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Poweramp Bar Lift Owner & User Manual

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Bar Lift
Safety Barrier
Owner's/User's Manual
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
Printed in U.S.A.
Manual No. 4111-0068
© 2018 Systems, LLC - All Rights Reserved
Oct. 2018

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  • Page 1 Bar Lift Safety Barrier Owner’s/User’s Manual 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 Printed in U.S.A. Manual No. 4111-0068 © 2018 Systems, LLC - All Rights Reserved...

  • Page 2: Table Of Contents

    Table of Contents Page Precautions Recognize Precautionary Information ..........1 General Operational Precautions ............1 Operational Precautions ..............2 Safety Decals ..................4 Placard ....................5 Owner’s/User’s Responsibilities............6 Introduction General Information ................8 Component Identification ..............9 Installation Installation Precautions ..............10 Installation ....................

  • Page 3: Precautions

    PRECAUTIONS Recognize Precautionary Information General Operational Precautions Safety-Alert Symbol The Safety-Alert Symbol is a graphic representation intended to convey a safety message without the Read and understand the Owner’s/User’s Manual and use of words. When you see this symbol, be alert become thoroughly familiar with the equipment and its to the possibility of death or serious injury.

  • Page 4: Operational Precautions

    PRECAUTIONS Operational Precautions Learn the safe way to operate this equipment. Read and understand the manufacturer’s instructions. If you have any questions, ask your supervisor. Stay clear of dock leveling device when transport Chock/restrain all transport vehicles. Never vehicle is entering or leaving area. remove the wheel chocks or release the restraining device until loading or unloading is finished, and transport driver has been given...
  • Page 5 PRECAUTIONS Operational Precautions 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: Safety Decals

    PRECAUTIONS Safety Decals PINCH POINT KEEP CLEAR 1751-0140 Rev B 1751-0140 Decal Size: 3 x 1 File Name: 1751-0140 Rev B 4111-0068 — Oct. 2018 © 2018 Systems, LLC...

  • Page 7: Placard

    PRECAUTIONS Safety Decals 1.50" DO NOT 2.43" PROUDLY MADE FORK THIS SIDE SYSTEMS, INC. GERMANTOWN, WI MALVERN, AR 1751-0329 Rev A 1751-0735 DO NOT Control Box Size: FORK THIS SIDE File Name: 1751-0329 Rev A Decal Size: 2.75 x 1.25 Decal Size: 13 x 2 File Name: 1751-0735 Arc Flash and...

  • Page 8: Owner's/User's Responsibilities

    OWNER’S/USER’S RESPONSIBILITIES 1) The manufacturer shall provide to the initial the owner’s/user’s company policies, operating purchaser and make the following information conditions and the manufacturer’s specific readily available to the owners/users and their instructions provided with the dock leveling agents, all necessary information regarding device.
  • Page 9 OWNER’S/USER’S RESPONSIBILITIES 7) Loading dock safety equipment should never instructions, labels, decals and placards or be used outside of its vertical working range, or their equivalent. Written documentation of outside the manufacturer’s rated capacity. It shall maintenance, replacement parts or damage also be compatible with the loading equipment should be kept.

  • Page 10: Introduction

    This storing handrail for foot traffic at the dock. manual describes these changes where applicable. Each Bar Lift Barrier unit and control panel has been The Poweramp Bar Lift Barrier adds enhanced safety factory pre-wired and tested to ensure satisfactory to any loading dock by preventing forklift trucks from operation.

  • Page 11: Component Identification

    INTRODUCTION Component Identification Inspect package and all components. Report any missing or damaged items immediately and note on the shipping Bill Of Lading (BOL). Figure 4 A — Base Assembly D — Control Box* B — Barrier Arm E — Rear Sheet Metal Cover C —...

  • Page 12: Installation

    INSTALLATION Installation Precautions If it is necessary to service the barrier with the arm DO NOT connect the barrier electrical wiring and in the vertical position, engage a safety chain to ground connections until all welding has been prevent the arm from falling. completed.

  • Page 13: Installation

    6. Position the base assembly (D) as needed and 2. In order to determine Bar Lift Barrier mounting install six (6) 5/8” x 5” min. concrete anchors. location, position the barrier so that it is centered in door opening and at least 14”...

