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PowerHook® Owner`s/User Manual

1. gt Standard Length Standard length L 0 ON 1 O O O 0 Item Quantity Part Number Description 0521 0123 Powerhook Cylinder Onl B 1 7054 0001 Powerhook Arm Weldment 7054 0010 Powerhook Standard length Provide dock leveler and or PowerHook serial number when calling or faxing orders 4111 0010 July 2014 51 PARTS Bri A tom Quy Partnumber ese 7070707077 8 1 70540010 Cylinder Assembly PowerHook S 60 1 99040110 Hydraulic Hose Assembly 1 2 10081 20 00 8 JIC D 1 93010116 Fitting 90 Degree 8 ORBM 8 JICM 000000000 2 2101 0012 Hex Head Cap screw 5 1618 UNC 14 000000000 F 2 211008 Lack Washer Bng gt S O G 2 2101 0057 Hex Head Cap screw 5 16 18UNCx1 2 J 52 4111 0010 July 2014 NIN gt NO PARTS PowerHook Valve Body Assembly Pressure switch was used until July 2008 Pressure differential valve replaced the pressure switch located on the hook see pg 56 Pressure Switch Assemebly 0963 0002 Cartridge Valve 3 way 2 position 8581 0005 1 oo 1 Controls flow to from Powerhook dumps excess flow tank 8581 0089 39 Fring reta ine ump ine topump 21 cable Wire harness 48
2. FIG B Le A Maintenance Position Serial Tag SAFETY OWNER S USER S RESPONSIBILITIES The owner user should recognize the inherent dangers of the interface between the loading dock and the transportation 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 and operating conditions Maintaining updating and re training all operators on safe working habits and operation of the equipment regardless of previous experience should be done on a regular basis and should include an understanding and familiarity with all functions of the equipment Owner s user s shall actively maintain update and retrain all operators on safe working habits and operations of the equipment The manufacturer shall provide to the initial purchaser all necessary information regarding Safety Information Operation Installation and Safety Precautions Recommended Initial and Periodic Inspections Procedures Planned Maintenance Schedule Product Specifications Troubleshooting Guide Parts Break Down Warranty Information and Manufacturers Contact Information as well as tables to identify the grad
3. Keep a safe distance from both side edges 4111 0010 July 2014 wee otay clear of dock leveling device when freight carrier is entering or leaving area Do not move or use the dock leveling device if anyone is under or in front of it Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts SAFETY Do not use dock leveling device if freight carrier is too high or too low he y Ur 3 10 3 o 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 4111 0010 July 2014 ALWAYS disconnect electrical power source and ground wire before welding on dock leveler DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler Always ground to the dock leveler frame Failure to follow these instructions may result in damage to dock leveler and or serious personal injury or death DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded DO NOT grind or weld if un contained hydraulic 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 keep a fire extinguisher of the proper type
4. NOTE At least two people may be required to manually move the lip 5 After adjusting proximity switch and target slowly move the lip up by hand while observing the target and proximity switch The target MUST NOT contact the switch otherwise damage to switch will occur Readjust switch and or target if necessary then recheck for interference 34 OPTIONAL EQUIPMENT ADJUSTMENTS Full Below Dock Position Lip Fully Extended Position od R Lip Keeper Whenever the platform lip is at the fully extended Whenever the platform lip is at the full below dock position the following conditions will exist for a position the following conditions will exist for a normally operating ARTD normally operating ARTD e Target not in the sensing area of proximity switch e Proximity switch senses target e Proximity switch OFF open no signal sent to the e Proximity switch ON closed signal sent to the control panel control panel Proximity switch indicator light is OFF e Proximity switch indicator light is ON e f the platform lip is resting on the vehicle bed Platform will automatically rise after approximately a the platform will stay at this position unless the six second delay then returns to the cross traffic operator activates the leveler position 4111 0010 July 2014 35 TROUBLESHOOTING POWERHOOK Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenan
5. Supplied by Systems Inc attached to KS5 pan Existing plate s must be removed since it is partially located in the concrete that is to be removed for the pan Existing plate s can be reused if the integrity of the plate has not been altered during its removal and if all the old concrete is chipped away from the anchors A new plate s is supplied by others or is available from Systems Inc at extra cost Existing plate s must be removed since it is located in the area of the concrete that is to be removed for the pan A new plate s is supplied by Systems Inc Attached to pan Dispose of old existing plate Existing plate s does not have to be removed since it is not in the area of the concrete that is to be removed for the pan Existing plate s to be reused Installation Instructions for KS5 when dock leveler is Additional instructions for KS5 when dock leveler is power by a Centrapower powered by a remote power pack 1 Drain power pack 1 Following step 1 4 of normal retrofit instructions page 13 2 Disconnect and label hydraulic hoses that are A Disconnect and label the hydraulic hoses attached to the logic block The logic block is attached to the Centrapower Hydraulic valve attached to the underside of the dock leveler assembly platform B Cap off all open fittings to prevent contamination A Cap off all open fittings to prevent contamination 2 Step 21 Reinstall leveler B Tie off hoses to preven
