SYSTEMS Poweramp PowerStop AAL Owner & User Manual Download Page 1

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PowerStop

Vehicle Restraint

Poweramp

• Division of Systems, LLC • W194 N11481 McCormick Drive • Germantown, WI 53022

800.643.5424 • fax: 262.255.5917 • www.

poweramp

.com • [email protected]

Printed in U.S.A.

Manual No. 4111-0014

Apr. 2020

Owner’s/User’s Manual

Summary of Contents for Poweramp PowerStop AAL

Page 1: ...on of Systems LLC W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 255 5917 www poweramp com techservices poweramp com Printed in U S A 2020 Systems LLC All Rights Reserved Manual...

Page 2: ...gnize Precautionary Information 1 General Operational Precautions 1 Operational Precautions 2 Safety Decals 4 Placard 4 Owner s User s Responsibilities 6 Introduction General Information 8 Component I...

Page 3: ...death or serious injury Follow the instructions in the safety message panel The use of the word DANGER signifies the presence of an extreme hazard or unsafe practice which will most likely result in d...

Page 4: ...hands and feet clear of pinch points Avoid putting any part of your body near moving parts Chock restrain all transport vehicles Never remove the wheel chocks or release the restraining device until l...

Page 5: ...use dock leveling device if transport vehicle is too high or too low Do not overload the dock leveling device Do not operate any equipment while under the influence of alcohol or drugs Do not leave e...

Page 6: ...AL 00 01 000 005 ANGULAR 1 DRAWN BY CHECKED BY DRAWING NO DATE BDK 4 14 2020 S Y S T E M S L o a d i n g D o c k E q u i p m e n t P O W E R A M P M C G U I R E D L M This print is the property of Sys...

Page 7: ...osition Press DOCK ALERT STATUS button 3 Inside light is GREEN AMBER and outside light is RED 4 Loading unloading may proceed with caution BY PASS RESET RETURN TO NORMAL OPERATION 1 When loading unloa...

Page 8: ...replacements 5 Modifications or alterations of restraining devices shall be made only with prior written approval from the original manufacturer These changes shall be in conformance with all applica...

Page 9: ...spection in accordance with all manufacturers recommendations are the sole responsibility of the owner user 10 Manufacturer s recommended maintenance and inspection of all restraining devices shall be...

Page 10: ...urrent information on the PowerStop vehicle restraint Figure 4 Due to ongoing product improvement some parts may have changed along with operation and troubleshooting methods This manual describes the...

Page 11: ...S I N P O W E R S T O P H O O K W E L D M E N T 9 4 1 3 0 1 2 3 1 4 1 L O W P O W E R S T O P H O O K W E L D M E N T 9 4 1 3 0 1 2 7 1 F I N A L B A S E W L D T 2 7 P S T O P 9 4 1 4 0 0 8 3 1 4 2 F...

Page 12: ...draulic fluid or other flammable liquid is present Stray sparks can ignite spills or leaks near the work area Always clean up the oil leaks and spills before proceeding with grinding or welding Always...

Page 13: ...nc and repre patent and other rights including exclusive rights of not convey any permission to reproduce print or ma granted only by written authorization signed by an o 20 X 1 1 8 TYP 5 TYP 3 8 20 2...

Page 14: ...ission to be granted only by written authorization signed by an officer or other authorized agent of Systems LLC thereof MATERIAL STOCK NO 9415 0062 FINAL ASM PSTOP STOPTITE 2018 REV A ECN 18 066 If 2...

Page 15: ...52 0216 2 2 1 7 8 TUBE LIP HINGE 9512 1146 4 3 TOLERANCES UNLESS OTHERWISE NOTED FRACTIONAL 1 32 DECIMAL 00 01 000 005 MATERIAL DRAWN BY CHECKE DRAW BDK IMBED WELDMEN L o a d i n g D o DRIVEWA 2 1 2 1...

