Poweramp Bar Lift Owner & User Manual Download

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Bar Lift

Safety Barrier

Printed in U.S.A.

Manual No. 4111-0068

Oct. 2018

Poweramp

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

800.643.5424 • fax: 262.255.5917 • www.

poweramp

.com • [email protected]

Owner’s/User’s Manual

Summary of Contents for Bar Lift

Page 1: ... 2018 Systems LLC All Rights Reserved Manual No 4111 0068 Oct 2018 Poweramp Division of Systems LLC W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 255 5917 www poweramp com techservices poweramp com Owner s User s Manual ...

Page 2: ...all Control Panel and Wiring 12 Put New Barrier Into Service 13 Operation Operational Precautions 14 Operating Instructions 15 Maintenance Maintenance Precautions 16 Periodic Maintenance 18 Adjustments Adjust Main Pressure Relief 20 Adjust Flow Control 21 Troubleshooting Troubleshooting 22 Parts Barrier Arm Receiver 26 Base Assembly 28 Powerpack Assembly 30 Cylinder Assembly 32 Valve Assembly 34 S...

Page 3: ...f California to cause cancer or birth defects or other reproductive harm For more information go to www P65Warnings ca gov Safety Alert Symbol The Safety Alert Symbol is a graphic representation intended to convey a safety message without the use of words When you see this symbol be alert to the possibility of death or serious injury Follow the instructions in the safety message panel The use of t...

Page 4: ...t of it Keep 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 loading or unloading is finished and transport driver has been given permission to drive away Do not use a broken or damaged dock leveling device or restraining device Make sure proper ser...

Page 5: ...utions Do not 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 equipment or material unattended on dock leveling device ...

Page 6: ...4 4111 0068 Oct 2018 2018 Systems LLC PRECAUTIONS Safety Decals Decal Size 3 x 1 File Name 1751 0140 Rev B PINCH POINT KEEP CLEAR 1751 0140 Rev B 1751 0140 ...

Page 7: ...r Return dock leveler to its stored position at dock level Failure to follow posted instructions will result in death or serious injury Call 262 255 1510 for replacement placards warning labels or owner s user s manuals File Name 1751 0730 Rev B Decal Size 9 12 x 3 25 MAINTENANCE SERVICE 7 Stay clear of hinges and front and sides of moving dock leveler 8 N e v e r u s e d a m a g e d o r malfuncti...

Page 8: ...he interface between the loading dock and the transport vehicle The owner user should therefore train and instruct all operators in the safe operation and use of the loading dock equipment in accordance with manufacturer s recommendations and industry standards Effective operator training should also focus on the owner s user s company policies operating conditions and the manufacturer s specific ...

Page 9: ...oduct warranty the dock safety equipment must have been properly installed maintained and operated in accordance with all manufacturer s recommendations and or specified design parameters and not otherwise have been subject to abuse misuse misapplication acts of nature overloading unauthorized repair or modification application in a corrosive environment or lack of maintenance Periodic lubrication...

Page 10: ...ncrete with 5 8 x 5 anchors An optional plate is available that is attached to the barrier bar to prevent the forks from a forklift truck to go under the barrier and damage the overhead door This unit is rated to withstand repeated impacts by a 10 000 lb load moving at 4 mph Standard units including stanchion barrier arm and receiver pocket are 12 1 wide Customized widths and gusseted models are a...

Page 11: ... D Control Box E Rear Sheet Metal Cover Control box appearance and location may vary depending on options Component Identification Inspect package and all components Report any missing or damaged items immediately and note on the shipping Bill Of Lading BOL INTRODUCTION Figure 4 B E C A D ...

Page 12: ...y damage the motor hydraulics wiring and or control panel Installation Precautions INSTALLATION Only trained installation professionals with the proper equipment should install this product Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the equipment before installation is complete A hard hat or other applicable head protection...

Page 13: ... sheet metal cover from main body may help the assembly process 2 In order to determine Bar Lift Barrier mounting location position the barrier so that it is centered in door opening and at least 14 away from the wall 14 wall clearance is required to remove pivot pin 3 Check overhead clearance with barrier in raised position to ensure that the barrier arm will not interfere with the overhead door ...

Page 14: ...that conforms to the 1999 National Electrical Code Section 250 50 section a or section c for a grounding electrode system B A C A Disconnect Panel B Control Panel provided by others C Distance 48 in 1219 mm INSTALLATION Make sure that the power source has been locked out and tagged according to OSHA regulations and approved local electrical codes All electrical work including the installation of t...