6. 5 wire 5000 43050094 22 Cable individual not shown Individual wire 48 connects to single delta coil 4111 0010 July 2014 93 Cartridge valve 3 way 2 position D P C H H Elbow 45 Fitting H Fluid to positioning cylinder 9301 0120 C N H PARTS Remote Power Pack Assembly Vent Tube Pressure Line Return Line 54 4111 0010 July 2014 PARTS Power Pack Assembly em Quantity Part Number pann 777777777 8 2 9301 0029 Seal Thread gt 0 1 9301 0199 Breather Cap 3 8 NPT Male 0000000000 Pump Only G Cap Screw 5 16 18 UNC x 3 1 2 in Grade 5 Gasket Pump Coupling Assembly 9302 0017 Plate Drive S 9395 1 Provide dock leveler serial number and type of installation when calling or faxing orders Provide dock leveler serial number voltage and phase when calling or faxing orders 4111 0010 July 2014 99 PARTS Pressure Differential Valve and Block Decal on this side To front hook cylinder After July 2008 the Pressure Differential Valve takes the place of the Pressures Switch The Pressure Differential Valve tells the PLC to stop retracking when the Powerhook makes contact with the ICC bar item Quantity Part Number Desin 00000077 Cable Assembly 48 B 1 8581 0135 Pressure Differential Switch Regeneration valve D 3 9301 0116 Fitting Elbow 90 Deg 8 O Ring To amp 8Jic
7. Modify the underside of the dock leveler platform as indicated on the Dock Leveler Modification Drawing s attached to this manual Remove hydraulic fluid To do so locate the return port at the drive plate for the hydraulic pump Set a catch vessel below the port Remove the hose at the return port and allow the hydraulic fluid to drain from the reservoir When the reservoir is empty reinstall the hose Dispose of the fluid properly KS5 INSTALLATION These installation instructions were written for retrofitting a Powerampe hydraulic dock leveler with integral power pack with a PowerHooke KS5 Vehicle Restraint you are not adding the PowerHooke to an existing dock leveler some steps may not be needed or additional procedures may be required as follows When installing in new construction i e new PowerHook and new Poweramp hydraulic leveler in a newly prepared pit skip steps 1 through 6 Platform modifications step 6 were completed prior to shipment When installing PowerHook with a Poweramp hydraulic dock leveler which is powered by remote power pack or a CentraPowere system refer to the manuals provide with those units as well as to page 15 in this manual When installing Powerhook with a mechanical dock leveler or a hydraulic dock leveler manufactured by another company the PowerHook must be equipped with a remote hydraulic power pack See page 53 of this manual Review the Field Wiring Dr
8. 0 120 V EACH INCANDESCENT STANDARD 0 21 V EACH LED OPTIONAL 115 0 0 025 A 0 115 V 005 05A0120V HYDRAULIC FLUID Wi OPTIONAL POWERAMP MCGUIRE DLM quipmen oading Doc LADDER DIAG RAM FF KSS OPTIONAL PLC2 AUDIBLE ALARM amp OR DRY CONTROL CIRCUIT amp OR OVERHEAD DOOR CLOSED CONTACT 55 8 B amp 407 410 SOL D DIRECTS FLUID TO RAISE RESTRAINT WHEN DE ENERGIZED RESTRAINT WHEN ENERGIZED 115 V 1 PHASE 60 HZ 411 LTS OK TO BACK IN OR PULL AWAY LTS NOT OK TO 412 IN OR PULL AWAY LTS de LT7 ENERGIZES IF TRUCK ATTEMPTS TO PULL AWAY WHILE RESTRAINT ENGAGED AT ICC BAR 100 101 102 Mi ENERGIZES HYDRAULIC PUMP MOTOR SOL C DIRECTS FLUID TO EXTEND RESTRAINT WHEN DE ENERGIZED RETRACT RESTRAINT WHEN ENERGIZED e Nw 510 CHECK THOSE OPTIONS THAT APPL X LANYARD K ue out STOP DX LS INTERLOCKING X HYDRAULIC FLUID WARMER U DX RE INTERLOCKING X DRY CONTROL CIRCUIT 400 DX AUTO RETURN X DOOR CLOSED CONTACT S E STOP XJ DRY INTERLOCKED CONTROL CIRCUIT Sup our S STROBE LIGHT X AUDIBLE ALARM x DRY INTERLOCKED PUSHBUTTON CONTROL CIRCUIT A DRAWNG SHOWS SYSTEM AT REST WTH POWER OFF amp OVERHEAD DOOR NOT FULLY RAISED B C REPRESENTS A TERMINAL BLOCK C DOOR OPEN CONTACT UNE 218 BY OTHERS DOOR OPEN CONTACT MAY BE PROVIDED BY POWERAMP IF SPECIFIED DOOR OPEN CONTACT TO PREVENT OPERATION OF LEVELER UNTIL
9. 18 19 20 21 22 23 24 e 26 INSTALLATION Y 2 ES SES LPS K IDS L 21555 B Shipping Bands A Lifting Bracket 2 used 10 This set up is only required if the dock leveler is a CLEAN PITO model A Burn or grind off welds where the maintenance prop and hoist cylinder trunnion box are welded to any steel imbedded in the pit B Refer to the CLEAN PIT Installation Instruction in the dock leveler owner s user s manual The center angle and the front angle which were removed during the original installation are to be reinstalled NOTE If the angles are supplied by Systems Inc the angles are shipped with the vehicle restraint pan unit Set the leveler platform in the cross traffic position the lip fully folded inside the lip keepers and the platform level with the dock floor Place a shipping band through the lip hinge and around the front frame angle of the leveler Secure the banding The banding is to secure the frame angle to the platform when the leveler is removed from the pit Burn or grind all welds where the top rear frame angle of the dock leveler is welded to the rear pit curb angle Hemove Dock leveler from the pit using the lifting brackets 11 12 13 14 14 INSTALLATION Existing Dock Leveler Hoist Cylinder Trunnion Plates Length CLEAN PIT Model 6 10 or 12 Foot Supplied by others available from Systems Inc at extra costs
10. Safety Information Safety Alert Symbol The Safety Alert Symbol identifies important safety messages on equipment safety signs in manuals or elsewhere When you see this symbol be alert to the possibility of personal injury or death Follow the instructions in the safety message The use of the word DANGER signifies the presence of an extreme hazard or unsafe practice which will most likely result in severe injury or death The use of the word WARNING signifies the presence of a serious hazard or unsafe practice which may result in serious injury or death The use of the word CAUTION signifies possible hazard or unsafe practice which could result in personal injury IMPORTANT The use of the word IMPORTANT is to draw attention to a procedure that needs to be followed to prevent machine damage 4111 0010 July 2014 SAFETY Operational Safety Precautions f Learn the safe way to operate this equipment Read and understand the 4 manufacturer s instructions If you have any questions ask your supervisor O Chock restrain all freight carriers Never remove the wheel chocks until loading or unloading is finished and vehicle driver has been given permission to drive away ke Do not use a broken or damage dock leveling device Make sure proper service and maintenance procedures have been performed before using a Aa 11 E Make sure lip overlaps onto transport vehicle at least 4 in 102 mm