  • Page 14: Install Control Panel And Wiring

    INSTALLATION Install Control Panel and Wiring Where indicated, all components must be connected Make sure that the power source has been locked to a SAFETY EARTH GROUND that conforms to out and tagged according to OSHA regulations and the 1999 National Electrical Code Section 250-50 approved local electrical codes.

  • Page 15: Put New Barrier Into Service

    INSTALLATION Put New Barrier Into Service Figure 8 Figure 9 A — Lift Cylinder D — Spacer B — Barrier Arm E — Rue Clip C — Cylinder Pin F — Pivot Pin Grease Fitting 1. Remove pipe plug from filler port on hydraulic fluid 7.

  • Page 16: Operation

    OPERATION 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 body near moving parts.

  • Page 17: Operating Instructions

    OPERATION Operating Instructions L o a d i n g Figure 10 MATERIAL DRAWN BY Raising Barrier Lowering Barrier TOLERANCES (UNLESS OTHERWISE NOTED) FRACTIONAL:  1/32" DECIMAL: .00 =  .01" .000 =  .005" ANGULAR:   1. Visually check path of barrier travel (Figure 10) to 1.

  • Page 18: Maintenance

    MAINTENANCE Maintenance Precautions Figure 11 A— Tag Out Device B —Lock Out Device When working with electrical or electronic controls, make sure that the power source has been tagged (A) and locked out (B) according to OSHA regulations * If it is necessary to service the barrier with the arm and approved local electrical codes (see Figure 11).
  • Page 19 MAINTENANCE This page intentionally left blank. 4111-0068 — Oct. 2018 © 2018 Systems, LLC...

  • Page 20: Periodic Maintenance

    MAINTENANCE Periodic Maintenance Figure 12 A — Rear Service Panel D — Fluid Reservoir B — Cylinder Pin E — Breather Cap C — Pivot Pin Grease Fitting To ensure normal operation of the barrier, use only Weekly Maintenance aircraft hydraulic fluid designed to meet or exceed military specification MIL-H-5606-G.
  • Page 21 MAINTENANCE Quarterly Maintenance (continued) • Remove rear service panel (A) and lubricate the hydraulic cylinder pins (B) with light weight machine oil (see Figure 12): • Lubricate the grease zerk inside the barrier arm (C) white lithium grease (see Figure 12). Failure to properly lubricate the barrier will cause abnormal operation of the barrier.

  • Page 22: Adjustments

    ADJUSTMENTS Adjust Main Pressure Relief 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.

  • Page 23: Adjust Flow Control

    ADJUSTMENTS Adjust Flow Control Flow Control Adjustment Note: The down speed flow control is factory set. If original setting is lost, or if the barrier bounces while lowering, the flow control will require adjustment. When properly adjusted, the barrier arm will smoothly lower from fully raised to fully lowered in 10-12 seconds, without bouncing.

  • Page 24: Troubleshooting

    TROUBLESHOOTING If it is necessary to service the barrier with the arm When service is required, always lock all electrical in the vertical position, engage a safety chain to disconnects in the OFF position. prevent the arm from falling. Always post safety warnings and barricade the In addition, it is recommended and good safety work area at dock level and ground level to practice to use use an additional means to support...
  • Page 25 TROUBLESHOOTING Symptom Possible Cause Solution Check for blown fuses at branch circuit disconnect. Replace fuse. Determine cause of blown fuse. Check motor starter as follows: 1. Disconnect wires at load side of starter. 2. Energize the starter. No voltage is present on 3.
  • Page 26 TROUBLESHOOTING Symptom Possible Cause Solution Remove load. Unit is designed to raise no more than Load on barrier arm. its own weight Remove coil from cartridge valve and cartridge valve from valve block. -Check valve for contaminants and/or damage. -Replace valve if damaged. Barrier will not raise.
  • Page 27 TROUBLESHOOTING Symptom Possible Cause Solution Add fluid, see page 18 for proper fluid level and Low hydraulic fluid. type. Adjust pressure relief. NOTE: The pressure relief valve must not be set at a level that causes the motor operating current Pressure relief valve set too Barrier raises very to exceed the full load amp value* at any time,...