Page 15: ...ceiver weldment as needed and install three 3 5 8 x 5 min concrete anchors 8 Test system to verify proper operation Amber light should be off when barrier arm is in the horizontal position barrier in use and in the vertical position barrier stored Pressing the raise button should cause the barrier arm to raise smoothly releasing the raise button should stop barrier arm motion Pressing the lower bu...

Page 16: ...r before using DO NOT operate any equipment while under the influence of alcohol or drugs DO NOT leave equipment or material unattended on the barrier Operational Precautions Stay clear of barrier when transport vehicle is entering or leaving dock area DO NOT move or use the barrier if anyone is under or in front of barrier Keep hands and feet clear of pinch points Avoid putting any part of your b...

Page 17: ... button Amber light will turn on indicating barrier is mid travel 3 When amber light goes off release RAISE push button Operating Instructions Lowering Barrier 1 Visually check path of barrier travel Figure 10 to make sure it is clear of objects and personnel 2 Press and hold LOWER push button Amber light will turn on indicating barrier is mid travel 3 When amber light goes off release LOWER push ...

Page 18: ... This additional means may include but is not limited to a boom truck fork truck stabilizing bar or equivalent A hard hat or other applicable head protection should always be worn when working under or around the barrier Always stand clear of the raised barrier arm when working in front of the barrier Figure 11 A Tag Out Device B Lock Out Device A B When working with electrical or electronic contr...

Page 19: ...17 4111 0068 Oct 2018 2018 Systems LLC MAINTENANCE This page intentionally left blank ...

Page 20: ...ration of the barrier use only aircraft hydraulic fluid designed to meet or exceed military specification MIL H 5606 G It is recommended that the following hydraulic fluids be used ULTRA VIS HVI 15 Aero Shell Fluid 4 or Fluid 41 Mobil Aero HFA Mil H5606A or Aero HF Texaco Aircraft Hydraulic Oil 15 or 5606 Exxon Univis J13 Castrol Brayco Micronic 756 These fluid brands can be mixed together Use of ...

Page 21: ...emove rear service panel then locate fluid reservoir D 4 Remove breather cap E 5 Measure fluid level using the dipstick attatched to the breather cap E The fluid level should contact the tip of the dipstick approximately 1 1 2 in 38 1 mm from top of reservoir with barrier in the lowered position 6 Add hydraulic fluid if necessary Use only recommended fluid see page 18 7 Install breather cap and se...

Page 22: ...ew B tighten jam nut A 6 Turn ON electrical power to the barrier 7 Test barrier and repeat steps 1 6 as necessary ADJUSTMENTS If it is necessary to service the barrier with the arm in the vertical position engage a safety chain to prevent the arm from falling In addition it is recommended and good safety practice to use use an additional means to support the raised barrier arm This additional mean...

Page 23: ...electrical power to the barrier 3 Locate the flow control valve C Loosen the allen head set screw on the adjusting knob 4 Set adjusting knob D as follows To decrease the lowering speed adjust knob clockwise To increase the lowering speed adjust knob counterclockwise 5 Once ideal down speed flow control setting is achieved lock the adjustment in place by tightening the hex set screw on the adjustme...

Page 24: ...fore performing the detailed troubleshooting procedures check the following items first TROUBLESHOOTING If it is necessary to service the barrier with the arm in the vertical position engage a safety chain to prevent the arm from falling In addition it is recommended and good safety practice to use use an additional means to support the raised barrier arm This additional means may include but is n...

Page 25: ...rter 5 Line side and load side voltages should be approximately the same Replace starter if voltage values are considerably different from one another Check all wiring to motor for high resistance or no connection Three phase units only Barrier does not raise or lower Motor runs in reverse Phase reversed Reverse any two legs at the branch circuit disconnect Single phase units only Barrier does not...

Page 26: ...eakage Operate unit Replace valve if problem persists after all other troubleshooting procedures Barrier will not lower Faulty spool valve Remove coil from cartridge valve and cartridge valve from valve block Check valve for contaminants and or damage Replace valve if damaged Carefully wipe valve with clean rag do not damage O rings on valve NOTE Do not over tighten coil on valve Max torque is 10 ...

Page 27: ... or valve s Replace damaged hose s Check and remove blockage from hose s and or valve s Barrier bounces while lowering Down speed control valve page 21 set too fast Adjust valve see page 21 for adjustment instructions Amber light does not turn on Blown bulb Replace Amber light does not turn off when arm stores vertically Upper limit switch not operating Adjust or replace switch Amber light does no...

Page 28: ...26 4111 0068 Oct 2018 2018 Systems LLC PARTS Barrier Arm Receiver A DIVISION OF SYSTEMS INC GERMANTOWN WI 53022 S Y S L o a d i 6 5 4 3 7 8 9 ...