11. a pit concealed and out of the way enabling dock workers to clear the driveway approach of snow or debris The PowerHook 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 PowerHook vehicle restraint the control panel will allow for operation of both units in the same control panel Each PowerHook Poweramp dock leveler and control panel has been factory pre wired and tested to ensure satisfactory operation To illustrate which connections are to be made in the field at installation electrical drawings are included with each order or by contacting Poweramp Technical Services Once again thank you and congratulations on your purchase of a Poweramp PowerHook vehicle restraint PowerHook vehicle restraint operating system Designed by Poweramp to be a marvel of simplicity and efficiency your vehicle restraint when properly installed will provide many years of trouble free performance with an absolute minimum of maintenance Its revolutionary hydraulic system efficiently controls and operates every function To obtain maximum performance and longest possible use a simple program of preventive maintenance is recommended and is outlined in this manual The PowerHook is the original vehicle restraint to seek find and maintain a tight continuous hold on the HIG Rear Impact Guard bar effective
12. hoist cylinder trunnion plates S which must be imbedded into the pit floor as shown on the pit drawing If the existing dock leveler is a CLEAN PIT model it may be possible to reuse the existing plate On eight foot long dock levelers the plate is an integral part of the vehicle restraint and a separate plate is not required See table on page 15 Install restraint pan into the pit Insert spreader bar into pan to reinforce during concrete pour Make sure the pan s square and flush with the pit floor and front dock wall Pour concrete around the vehicle restraint pan and Hoist cylinder trunnion plates s that s to be imbedded in the pit floor if the plate is separate from the pan Allow sufficient time for the concrete to set Assembly vehicle restraint only required if pan was shipped separately A Remove all trunnion keepers B Grease cylinder trunnions C Install cylinders D Install all trunnion keepers and prox switches See adjustments pg 28 Reinstall the dock leveler as indicated in the dock leveler manual Do not complete electrical connections until all welding is complete Modify dock leveler frame as needed per Dock Leveler Modification Drawing Install all hydraulic hose and fill system with approved hydraulic oil See page 26 Install outside signs and lights Finish all electrical connections Adjust and test leveler and restraint operations 4111 0010 July 2014 15 16 17
13. leave Make sure platform lip rests on the transport vehicle bed with at least 4 in 102 mm of overlap Maintain a safe distance from side edges of leveler during the loading unloading process Failure to follow these instructions may result in serious personal injury or death 20 OPERATION SEQUENCE OF OPERATION BYPASS 1 Secure transport wheels with wheel chocks 2 Use key to activate BYPASS mode Inside Green Light with Amber Caution Light Outside Red Light and Strobe 3 Position dock leveler onto transport vehicle 4 When loading or unloading is complete return dock leveler to the stored position Inside Green Light with Amber Caution Light Outside Red Light 5 MUST READ DECAL Before RESET can be started Depending on the year of manufacture there s is two different ways to RESET the system A Reset BYPASS mode to NORMAL mode by pressing the ENGAGE button once Inside Red Light Amber turns Off Outside Green Light Pressing the ENGAGE button during any part of the cycle will end the BYPASS mode Pressing the ENGAGE button a second time will cycle the PowerHook B Reset BYPASS mode to NORMAL mode by pressing the RELEASE button once Inside Red Light Amber turns Off Outside Green Light Pressing the RELEASE button during any part of the cycle will end the BYPASS mode 6 Remove wheel chocks from the transport vehicle wheels when vehicle is ready to depart 21 SEQUENCE OF OPERATI
14. nearby when grinding or welding Failure to follow these instructions may result in serious personal injury or death ALWAYS stand clear of dock leveler lip when working in front of the dock leveler Failure to do this may result in serious personal injury or death 4 DANGER AW Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De energize equipment before working on or inside Do not open cover without appropriate PPE Refer to NFPA 70E for PPE requirements This panel may contain more than one power source Hazardous Voltage Will Cause Severe Injury or Death 4111 0010 July 2014 SAFETY Maintenance Safety Precautions Hydraulic and electrical power must be OFF when servicing the equipment For maximum protection use an OSHA approved locking device to lock out all power sources Only the person servicing the equipment should have the key to unlock the device 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 The maintenance prop must be in the upright service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the device SAFETY Dock Leveler Safety Decal s Every 90 days quarterly in
15. wires 60 through 63 as originally connected n2 MEE aa pn 46 4111 0010 July 2014 TROUBLESHOOTING POWERHOOK To force the Hook in retract do the following set the dock leveler on the maintenance prop Turn off the disconnect switch es see WARNING on page 1 Disconnect field wires 60 61 62 and 63 Cap off the end of wires 60 61 and 63 with a wire nut Connect field wire 62 to the right side of any terminal block 11 Turn on the disconnect switch es Set the POWER OFF ON switch to ON oet the OPERATION SWITCH to BYPASS Push and hold the RA SE pushbutton Release the RA SE pushbutton when the Hook is retracted to the desired position 9 Turn off the disconnect switch es see WARNING on page 1 10 Reconnect field wires 60 through 63 as originally connected To force the Hook down lower do the following 1 Set the dock leveler on the maintenance prop 2 Turn off the disconnect switch es see WARNING on page 1 3 Disconnect field wires 60 61 62 and 63 Cap off the end of wires 60 and 62 with a wire nut Connect field wires 61 and 63 to the right side of any terminal block 11 the wires do not have to go to same terminal block 11 Turn on the disconnect switch es Set the POWER OFF ON switch to ON Set the OPERATION SWITCH to BYPASS In this step the Hook will lower rather quickly so it is suggested that the operator apply only a quick momentary push on the RA SE pushbutton thereby allowin
