SYSTEMS Poweramp PowerHold, Owner & User Manual

Page 1: ...ion 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 2019 Systems LLC All Rights Reserved Manual No 4111 0016 Aug 2019 Owner s User s Manual ...

Page 2: ...bly 47 Signs 48 Miscellaneous Customer Information 49 Warranty Back Cover 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 12 Concrete Dock Face 13 Driveway Mount 14 Cantilev...

Page 3: ...erious 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 death or severe injury The use of the word WARNING signifies the presence of a serious hazard or unsafe practice which could result in death or serious injury The use of the word CAUTION signifies possible hazar...

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 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 service and mai...

Page 5: ...t 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 PRECAUTIONS ...

Page 6: ...k 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 malfunctioning dock l...

Page 7: ...tion to restraint If equipped with a light communication system load and unload on GREEN light only 4 Maintenance or service must be performed by authorized personnel only Follow approved lockout tagout procedures FAILURE TO FOLLOW THESE INSTRUCTIONS WILL RESULT IN DEATH OR OTHER SERIOUS INJURY VEHICLE RESTRAINTS ENGAGE RESTRAINT 1 Open overhead door and visually check that transport vehicle is po...

Page 8: ...y 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 applicable provisions of the MH30 3 standard and shall also satisfy all safety recommendations of the original equipment manufacturer of the particular application 6 An operator training program should cons...

Page 9: ...nspection 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 performed in conformance with the following practices A planned maintenance schedule program must be followed only trained and authorized personnel shall be permitted to maintain repair adjust and i...

Page 10: ... firmly anchored to the drive way approach or the building wall for maximum holding power The PowerHold restraint is designed to withstand a pulling force of 30 000 lbs The PowerHold vehicle restraint comes equipped with an electrical control panel which allows push button operation of the vehicle restraint functions When combining a Poweramp Dock Leveler with a PowerHold vehicle restraint the con...

Page 11: ...G R E E N O N L Y A PowerHold Assembly B Control Box C Outside Light Assembly D Outside Signs Figure 4 Component Identification Inspect package and all components Report any missing or damaged items immediately and note on the shipping Bill Of Lading BOL Appearance may vary depending on options INTRODUCTION A B C D ...

Page 12: ...ng A Solenoid Coil Harness B Solenoid Coil C Diverter Valve D Pressure to Logic Block E Pressure to Restraint F Return from Restraint G Return to Logic Block H Pressure from Pump I Return to Pump C G F E I H A D B On combination units single Powerpack operating both leveler and restraint fluid directs to leveler until coil B is energized then diverter valve C directs fluid to restraint See Figure ...

Page 13: ...11 4111 0016 Aug 2019 2019 Systems LLC INTRODUCTION This page intentionally left blank ...

Page 14: ...d 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 keep a fire extinguisher of the proper type nearby when grinding or welding Only trained installation professionals with the proper equipment should install this product Always post safety warnings and barricade...

Page 15: ... Figure 8 Install anchors BILL OF MATERIAL DESCRIPTION PART NO QTY ITEM 20 X DECK PLATE 7952 0147 1 1 1 4 X CONCRETE ANCHOR 7952 0009 12 2 TOLERANCES UNLESS OTHERWISE NOTED FRACTIONAL 1 32 DECIMAL 00 01 000 005 ANGULAR 1 MATERIAL DRAWN BY CHECK DRAW Steel A36 JAH IMBED WLDT L o a d i n g D o This print is the property of Systems Inc and repre patent and other rights including exclusive rights of n...

Page 16: ...minimum BILL OF MATERIAL SIZE DESCRIPTION PART NO QTY ITEM 1 2 X 16 X 27 BAR 7952 0215 1 1 3 8 X 2 1 2 X 16 BAR 7952 0216 2 2 1 7 8 OD X 1 1 8 ID TUBE LIP HINGE 9512 1146 4 3 TOLERANCES UNLESS OTHERWISE NOTED FRACTIONAL 1 32 DECIMAL 00 01 000 005 ANGULAR 1 MATERIAL DRAWN BY CHECKED BY DRAWING NO DA BDK 7953 0 IMBED WELDMENT POWERS P O L o a d i n g D o c k E q u i p DRIVEWAY MOUNTE 2 1 2 1 1 4 4 4...