Page 29: ...005 Receiver Weldment Assembly Includes 4 9 4 1 9951 0005 Rubber Bumper 2 1 2 Dia x 1 5 1 2101 0089 Hex Head Cap Screw 3 8 16 UNC x 2 6 1 2101 0060 Washer Flat Zinc Plated 3 8 Dia 7 1 2101 0132 Washer Fender 1 2 Dia 8 1 2101 0079 Washer Flat Zinc Plated 1 2 Dia 9 1 2101 0040 Nylon Lock Nut 3 8 16 UNC x 2 Provide barrier arm serial number voltage phase and options when e mailing calling or faxing o...

Page 30: ...28 4111 0068 Oct 2018 2018 Systems LLC PARTS Base Assembly 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 ...

Page 31: ...2 2101 0059 Washer Flat 1 4 21 1 0615 0024 Limit Switch Assembly Upper 22 4 2101 0150 Round Head Machine Screw 10 24 UNC x 2 23 4 2101 0151 Nut Nylon Lock 10 24 UNC 24 1 0615 0025 Limit Switch Assembly Lower 26 1 4305 0180 Cable Assembly Wiring Harness 27 1 9442 0026 Pin 1 3 16 x 14 28 1 2101 0026 Pan Head Machine Screw Self Tap 8 32 UNC x 1 29 1 9411 0001 Access Cover Pin 30 1 9441 0002 Access Co...

Page 32: ...30 4111 0068 Oct 2018 2018 Systems LLC PARTS Powerpack Assembly 5 2 4 8 LOCATION FOR CONDUIT ASSY ITEM 6 NOT SHOWN A B K G H N P M E D C F J L Q ...

Page 33: ... 230V 3411 0019 Motor 3 Phase 208 230 460V F 1 9301 0007 Fitting Elbow 90 Deg Street 3 8 NPTM x 3 8 NPTF G 1 9301 0109 Fitting Con Str Thrd 6 ORB 6 JIC H 1 9301 0114 Fitting Elbow 90 Deg Str Thread 8 ORB 6 JIC J 1 9301 0116 Fitting Elbow 90 Deg Str Thread 8 ORB 8 JIC K 1 9301 0121 Filter Inline SAE 6 L 1 9301 0123 Fitting Conn Str Thread Swivel 6 ORB 6 JICF SW M 1 9301 0199 Breather Cap w Dipstick...

Page 34: ...Name 1751 1018 Rev A CRUSH HAZARD DO NOT DO NOT REMOVE extend hydraulic cylinder by a means other than hydraulic power hydraulic cylinder until you refer to owner s user s manual for proper maintenance procedures Failure to comply will result in death or serious injury 1751 1018 Rev A 7 ...

Page 35: ...Barrier Includes 1 6 1 1 0521 0017 Fitting Elbow 90 Deg Male 3 8 NPT x 8 JIC 2 1 0521 0032 Fitting Conn Swivel 3 8 NPT x 8 JIC Swivel 3 1 0521 0044 Fitting Elbow 90 Deg Male 3 8 NPT x 6 JIC 4 1 0525 0065 Cylinder Subassembly 5 1 8581 0012 Valve Flow Control Fine Adjust 6 1 9301 0143 Fitting Conn Male 3 8 NPT x 6 JIC 7 1 1751 1018 Decal Cylinder ...

Page 36: ...34 4111 0068 Oct 2018 2018 Systems LLC PARTS Valve Assembly ...

Page 37: ... Barrier Includes 1 7 1 1 8581 0011 Cartridge Valve 4 Way 2 1 8581 0081 Valve Cart Check Pilot Operated 3 1 8581 0107 Valve Cart Relief 4 1 8582 0052 Manifold Hydraulic Valve B2 5 2 9301 0113 Fitting Elbow 90 Deg Str Thread 6 ORB 6 JIC 6 6 9571 0007 Fitting Plug 1 8 NPTM 7 2 9904 0080 Hyd Hose 1 4 100R17 25 00 LG 6 SAE ORB 6 JICF Swivel ...

Page 38: ...36 4111 0068 Oct 2018 2018 Systems LLC PARTS Solenoid Coil Harness A B Item Quantity Part Number Description A 1 8581 0004 Coil Delta B 1 4305 0235 Cable Assembly 1 Coil 48 Long ...

Page 39: ...ntify the item ordered Do not use item numbers These are only for locating the position of the parts Always give MODEL NUMBER and or 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 Dock Leveler Information Model ___________________________________ Serial No ________________________________ Systems ...

Page 40: ... 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 by SYSTEMS LLC covered by this warranty SYSTEMS LLC shall remedy such defect by repairing or replacing any defective equipment or parts bearing the cost for the parts labor and transportation This sh...

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