16. 910 146 Refer to OSHA regulation 1910 147 4111 0010 July 2014 MAINTENANCE Service Dock Leveler Restraint Safely 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 Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death 24 MAINTENANCE IMPORTANT A low fluid level or the use of hydraulic fluids not equivalent to the fluid types recommended will cause abnormal operation of the leveler and WILL void warranty M Reservoir N 2 in 51 mm From Top of Reservoir P Breather Cap Q Fluid Level 25 Daily Maintenance e Make sure that all the Inside and Outside signal lights work Weekly Maintenan
17. A Division of Systems Inc PowerHook Vehicle Restraint MER E gt e 7 POWERAMP Division of Systems Inc s W194 11481 McCormick Drive Germantown WI 53022 800 643 5424 e fax 262 255 5917 e www docksystemsinc com techservices docksystemsinc com Printed in U S A Manual No 4111 0010 Copyright 2014 July 2014 Table of Contents Page Safety Recognize Safety Information eee 1 General Operational Safety Precautions 1 Pip Me 5 Owner s User s Responsibilities 7 Introduction General 8 Component lIdentification nenen eere 9 Installation Model identification m nna 10 KSA iaa 11 KS5 installation 13 NR EM A dicestedcuteesvonamueteeuene 16 Operation Sequence Of iia 21 ili T 22 Maintenance Service Dock Leveler Restraint Safely 23 Periodic Maintenance emm tm 25 Adjustment And Testing Testing PowerHook Operating Range 27 Adjust Powerhook Operating Range 28 Pressure Relief Adjustment ss 30 Adjust Dock Leveler and Vehicle Restrain
18. Adjustment Field wire 63 RV Valve a J 5 4 3 3 33 113 13 iLa 1 B Remove wire 36 from the field wire side of the The pressure relief on a Powerhook is not adjusted terminal strip input 3 by the relief mounted on the pump The pressure on the pump is preset and should not be adjusted The pressure relief for the systems is regulated by the relief located on the Big block for the Powerhook C Loosen lock nut and turn valve RV counter clockwise until the valve stops E Press the engage button the motor will run but the hook will not move Turn the RV valve clockwise until the hook lowers to 2 off the bottom of the pan then add one full turn clockwise and lock in place If the PLC shuts down the motor before adjustments have been reset the and continue were PLC shut off On KS6 and KS7 restraints the relief is preset from the factory and normally is not touched KS4 and KS5 vehicle restraints of some SC hooks the relief must be adjusted during installation KS4 and KS5 Pressure reliefs must be adjusted during the install or if the PPAC must be replaced F Install wire 86 back on the terminal strip input 3 A Raise Leveler on to the maintenance prop and on the PLC lock in place G Test hook for proper operation 30 4111 0010 July 2014 OPTIONAL EQUIPMENT ADJUSTMENTS Adjust Dock Leveler and Vehicle Restraint Interlock Dock Leveler Interlock The d
19. DOOR RAISED HIGH ENOUGH SUCH THAT LEVELER WALL NOT HIT DOOR DOOR OPEN WHEN DOOR IS IN LEVELER OPERATING ZONE DOOR OPE CONTACT TO BE CLOSED NONI SEEN DOCA 1 NDT AT IF DOOR OPEN CONTACT IS USED REPLACE JUMPER FORM TERMINAL BLOCKS 31 WTH DOOR OPEN D PROXIMITY SMTCH PRSS IS USED ONLY IF THE UNIT HAS EITHER THE LS INTERLOCKING OPTION OR THE AUTO RETURN OPTION IF NEITHER OF THE OPTIONS ARE USED CONNECT MRE 31 TO PLCI INPUT 10 E TERMINAL BLOCK 78 USED ONLY IF UNIT HAS THE E STOP OPTION TERMINAL BLOCK 79 ONLY USED IF UNIT HAS THE LIP OUT OR UP OUT STOP OPTION F WRE 64 IF UNIT DOES NOT HAVE E STOP OPTION WRE 64A IF UNT DOES HAVE E STOP OPTION THERE IS A TERMINAL BLOCK FOR 64 THERE IS NOT A TERMINAL BLOCK FOR 64A G TERMINAL BLOCKS 31 32 AND 72 ADDED ONLY IF THE UNIT HAS THE DOOR CLOSED CONTACT OPTION H TERMINAL BLOCK 43 USED ONLY IF UNIT HAS THE LS INTERLOCKING AND OR AUTO RETURN OPTION L WIRE COLORS NEAR COMPONENT REFER TO COLOR OF WIRE SUPPLIED BY THE COMPONENT MFGR BRN BROWN BLU BLUE BLK BLACK WHT WHITE RED RED YEL YELLOW amp ORG ORANGE 4 ee OM THE eee EXAMPLE 3 de 4 AT PBI 401 BY OTHERS DOOR CLOSED CONTACT MAY BE PROVIDED BY POWERAMP IF SPECIFIED DOOR CLOSED TICALLY RESET BYPASS MODE L TERMINAL BLOCK 21 USED ONLY IF THE UNIT HAS THE HYDRAULIC FLUID WARMER OPTION M TERMINAL BLOCK 42 USED ONLY IF UNIT HAS THE LANYARD OPTION IF THE UNIT DOES NOT HAVE THE E STOP OP
20. E button Hook should lower fully extend fully raise partially retract lower and then fully retract Inside Amber Light for 30 seconds then Red Alarm will sound if equipped Outside Red Light for 30 seconds then Green 3 Measure upper and lower limits of operating range The upper and lower limits of the vertical operating range should be 26 28 and 8 9 respectively Application Dependent T Hook In Highest eu Position Store Alarm ADIRE Y 8 9 Lower Limit Hook Must TL Drive Ext Clear pit xtended Floor While Hook In Lowest Extending Position NOTE Hook cannot be stopped while cycling To obtain measurements place tape measure next to the moving hook IMPORTANT The upper and lower limits of the operating range will vary with application pit depth These limits may not be attainable if variations in dock height and or pit depth exist Consult factory if this situation occurs 27 Testing PowerHook Operating Range 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 Failure to do this may result in serious personal injury or death 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 Failure to do this may result in serious personal injury or death Always stan