  • Page 28: Parts

    PARTS Barrier Arm & Receiver  A DIVISION OF SYSTEMS INC. GERMANTOWN, WI 53022 L o a d i 4111-0068 — Oct. 2018 © 2018 Systems, LLC...
  • Page 29 PARTS Barrier Arm & Receiver (continued) Item Quantity Part Number Description 2101-0108 Concrete Anchor, Rawl, 5/8 x 5 9445-____* Barrier Arm Assembly 9445-0005 Receiver Weldment Assembly (Includes 4-9) 9951-0005 Rubber Bumper, 2-1/2 Dia x 1 2101-0089 Hex Head Cap Screw, 3/8-16 UNC x 2 2101-0060 Washer, Flat, Zinc Plated, 3/8”...

  • Page 30: Base Assembly

    PARTS Base Assembly P O W E R A M P M C G U I R E D L M N C. L o a d i n g D o c k E q u i p m e n t 4111-0068 —...
  • Page 31 PARTS Base Assembly (continued) Item Quantity Part Number Description 9445-0006 Base Weldment 8583-0043 Valve Assembly 2101-0077 Hex Head Cap Screw, 5/16-18 UNC x 3 2101-0039 Nut, Nylon Lock, 5/16-18 UNC 0191-0018 Rubber Weatherseal See Page 30 Powerpack Assembly, Complete 2101-0029 Carriage Bolt, 5/16-18 UNC x 1 9904-0079 Hydraulic Hose, 1/4”100R1 x 28”, #6 JICF Swivel Both Ends...

  • Page 32: Powerpack Assembly

    PARTS Powerpack Assembly LOCATION FOR CONDUIT ASSY ITEM #6 (NOT SHOWN) 4111-0068 — Oct. 2018 © 2018 Systems, LLC...
  • Page 33 PARTS Powerpack Assembly (continued) Item Quantity Part Number Description 9395-0086* Powerpack Assembly, B2, 1-Phase (Includes A-Q)* 9395-0087* Powerpack Assembly, B2, 3-Phase (Includes A-Q)* 0521-0044 Fitting, Elbow, 90 Deg, 3/8NPTM, #6 JICM 2101-0039 Nylon Lock Nut, 5/16-18 UNC 2101-0077 Hex Head Cap Screw, 5/16-18 UNC 2101-0163 Washer, Flat, Zinc Plated, 5/16”...

  • Page 34: Cylinder Assembly

    PARTS Cylinder Assembly 4111-0068 — Oct. 2018 © 2018 Systems, LLC...
  • Page 35 PARTS Cylinder Assembly (continued) Item Quantity Part Number Description 0525-0075 Cylinder Assembly, B2 Barrier (Includes 1-6) 0521-0017 Fitting, Elbow, 90 Deg. Male, 3/8 NPT x #8 JIC 0521-0032 Fitting, Conn, Swivel, 3/8 NPT x #8 JIC Swivel 0521-0044 Fitting, Elbow, 90 Deg. Male, 3/8 NPT x #6 JIC 0525-0065 Cylinder Subassembly 8581-0012...

  • Page 36: Valve Assembly

    PARTS Valve Assembly 4111-0068 — Oct. 2018 © 2018 Systems, LLC...
  • Page 37 PARTS Valve Assembly (continued) Item Quantity Part Number Description 0525-0075 Valve Assembly, B2 Barrier (Includes 1-7) 8581-0011 Cartridge Valve - 4-Way 8581-0081 Valve, Cart, Check, Pilot Operated 8581-0107 Valve, Cart, Relief 8582-0052 Manifold, Hydraulic Valve, B2 9301-0113 Fitting, Elbow - 90 Deg, Str Thread, #6 ORB - #6 JIC 9571-0007 Fitting, Plug, 1/8 NPTM 9904-0080...

  • Page 38: Solenoid Coil & Harness

    PARTS Solenoid Coil & Harness Item Quantity Part Number Description 8581-0004 Coil, Delta 4305-0235 Cable Assembly, 1 Coil - 48” Long 4111-0068 — Oct. 2018 © 2018 Systems, LLC...

  • Page 39: Miscellaneous

    MISCELLANEOUS Customer Information Figure 17 Figure 16 NOTE: Refer to Figure 16 for left/right orientation of Dock Leveler Information barrier base and Figure 17 for example of decal. The BARRIER model/serial number decal is Model ___________________________________ located on the left side of the base assembly (A). Serial No.

  • Page 40: Warranty

    STANDARD PRODUCT WARRANTY SYSTEMS, LLC warrants that its products will be free from defects in design, materials and workmanship for a period of one (1) year from the date of shipment. All claims for breach of this warranty must be made within 30 days after the defect is or can with reasonable care, be detected.

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