Page 16: ...fillet welds Where possible cantilever bracket should also be welded to curb angle with 1 4 fillet weld Note Walls must be poured concrete 8 thick minimum to install with wedge anchors Concrete block...

Page 17: ...3 5 5 5 5 6 5 5 5 5 5 Bracket Up Store Operating wand by hanging in slot INSTALLATION PowerStop Mechanical Operating Wand Bracket Mount PowerStop operating wand bracket Figure 17 on the interior wall...

Page 18: ...onditions The routing of hydraulic and electrical lines from the Powerpack to the restraint are best placed through min 3 PVC hydraulic and 3 4 conduit electrical chase during pit construction Inside...

Page 19: ...5 6 17 1 8 9 RC BC HOLE FOR SEE NOTE 3 HOLE FOR SEE NOTE 3 BC RC 10 10 7 1 2 REF 3 13 15 INSTALLATION Conduit flexible or rigid must be connected between the limit switch on the restraint and the Pow...

Page 20: ...trol wiring to the field wires in the dock equipment junction boxes Refer to the electrical diagrams supplied with the dock equipment Note When installing electrical controls in a temperature controll...

Page 21: ...12v DC outside lights and wiring will cause the iDock Control System to enter a fault state and equipment will not function If 12v DC outside lights are already present and functioning they can be re...

Page 22: ...view of dock leveler and or vehicle restraint operations Suggested placement of placard is near control box attached to electrical conduit by using nylon cable tie If there is no control box present m...

Page 23: ...nder or around a dock leveler Always stand clear of platform lip when working in front of the dock leveler 1 Once all installation work is completed disconnect the external lifting device and lifting...

Page 24: ...6 Lower the restraint fully by pressing down on the hook weldment with the handle provided The restraint hook should lower fully until the latch is engaged 7 Transport vehicle can now depart Inside l...

Page 25: ...is unable to return to the working zone after one 1 attempt the hook will automatically return to the stored position and the iDock Control System will alert the operator that the restraint is no lon...

Page 26: ...n Condition Lights Inside Outside Restraint Engage Failure Bypass Mode prompt Red Amber Display Backlight Red Bypass Mode Green Amber Green Red on Dock Alert Red Reset Attempted Leveler in Use Red Amb...

Page 27: ...inform that repairs are in process and clearly state who is responsible for the lockout condition Refer to OSHA regulations 1910 146 Confined Space and 1910 147 Lockout Tagout Always post safety warn...

Page 28: ...around unit to prevent operation issues Make sure that all the inside and outside signal lights work if equipped Weekly Maintenance Operate the vehicle restraint through the complete operating cycle...

Page 29: ...t is recommended that the following hydraulic fluids be used ULTRA VIS HVI 15 Aero Shell Fluid 4 or Fluid 41 Mobile Aero HFA Mil H5606A or Aero HF Texaco Aircraft Hydraulic Oil 15 or 5606 Exxon Univis...

Page 30: ...e operated in BYPASS MODE Pressing the restraint RELEASE button when in BYPASS mode will return the leveler to NORMAL operating mode Special interlocking options are available upon request Call System...

Page 31: ...the target or bend the target to increase dimension B so that the target is not in the sensing range of the switch Make adjustments at switch and or target until vehicle restraint does not disengage t...

Page 32: ...tenance prop Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete A hard hat or other a...

Page 33: ...rectly or faulty Check wiring to capacitor Insufficient voltage Check wire size to control box from facility Consult Tech Services for correct wire size Motor energizes and runs but restraint will not...

Page 34: ...estraint to raise and de energized to lower Lights don t change Faulty stored prox switch Check stored prox switch wiring and operation Note Stored prox switch has two lights on switch GREEN when meta...

Page 35: ...pa no gra 8 1 5 3 2 4 3 9 5 6 7 10 Item Quantity Part Number Description 1 1 0941 0021 Spring Extension SS 2 1 0961 0614 Prox Switch RIG Sensor 3 2 2101 0032 Screw 1 4 20 x 0 38 Black Oxide 4 2 2101 0...