Page 17: ...per size plus any cantilever and subtract 4 See table and Figure 16 below Driveway Mount Determine offset then proceed with Driveway Mount instructions on page 14 Wall Mount For filler requirements determine offset and order a cantilever bracket as shown on page 46 then anchor cantilever bracket to dock face with six 6 wedge anchors 3 4 x 5 14 min or weld to the embed mounting plate with ten 10 4 ...

Page 18: ...ere it will not interfere with the leveler in below dock conditions 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 Note Figure 19 is provided as an example only specific routing may differ depending on leveler configuration Figure 19 A ...

Page 19: ...uit electrical chase during pit construction Note Figure 20 is provided as an example only specific routing may differ depending on leveler configuration TOLERANCES UNLESS OTHERWISE NOT FRACTIONAL 1 32 DECIMAL 00 01 000 005 ANGULAR 1 DRAWN BY BDK S L o a d i n This print is the property of Systems LLC and r of use and or manufacture and or sale Posses such permission to be granted only by written ...

Page 20: ...nect Panel B Control Panel provided by others C Distance 48 in 1219 mm Figure 21 INSTALLATION Install Control Panel and Wiring DO NOT connect the dock leveler electrical wiring and ground connections until all welding has been completed DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler Always ground welding equipment to the dock leveler frame NEVER to th...

Page 21: ...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 LLC and represents a proprietary article in which Systems LLC retains any and all patent and other rights including exclusive rights of use and or manufacture and or sale Possession of this print does not convey any permission to reproduce print or manufacture the article or articles shown the...

Page 22: ... 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 mount placard on wall to the immediate left of leveler at eye level A B C D A Control Box B Placard C Nylon Cable Tie D Conduit Placard Installation Instructions Control Box Conduit Nylon Tie Placard Owner Users a...

Page 23: ...21 4111 0016 Aug 2019 2019 Systems LLC INSTALLATION This page intentionally left blank ...

Page 24: ... when the shoe is standing vertically contacting the front edge of the horizontal member of the RIG without obstruction Stay clear of dock leveler and vehicle restraint when transport vehicle is entering or leaving dock area DO NOT move or use the dock leveler or restraint if anyone is under or in front of leveler Keep hands and feet clear of pinch points Avoid putting any part of your body near m...

Page 25: ...he RELEASE button once or through menu screens under OPERATION MODE Inside light RED Outside light GREEN 6 Release the transport vehicle wheels when transport vehicle is ready to depart Operation Bypass From Unsuccessful Engage If the restraint fails to successfully ENGAGE a trailer RIG in will automatically return to the stored position Inside light AMBER RED Outside light RED Bypass mode can the...

Page 26: ...on 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 Amber Display Backlight Red Reset Attempted Door Open Green Amber Display Backlight Red Reset Lights to Normal Mode Red Display Backlight 5 seconds Green Bypass Mode Condition Lights Inside Outside Main Menu Acti...

Page 27: ...t inform that repairs are in process and clearly state who is responsible for the lockout condition B A B A C D Figure 24 Figure 25 Figure 26 MAINTENANCE Refer to OSHA regulations 1910 146 Confined Space and 1910 147 Lockout Tagout Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the unit before maintenance is complete Unless the...

Page 28: ... 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 LLC and represents a proprietary article in which Systems LLC retains any and all patent and other rights including exclusive rights of use and or manufacture and or sale Possession of this print does not convey any permission to reproduce print or manufacture the article or articles sh...

Page 29: ...al conditions may require this more frequently See page 20 for list of approved fluids Check reservoir fluid level E See Figure 28 for Self Contanined SC units or Figure 29 for Remote Mount units 1 Turn OFF all electrical power to the restraint 2 Remove cover plate SC models 3 Remove breather cap F 4 Measure fluid level E The fluid level should be approximately 1 2 in 25 51 mm from top of reservoi...

Page 30: ...be worn when working under or around a dock leveler Always stand clear of platform lip when working in front of the dock leveler NOTE Unit can only be dry cycled without trailer present at dock 1 Make sure BYPASS mode has not been activated Inside light RED Outside light GREEN 2 Momentarily press the ENGAGE button 3 The restraint will raise to 90 degrees time out when it fails to detect a RIG bar ...