21. G A600 CR2 CONTACT RATING 7 5 A GEN USE 120 VAC 212 PB3 RAISES LEVELER 115 ii 213 LS OPTIONAL LANYARD PULL RING RAISES LEVELER rJ S 8 INDICATES LEVELER UP FULLY FOLDED WHEN CLOSED NOT FULLY FOLDED WHEN OPEN 216 SEE NOTE N OPTIONAL DOOR OPEN CONTACT DOOR OPEN CONTACT IF USED INDICATES DOOR N LEVELER OPERATING ZONE WHEN OPEN NOT IN LEVELER OPERATING ZONE WHEN CLOSED 217 218 219 KS FAULT RESET A 52 FEATURES ONLY THOSE FEATURES THAT AFFECT TRANSFORMER VA ARE LISTED TAEI FLUID WARMER MOTOR NAMEPLATE DATA DRAWNG SHOWS TI TRANSFORMER WTH A DUAL VOLTAGE PRIMARY WRED FOR 460 V OPERATION SOME APPLICATIONS WLL ONLY 48 4111 0010 July 2014 ELECTRICAL DIAGRAM GENERIC F DE ENERGIZED WHEN IN BYPASS SOL E OPTIONAL E STOP LEVELER ONLY BLOCKS FLUID FROM LEVELER TO RESERVOIR WHEN ENERGIZED DIRE UP WHEN ENERGIZED 0 6 EEO Rs RRR 8B ONLY THE CONTROL ASSY IS A UL LISTED PANEL ALL OTHER EQUIPMENT IS REMOTE FROM THE CONTROL ASSY IS NOT PART OF ANY UL LISTED PANEL COMPONENT LOCATION TABLE COMPONENT LOCATION INDICATED BY PHANTOM LINES CONTROL ASSY UL LISTED PANE OUTSIDE SIGNAL LIGHT ASSY 0D OVERHEAD DOOR BY OTHERS LOAD DATA EXTERNAL LOADS ALL LOADS 110 120 VAC SOL AB CI SOL EF OPTIONAL C2 D O20 A 8 TIOV EACH 0 21 A O 110 V EACH LT5 6 A
22. ON NORMAL 1 Check that the transport vehicle is positioned squarely against the dock bumpers Inside Red Light Outside Green Light 2 Push ENGAGE button to activate restraint Inside Red Light Outside Red Light and Strobe 3 Visually inspect restraint for proper engagement If RIG Rear Impact Guard is damaged or missing dock leveler can be used in BYPASS IF BYPASS MODE IS REQUIRED SEE SEQUENCE OF OPERATION BYPASS FOR NORMAL OPERATION AFTER TRAILER RIG IS ENGAGED CONTINUE WITH STEP 4 4 Position dock leveler onto transport vehicle 5 When loading or unloading is complete return dock leveler to the stored position 6 Release vehicle restraint and or remove chocks from transport vehicle wheels 4111 0010 July 2014 PLACARD Placard Installation Instructions e Owner is responsible for the installation and placement of product placards e Make sure placard is in plain view of dock leveler operations e Suggested placement of placard is near control box attached to electrical conduit by using nylon tie If there is no control box present mount placard on wall to the immediate left of leveler at eye level TUR RT RES SSS donas STN SCANS SES SN ES 4 N lt SS C AMA ANA YAA A NANA 22 4111 0010 July 2014 MAINTENANCE Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler b
23. OOK Locate switch on rear of guide track Observe indicator light at controller input 6 that receives signal from switch Input light should turn OFF when restraint fully extended If this does not occur Check switch position loosen two guide track mounting bolts tap guide track assembly back towards rear pit wall Switch should be positioned approximately 1 4 from the inside wall of the track Make sure that the switch face does not extend further than the guide track mounting bars welded to the cylinder Position switch so that face will not come into contact with guide rod Tighten nuts to secure switch DO NOT over tighten nuts Maximum tightening torque is 25 Ib ft Run restraint Make sure motor shuts off when hook is in stored position If motor does not shut off reposition guide track slightly forward of current position Locate solenoid See Parts Valve Block Remove coil from cartridge valve and cartridge valve from valve block Check valve for contaminant s and or damage Replace valve if damaged Carefully wipe valve with clean rag do not damage O rings on valve Check valve block for contaminant s Replace valve and coil NOTE Do not over tighten valve into block Max Torque 30 40 Ib ft or snug to prevent leakage Tighten coil snug avoid over tightening and causing valve to bind Operate unit Replace valve if problem persists and all other troubleshooting procedures perform
24. Powerhooks with new style valving do not have any solenoid valves in the hydraulic valve block that is on the hook cylinder Powerhooks with old style valving have 2 solenoid valves in the hydraulic block that is on the hook cylinder WARNING Risk Of Electric Shock That Could Result In Severe Personnel Injury Or Death Before disconnecting and or connecting any wires inside the control panel turn off all power entering the control panel at the disconnect switch es Some units may require 2 disconnect switches to be turned off before all power entering the control panel is turned off The POWER OFF ON selector switch on the control panel is NOT a disconnect switch The solenoids are originally connected as follows Field Wire Number Computer Terminal For any of the following troubleshooting steps to work the solenoids need to be working correctly and the motor needs to be pumping fluid To force the Hook out extend do the following Set the dock leveler on the maintenance prop Turn off the disconnect switch es see WARNING above Disconnect field wires 60 61 62 and 63 Cap off the end of each wire with a wire nut Turn on the disconnect switch es Set the POWER OFF ON switch to ON oet the OPERATION SWITCH to BYPASS Push and hold the RA SE pushbutton Release the RA SE pushbutton when the Hook is extended to the desired position Turn off the disconnect switch es see WARNING above 9 Reconnect field
25. RANTIES 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 INC AND ITS SUBSIDARIES SHALL NOT IN ANY EVENT BE LIABLE TO ANYONE INCLUDING THIRD PARTIES FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO BREACH OF WARRANTY LOSS OF USE LOSS OF PROFIT INTERUPTION OF BUSINESS OR LOSS OF GOODWILL PRODUCT SPECIFIC WARRANTY POWERHOOK SERIES LEVELER In addition to the Standard Product Warranty provided with all Poweramp Products Systems Inc guarantees materials components and workmanship to be free of defects for the following extended periods e Structural Warranty For a period of five 5 years from the date of shipment e Hydraulic Warranty For a period of five 5 years from date of shipment this warranty specifically applies to the hydraulic pump and motor all hydraulic cylinders hydraulic pressure lines and fittings and fluid control assemblies only e Electrical Warranty For a period of two 2 years from date of shipment this warranty specifically applies to the control box components guide track assembly pressure differential switch coils and proximity sensor when interlocked with Poweramp dock leveler only