Page 36: ...9 31 4 27 19 15 50 18 40 2 20 17 39 33 42 4 28 4 3 5 5 5 5 5 5 6 5 5 5 5 5 PARTS DETAIL A BILL OF MATERIAL DESCRIPTION PART NO QTY ITEM BRACKET PSTOP M RELEASE BAR 0192 0161 REF 1 PSTOP DEBRIS GUARD A...

Page 37: ...1 0336 Washer Tag Hole 1 2 Stainless Steel 20 2 2101 0349 Retaining Ring External Zinc Plated 21 2 2101 0376 Screw RHMS Torx 4 40 x 7 8 22 3 2101 0377 Screw THMS Torx 10 24 x 2 00 23 2 3051 0388 Screw...

Page 38: ...101 0189 8 19 1 2 13 UNC X 1 FLAT HEAD CAP SCREW 2101 0228 2 20 10 32 UNF X 1 4 RHMS SLOTTED 2101 0232 2 21 0 50 DIA X 0 375 LG SCREW SHLDR 2101 0335 1 22 STAINLESS STEEL WASHER TAG HOLE 1 2 2101 0336...

Page 39: ...ning Ring External Zinc Plated 23 2 2101 0373 Screw SHCS 5 16 18 X 1 3 8 24 2 2101 0375 Screw RHMS TORX 10 32 X 1 4 25 2 2101 0376 Screw RHMS TORX 4 40 X 7 8 26 3 2101 0377 Screw THMS TORX 10 24 X 2 0...

Page 40: ...ULAR 1 DRAWN BY CHECKED BY DRAWING NO DATE BDK 7 17 2017 S Y S T E M S I N C L o a d i n g D o c k E q u i p m e n t P O W E R A M P M C G U I R E D L M This print is the property of Systems Inc and r...

Page 41: ...DATE ST 2 28 201 9703 0005 FILLER WELDMENT 2 PROJECTION P O W E R A M P M C G U I R E D L M S Y S T E M S I N C L o a d i n g D o c k E q u i p m e n t This print is the property of Systems Inc and re...

Page 42: ...DRAWN BY C D BDK POWERP S Y S L o a d i n g This print is the property of Systems Inc a patent and other rights including exclusive not convey any permission to reproduce pr granted only by written au...

Page 43: ...9301 0221 Fitting 45 Degree 4 ORBM to 4 JICM 7 1 9391 0087 Powerpack 1 4HP 0 94GPM 1 phase 115v 725 RV 8 1 9391 0012 Powerpack Mounting Weldment 9 1 9391 0013 Powerpack Cover 10 1 8581 0117 Valve 4 W...

Page 44: ...to 8 JICM 8 1 8581 0004 Coil 115v Not Shown Item Description P Pressure From Pump R Return To Tank LP Presure To Logic Block LR Return From Logic Block BC Blind End of Cylinders RC Rod End of Cylinde...

Page 45: ...lete Light Housing Yellow Plastic With 12v LED Lights 1 1 3051 0002 Light Housing Only Yellow Plastic 2 1 3051 0147 Red LED Lens Housing Circuit Assembly 12v 3 1 3051 0149 Green LED Lens Housing Circu...

Page 46: ...town WI 53022 CAUTION PULL IN OR OUT ON GREEN ONLY C A U T I O N P U L L I N O R O U T O N G R E E N O N L Y Germantown WI 53022 Item Part Number Description A 1751 0033 Outside Sign Pull In Out B 175...

Page 47: ...r SERIAL NUMBER For service call or contact Systems LLC P O Box 309 Germantown WI 53022 Phone 800 643 5424 Fax 262 255 5917 www loadingdocksystems com MISCELLANEOUS Dock Leveler Information Model ____...

Page 48: ...of maintenance Periodic lubrication adjustment and inspection in accordance with all manufacturers recommendations are the sole responsibility of the Owner User In the event of a defect as determined...

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