Page 31: ...or removed See Figure 30 for reference 1 Adjust Raised Prox Switch With the Z bar rotated directly over the prox switch The prox switch distance should between 1 16 and 1 8 2 Adjust Engaged Prox Switch The prox switch must be backed off 1 2 turn from flush with the latch block thread in until flush with the latch block and then turn prox switch out CCW 1 2 turn until switch is no longer flush with...

Page 32: ...the dock leveler so that the restraint cannot be operated until the leveler is stored in the cross traffic position lip fully folded inside the keepers and the platform level with the dock floor Interlocking is overridden when the OPERATION MODE is in BYPASS This allows the independent operation of the leveler the restraint cannot be operated in BYPASS MODE Pressing the restraint RELEASE button wh...

Page 33: ... 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 transport vehicle See Figure 31 Note If adjustments are required in this step make sure that the interlocking described in Step 3 is still in effect after Step 6 adjustments are complete 7 Press the RAISE button The dock leveler will raise Th...

Page 34: ... unauthorized use of the vehicle restraint before maintenance is complete Note See Figure 32 for visual identification 1 Lock out tag out leveler and barricade work area 2 Remove front cover plate 4 screws 3 Remove bolt and washer holding cylinder in place 4 Install rod through front opening Rod will fit into indentation in the slide block 5 Hammer rod 4 to 5 hits until the slide block travels pas...

Page 35: ...d OPEN Use meter to check for contact closure when output ON TROUBLESHOOTING When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance 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 i...

Page 36: ... branch circuit disconnect Single Phase Units Only Restraint does not operate Motor energizes but does not run Line voltage too low Check wiring to motor for high resistance Check for loose or corroded connections Check if gauge of wires to motor are of correct size and specification for load requirement Replace if necessary Faulty motor centrifugal switch Replace motor Faulty motor capacitor Repl...

Page 37: ...r all other troubleshooting procedures performed Solenoid energized Locate solenoid see page 40 Coil should not be energized when Powerhold is in engage mode Relay or controller contact has stuck contacts Test coil for magnetism Coil must be de energized to release the transport vehicle Combination Units Only Restraint does not raise but leveler raises Solenoid not energized Locate solenoid see pa...

Page 38: ... ring and prevent leakage Operate unit Replace valve if problem persists after all other troubleshooting procedures Combination Units Only Restraint will not lower but leveler raises Solenoid not energized Locate solenoid see page 40 Coil must be energized when Powerhold is in disengage mode Check valve for magnetism at the coil Faulty spool valve Remove coil from cartridge valve and cartridge val...

Page 39: ...ctivation of raised prox switch The shoe will rotate as the hydraulic cylinder extends and the slide block on the cylinder pushes a rod to make contact with the Z bar The Z bar will pass over the raised prox switch Check for frozen or rusted push rod bent or damaged Z bar or faulty prox switch adjustments Replace any parts if faulty Faulty activation of engaged prox switch The restraint shoe must ...

Page 40: ...38 4111 0016 Aug 2019 2019 Systems LLC PowerHold Assembly D A C K G H B F Q T S W Q I N J L M O P Y U V E R X PARTS ...

Page 41: ... 6 Jic Swivel Both Ends L 1 9412 0095 Push Rod M 1 2101 0045 Cotter Pin 1 8 x 1 00 N 2 9412 0063 Removable Track Stop O 4 2101 0009 Bolt 5 16 18 P 1 9411 0056 Access Cover Top Q 6 2101 0099 Screw 1 4 20 UNC x 3 8 R 1 9411 0060 Cover Front S 1 9411 0058 Weather Seal Hold Down T 1 0192 0016 Weather Seal Ratchet U 1 2753 0001 J Box Cover and Gasket SC standard includes screws 2753 0002 J Box Cover an...

Page 42: ...RSED ITEMS 1 2 UPDATED SCHEMATIC NOTE DESCRIPTION 1 TO ROD END PHOLD CYL 2 RETURN TO TANK 3 TO BLIND END OF PHOLD CYL 4 PRESSURE FROM PUMP BILL OF MATERIAL SIZE DESCRIPTION PART NO QTY ITEM DELTA DE RVA 00 1500 VALVE CART RELIEF DIR ACTING 8581 0089 1 1 DELTA DG S4D 00 CARRIAGE VALVE 4 WAY 8581 0149 1 2 HYDRAULIC VALVE MANIFOLD PHOLD S C 8582 0035 1 3 3 16 DIA X 3 4 SPRING PIN 9301 0022 1 4 4 ORB ...