26. TION WRE 31 MUST BE CONNECTED TO PLCI INPUT 11 K DOOR CLOSED CONTACT CONTACT USED TO AU 115 V 1 PHASE 60 HZ 100 V 240 VAC LINE 308 62 49 4111 0010 July 2014 PARTS OPERATING DANGER INSTRUCTIONS Read and follow all instructions warnings and maintenance schedules in VEHICLE RESTRAINTS the manual and on placards Vehicle restraint operation and servicing is restricted to trained personnel ENGAGE RESTRAINT 1 Open overhead door and visually check that truck is positioned squarely against dock bumpers and has a RIG bar Inside light is RED and outside light is GREEN 1 Before using the vehicle restraint Remove any debris snow or ice that may obstruct vehicle restraint operation e Alert personnel in the area of potential vehicle restraint operation and ensure area is clear Operate the vehicle restraint thru one complete cycle inspecting it for proper operation and light sequence Advise maintenance personnel of any damage or improper operation immediately Remove all malfunctioning or damaged vehicle restraints from service using 3 Once RIG has been secured inside light is approved lockout tagout procedures GREEN outside light is RED 2 Before attempting to restrain a transport vehicle Verify that transport vehicle is positioned squarely against dock RELEASE RESTRAINT bumpers 1 To release truck restraint depress the Inspect the transport vehicle s rear impact guard RIG Dam
27. aged or RELEASE button When safely stored inside missing RIGs may not allow the vehicle restraint to securely capture the light is RED and outside light is GREEN RIG Wheel chocks must be used whenever the ability for the vehicle restraint to capture the RIG is in question NOTE The transport vehicle s suspension and load condition will effect trailer height 2 Depress the ENGAGE button to activate restraint 3 After activating vehicle restraint BYPASS Verify that the transport vehicle s RIG has been restrained successfully 1 If restraint is unable to secure transport In the event this cannot be determined use wheel chocks in addition to vehicle s RIG use wheel chocks to secure restraint transport vehicle at the dock f equipped with a light communication package load and unload on GREEN light only 2 Turn switch to BY PASS Inside light is GREEN outside lightis RED 4 Maintenance or service must be performed by authorized personnel only Follow approved lockout tagout procedures 3 Loading unloading may proceed with tion FAILURE TO FOLLOW THESE INSTRUCTIONS oe COULD RESULT IN DEATH OR OTHER SERIOUS BY PASS RESET RETURN TO NORMAL OPERATION INJURY 1 When loading or unloading is completed and wheel chocks are removed manual W 1 262 255 1510 or 1 800 643 5424 reset of BY PASS is accomplished by MCGUIRE 1 i DLM Call for additional placards or manuals or with questions depressing the RELEASE button or tur
28. allow the hydraulic fluid to drain from the reservoir When the reservoir is empty reinstall the hose Dispose of the fluid properly 6 Install restraint pan into the pit Insert spreader bar into pan to reinforce during concrete pour Make sure the pan s square and flush with the pit floor and front dock wall 4111 0010 July 2014 INSTALLATION Hook Cylinder Trunnion Hook Cylinder Keepers Hold down Cylinder Trunnion Pour concrete Around The Vehicle Restraint Pan Vertical Valve Block KS4 Pan Inside view Hook Valve Block 12 4111 0010 July 2014 INSTALLATION Post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before installation has been completed Failure to follow the installation instructions can result in damage to dock leveler the facilities and or serious personal injury or death IMPORTANT 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 the platform Failure to follow these instructions may damage the motor hoist cylinder wiring and or control panel Shut off all power to dock leveler control assembly Disconnect all wires at the junction box located on the rear pit wall
29. awing and the certified pit drawing attached to this manual The PowerHook KS5 vehicle restraint with a hydraulic dock leveler requires two separate 3 4 conduit runs from the control assembly to the junction box located at the rear pit wall An additional conduit if required may be run either in a trench dug in the concrete or in a space between the pit walls and the dock leveler The dock leveler will be removed from the pit steps 9 14 and reinstalled in the pit If additional conduit is to be imbedded in the concrete it may be best to do so when the dock leveler is not in the pit If a surface route is planned it may be better to install the conduit after returning the dock leveler to the pit 2 Raise the platform following instructions in the Use a fork vehicle or other method to raise dock leveler owner s users manual and support and hold the dock leveler platform Remove the with the maintenance prop maintenance prop 3 Attached lifting plates supplied by others to the Burn or grind all welds where the dock leveler frame is welded to steel imbedded in the pit outboard joists on both sides of the dock leveler Use front hole on one side and rear hole on the other NOTE frame removal on 10 and 12 long CLEAN PITe units may not be necessary Consult factory 4111 0010 July 2014 13 Cut pit for the vehicle restraint pan as indicated on the Pit Drawing Cut out or chip to accommodate 3 8 x 16 x 16
30. cate the proximity switch that is mounted in the bracket located on the trunnion for the hook cylinder Locate the target for the switch See Figure 12 NOTE The position of the target in relation to the switch will determine the lower travel limit of the hook When the hook lowers the target is positioned into the sensing area of the proximity switch The switch is activated when the target is sensed at which time Input 3 on the PLC should be ON At no time should the target come into direct contact with the switch The typical factory set position for the target is at the 10 o clock position looking at it from the side with the hook lowered sensor at 12 o clock See Figure 13 B Loosen the bolt that holds the target C Lower Hook Turn the target 2 4 degrees counterclockwise if top of the hook is greater than 9 D Raise Hook Turn the target 2 4 degrees clockwise if the top of the hook is less than 8 E Repeat Steps C or D until the lower vertical limit of the top of hook is 8 9 above the apron When adjustments are completed hold the target in place and tighten the bolt 2 Test with transport vehicle or a ICC bar simulator The simulator must span min of 6 past both sides of pan 3 Press the ENGAGE button Vehicle restraint hook should lower extend raise and retract until it locks onto the ICC bar Power pack should then shut off 4111 0010 July 2014 ADJUSTMENTS Powerhook Pressure relief
