or lane. There are four types of typical installations. Refer to Section 12, Figures 2 and 3 to determine if the installation is left- or right-hand orientated. Secondly; pay attention to the spike impact direction: • Similar direction of travel prevents vehicles from exiting whilst the boom pole is still down (Normal direction of traffi c) • Opposing direction of travel prevents vehicles entering against the fl ow of traffi c whilst the boom pole is down FIGURE 6. RHS SIMILAR DIRECTION OF TRAVEL FIGURE 4. SPIKE IMPACT DIRECTION - SIMILAR FIGURE 5. SPIKE IMPACT DIRECTION - OPPOSING Direction of travel Road Level Road Level Direction of travel el el Direction of normal traffi c fl ow INTRODUCTION SECTION 12

FIGURE 9. LHS OPPOSED DIRECTION OF TRAVEL FIGURE 8. LHS SIMILAR DIRECTION OF TRAVEL Direction of normal traffi c fl ow Direction of normal traffi c fl ow Direction of normal traffi c fl ow INTRODUCTION SECTION 12

Similar 13.1.1. Stripping the drive linkage assembly 13. RHS Flush Mount - Similar Direction of Travel RHS FLUSH MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 13

FIGURE 14 Left-hand Side Orientation 68mm 77.5mm Right-hand Side Orientation RHS Installations LHS Installations FIGURE 18 STEP 8 Grub Screw Grease nipple Bearing housing Bearing housing Remove Short Drive Arm FIGURE 15 FIGURE 17 FIGURE 16 STEP 5 STEP 7 STEP 6 The grease nipples on the bearing housings must face up (Section 13, Figures 17 and 18). Take note of the orientation of the Linkage frame, the Bearing Shaft Assembly, and the Drive linkage arm (Section 13, Figure 18). Grease nipple Grease nipple RHS FLUSH MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 13

Figure 19. 1. The drive arm must point as is shown in Section 13, Figure 19 2. The notch must be at the bottom of the shaft (6 o’clock) 3. The bolt head must face the bottom and the nut on top 4. The angle of the bolt and nut must be as shown (11 o’clock) STEP 9 Replace the bearing housing bolts once everything is in the correct orientation. Hand-tighten for the time being. RHS FLUSH MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 13 FIGURE 19 VIEW A 11 o’ clock 6 o’ clock 1 3 4 2

the drive linkage assembly without fastening the bolts. Check that the linkage cover plate is in the correct position and that there is ample clearance for the drive arm (Section 13, Figure 20). Linkage cover plate 13.2. Spike Module Assembly 13.2.1. Preparing the Spike Module assembly(ies) for installation Spring Washer M8x20 screw Trench cover FIGURE 21 FIGURE 22 STEP 1 STEP 2 VIEW A RHS FLUSH MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 13

Take note of the orientation of the sandwich plate to the linkage unit before fi xing them to the spike module assembly (Section 13, Figure 23). Sandwich plate Linkage unit M12 Nut M12x25 bolt Spike module To assist with the alignment and adjustment of the shafts, loosen (but do not remove) the bolts on all of the bearing housings. STEP 3 Using six M12x25 bolts, fi x one spike module to another (Section 13, Figure 25). FIGURE 25 Ensure that the shafts align throughout the assembly Bearing housing M12x25 Bolt Spike Module M12 Nut FIGURE 23 FIGURE 24 STEP 1 STEP 2 RHS FLUSH MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 13

The coupler is used to connect and align the shafts together. It is essential that the coupler is assembled correctly; failing to do so will result in slipping of the spikes which is undesirable. Place the spikes into the down position (and the drive arm pointing upwards) to aid in the fi tment of all the shaft couplings. FIGURE 27 FIGURE 26. SHAFT COUPLER Dowel pin Dowel pin Bottom coupler Bottom coupler Groove Shaft Top coupler Cap screws FIGURE 28 FIGURE 30 FIGURE 29 FIGURE 31 STEP 1 STEP 3 STEP 2 STEP 4 Top coupler Shaft Bottom coupler Dowel pin Groove in shafts Bottom coupler Cap screws Dowel pin Top coupler 60Nm 60Nm RHS FLUSH MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 13

coupled, check that they move freely. Tighten Grub Screws Far end of the assembly Drive linkage end of the assembly 20mm PVC Conduit The length of the PVC conduit will be relative to the length of the spike modules combined. Ensure that a further 38mm is added to this to account for the modules and coupling (Refer to Section 13, Figure 35). 13.2.4. Proximity sensor installation FIGURE 32 FIGURE 34 FIGURE 33 STEP 6 STEP 1 STEP 7 RHS FLUSH MOUNT - SIMILAR DIRECTION OF TRAVEL SECTION 13