Page 43: ...Thread 6 ORB x 8 JIC E 1 9301 0116 Fitting Elbow 90 Deg STR Thread 8 ORB x 8 JIC G 1 8581 0004 Coil Delta H 1 4301 0001 Cable Assembly 48 Lg PowerHold and Leveler Combination Valve Block Provide vehicle restraint serial number when e mailing calling or faxing orders PARTS H B G D 1 2 D 3 E 4 C 5 C 6 On combination units single Powerpack operating both leveler and restraint fluid directs to leveler...

Page 44: ...ch C 1 0941 0008 Spring D 1 0941 0009 Spring E 1 2101 0012 Bolt 5 16 18 UNC F 1 2101 0058 Nut Hex 5 16 18 UNC G 1 9414 0081 Latch Assembly Complete With Prox Switches Provide vehicle restraint serial number when e mailing calling or faxing orders PARTS Engaged Prox Switch DC Input 2 A Raised Prox Switch DC Input 3 A Stored Prox Switch DC Input 1 B G D E F C ...

Page 45: ...er Powerpack C 1 9301 0121 Inline Filter SAE 6 D 2 9904 0051 Hose 16 00 LG 3 8 NPTM 6 JIC Swivel Female F 4 2101 0009 Hex Head Cap Screw Grade 2 5 16 18 UNC x 3 4 G 3 2101 0153 Hex Head Cap Screw Zinc Plated 1 4 20 UNC x 1 2 H 1 3411 0049 Motor SC 8 2012 present 6 8FLA B A D F C Pressure Return G H Provide vehicle restraint serial number when e mailing calling or faxing orders Contact Tech Service...

Page 46: ...t Remote mount powerpack pressure is factory set PARTS Remote Mount Powerpack Assembly TOL UNLESS O FRACTIONA DECIMAL 00 0 000 ANGULAR DRAWN B L This print is the pro of use and or manu such permission to MATERIA Vent Pressure Return W B C D E F G H L K M N J P Q R T U V X Y S Z AA AC AD A AB ...

Page 47: ... 9303 0002 Coupling Assembly H 1 9302 ____ 1 Plate Drive J 1 9904 0071 Hose 1 2 100R1 x 17 8 ORB x 8 JICF Swivel K 1 0521 0017 90 Elbow 3 8 NPT Male x 8 JIC Male L 1 0521 0007 90 Elbow 1 4 NPT Male x 1 4 Tube M 1 3411 ____ 2 Motor Only N 1 9301 0012 Straight Fitting 8 ORB Male x 8 JIC Male P 1 0521 0014 Ball Check Q 1 9301 0024 Guide Check Ball R 1 9302 0009 Spring Relief Valve S 1 9303 0003 Screw...

Page 48: ...IT P STOP P HOLD FILLER 2103 0002 DRAWN BY CHECKED BY DATE MJH 3 30 2018 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 MATERIAL STOCK NO FILLER KIT POWERHOLD HOLDTITE FORMED ZINC PLATED 1 2 18 055 3 30 2018 RELEASED Item Part Number Description 1 9416 0003 Filler Kit Hold Restraint Formed Zinc Plated 2 14 projection Filler Kits Must specify required filler projection ...

Page 49: ...plete 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 Circuit Assembly 12v 4 1 3051 0068 Mounting Gasket 5 4 3051 0105 Clip Lens Holding 6 4 3051 0104 Screw Lens Holding 7 1 Conduit Fastener 3 4 x 3 8 Provide vehicle restraint serial number when e mailing ca...

Page 50: ...OUT ON GREEN ONLY Germantown 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 1751 0034 Outside Sign Pull In Out Mirror Image A B ...

Page 51: ...m 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 LLC Job No __...

Page 52: ...ion This shall be exclusive remedy for all claims whether based on contract negligence or strict liability WARRANTY LIMITATIONS THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SYSTEMS LLC AND ITS SUBSIDIARIES SHALL NOT IN ANY EVENT BE LIABLE TO ANYONE INCLU...