31. ce e Operate the dock leveler and PowerHook through the complete operating cycle to maintain lubrication Quarterly Maintenance e Lubricate the following areas with white lithium grease Hook cylinder trunnions Position cylinder trunnions Inspect Prox harness Inspect Hoses ee a A B C D Yearly Maintenance e Lubricate the following areas with white lithium grease A Hook cylinder trunnions B Position cylinder trunnions C Inspect Prox harness D Inspect Hoses E Change Hydraulic Oil May change more frequent depending on conditions IMPORTANT Failure to properly lubricate the Vehicle Restraint will cause abnormal operation 4111 0010 July 2014 MAINTENANCE KS5 or KS6 and KS7 e Check reservoir fluid level Q 1 Put the dock leveler platform at the full below dock position Turn OFF all electrical power to the leveler Remove inspection plate Remove breather cap P aE N Measure fluid level The fluid level should be approximately 2 in 51 mm N from top of reservoir 6 Add hydraulic fluid if necessary Use only recommended fluid 7 Install breather cap and inspection plate M Reservoir P Breather Cap Top ot as 8 Turn ON electrical power to the leveler Reservoir 9 Return the platform to the cross traffic position IMPORTANT Use of fluids that do not have equivalent KS4 O
32. ce prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death 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 Failure to do this may result in serious personal injury or death 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 Failure to do this may result in serious personal injury or death Before performing the detailed troubleshooting procedures check the following items first Check all fuses inside the control panel s Replace any blown fuse s with a fuse of equal specification e Make sure the correct voltages are present at the proper locations inside the control panel s Replace flasher with wire If lights operate lights will not flash replace flasher Heset overload relay 3 p
33. d clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death Follow the installation instructions found in the PowerHook Owners Users Manual prior to attempting any adjustments With the PowerHook installed in the hook pan and power supplied to the pump motor proceed with the PowerHook adjustments 4111 0010 July 2014 Hook cylinder trunnions wN Q Trunnion keepers Position cylinder trunnions Figure 11 4111 0010 July 2014 ADJUSTMENTS Adjust PowerHook Operating Range Hook Cylinder CN gt Threaded Eye 4 v and Jam Nut Clock Wise e Counter clock Wise Hose Port Figure 10 1 Adjust the upper vertical limit of PowerHook operating range if necessary A Locate the hook cylinder assembly and the hold down cylinder assembly The length of the threaded eye on the hold down cylinder
34. e slope for all variations of length or configuration of the dock leveling device and information identifying the maximum uncontrolled drop encountered when sudden removal of support while in the working range of the equipment It is recommended that when the transportation vehicle is positioned correctly in the dock opening and in contact with both bumpers there shall be a minimum of 4 00 inches 100mm overlap of the leveling device and the transportation vehicle at all times during the loading and unloading process The Owner User must review all name plates placards decals instructions and posted warnings and place the same in view of the operator or maintenance personnel for whom such warnings are intended for Contact manufacturer for any replacements Manufacturers recommended periodic maintenance and inspection procedures in effect at the date of shipment shall be followed at all times Written documentation of maintenance replacement parts or damage should be retained In the event of damage notification to the manufacturer is required Loading dock equipment that has been structurally damaged or has experienced a sudden loss of main support while under load such as what might occur when a transport vehicle pulls out from under the leveling device shall be removed from service inspected by a manufacturer s authorized representative and repaired or replaced as needed before being placed back in service Any modifications or alterati
35. eck all wiring to motor for high resistance or no connection Replace motor Three phase units only Phase reversed Heverse any two legs at the branch circuit Restraint does not disconnect operate Motor runs in reverse Single phase units only Line voltage too low Check wiring to motor for high resistance Check for Restraint does not loose or corroded connections Check wire gauge for operate correct size and specification for load requirement Replace if necessary Motor energi l our Defective motor centrifugal Replace motor does not run switch Defective motor capacitor Replace motor Restraint operates Low hydraulic fluid Add fluid see Maintenance section for proper fluid slowly level and type Pressure relief valve set too Locate valve on main valve block labeled RV Turn the valve all the way counter clockwise While operating the restraint slowly turn the valve in clockwise until the restraint lowers and begins to extend Turn valve in an additional 1 2 turn clockwise NOTE The pressure relief valve must not be set 8 level that causes the motor operating current to exceed the full load amp value at any time including when operating in pressure relief The full load amp value can be found on the inside cover of the control panel Damage or blocked Heplace damaged hose s Check and remove hydraulic hose s and or blockage from hose s and or valve s valve s 4111 0010 Jul
36. ed Locate positioning cylinder Place pan under hose connected to cylinder to catch fluid SLOWLY loosen hose since fluid may exit cylinder rapidly cylinder is spring loaded with spring compressed when lowered A cylinder that is not binding will raise as fluid leaves the cylinder A cylinder that is binding will remain lowered even when the hose is completely removed from the cylinder Replace a cylinder that is binding 43 Lowered restraint Proximity switch on rear of returns to fully retracted closest to rear pit wall position but unit does guide track that senses not automatically shut when restraint fully retracted OFF out of adjustment Pump Operates in pressure relief Restraint remains lowered Restraint fully retracted Solenoid D valve stuck but does not raise even when ON OFF switch turned OFF Binding inside positioning cylinder 4111 0010 July 2014 TROUBLESHOOTING DOCK LEVELER Platform does not Heavy object s on platform Remove object s from platform rise Pump operates in pressure relief mode NOTE For safety reasons the dock leveler is designed to lift only the platform s own weight Dock leveler binds Check for visible obstructions that could cause binding Remove obstructions If no obstructions found call Poweramp Technical Services See inside back cover for phone number and address Pressure relief set too low Increase pressure relief See Adjus
37. efore maintenance is complete Failure to do this may result in serious personal injury or death Whenever maintenance is to be performed under the dock leveler platform support the platform with maintenance prop C Position the maintenance prop behind front header plate D while staying clear of the lip The lip will fold down after the platform has rested on the maintenance prop Lock the maintenance prop in the service upright position using an OSHA approved lockout device A and Tag out device B Whenever servicing the dock leveler lock the electrical power disconnect in the OFF position Use only an OSHA approved lockout device A and Tag out device B Only the person servicing the equipment should have the capability to remove the lockout devices The Tag out devices must inform that repairs are in process and clearly state who is responsible for the lockout condition Refer to OSHA regulation 1910 146 Refer to OSHA regulation 1910 147 23 j 2 la 2 4 Service Dock Leveler Restraint Safely A A 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 Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working u
38. fully lowers from stored position but does not extend that senses when restraint lowered target and or switch out of adjustment Solenoid B valve stuck ON or Solenoid s C1 or C2 valve s stuck ON Restraint does not tightly engage vehicle trailer RIG bar inside lights turn GREEN but gap exists between RIG bar and restraint Pressure switch trip point set too low trip point set too Low Incorrect type of hydraulic Drain and re fill system with proper fluid See fluid used Maintenance section for proper fluid level and type 41 4111 0010 July 2014 TROUBLESHOOTING POWERHOOK Restraint engages Pressure switch trip point Pressure switch is factory set Do not attempt to transport vehicles set too high adjust in field replace switch with factory RIG bar but does not automatically shut OFF Pump operates in Pressure differential switch Pressure differential switch is factory set Switch pressure relief trip point set too high must be replaced Restraint extends Solenoid B valve stuck Locate solenoid See Parts Valve Block from RIG bar engaged ON or solenoid s C1 or Remove coil from cartridge valve and cartridge valve position fully lowers but C2 stuck OFF from valve block does not retract Check valve for contaminant s and or damage Replace valve if damaged Carefully wipe valve with clean rag do not damage O rings on valve Check valve block for contami
39. g the Hook to only lower slightly The operator may have to apply additional quick momentarily pushes on the RA SE pushbutton in order to get the Hook to lower to the desired position i gt EE L OI A l el Momentary push the RA SE pushbutton If necessary keep momentarily pressing the RA SE pushbutton until the Hook is lowered to the desired position 9 Turn off the disconnect switch es see WARNING on page 1 10 Reconnect field wires 60 through 63 as originally connected 4111 0010 July 2014 47 ELECTRICAL DIAGRAM GENERIC CUSTOMER SUPPLIED 208 230 460 575 V 3 PHASE 60 HZ FROM BRANCH CIRCUIT DISCONNECT SWITCH amp OVERCURRENT DEVICE BY OTHERS SELECT DISCONNECT SWITCH de OVERCURRENT DEVICE PER THE NEC 101 LOCATE A DISCONNECT SWITCH ADJACENT TO THE CONTROL ASSY 102 DUAL BENT IME DELAY 103 BRANCH CIRCUIT PROTECTION 104 ma We H2 H4 0X2 VAC 115 120 107 10 PB1 ACTIVATES RESTRAINT PB2 ACTIVATES RESTRAINT 108 KS BYPASS 216 312 312 CRI OPTIONAL 206 DE ENERGIZED WHEN E STOP ACTIVATED 110 112 111 OPTIONAL Ml EM 218 6 A2 DL OPTIONAL 0 21 UNE 111 SEE NOTE M ul Y ANN OPTIONAL 112 HYDRAULIC FLUID WARMER NA 113 113A 210 114 OPTIONAL DRY CONTROL CIRCUIT FOR AIR SHELTER OR INFLATABLE SEAL OR OTHER CUSTOMER SPECIFIED EQUIPMENT an CLOSED F RASED amp RETRACT MOMENTARY SIGNAL ONLY SS4 CONTACT RATIN
40. hase or replace fuse 1 phase or reset breaker 1 phase new models Determine cause of device tripping NOTE If replacing fuse use fuse with equal specification Check controller output that sends a signal to starter or relay Output may have failed OPEN Use meter to check for contact closure when output ON 4111 0010 July 2014 Inside and outside signal Bad Flasher lights do not operate Controller PLC RUN indicator is on solid not flashing Unit operates as normal Restraint does not Motor overload device operate Motor does not tripped energize Motor starter 3 phase or motor relay 1 phase not energizing 36 TROUBLESHOOTING POWERHOOK Three phase units only 3 Phase units only no Check for blown fuses at branch circuit disconnect Restraint does not voltage is present on one Replace fuse Determine cause of blown fuse operate Motor energizes line Check motor starter as follows OUP COES MOLNAR 1 Disconnect wires at load side of starter 2 Energize the starter 3 Measure line to line voltage at line side of starter 4 Measure line to line voltage at load side of starter Line side and load side voltages should be approximately the same Replace starter if voltage values are considerably different from one another NOTE A motor that is If motor hums but does missing voltage on one line not run overload device s said to be single phased should trip Ch
41. he dock leveler DO NOT operate any equipment while under the influence of alcohol or drugs DO NOT leave equipment or material unattended on the dock leveler Failure to follow these instructions may result in personal injury and or damage to equipment AA DANGER LA Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De energize equipment before working on or inside Do not open cover without appropriate PPE Refer to NFPA 70E for PPE requirements This panel may contain more than one power source Hazardous Voltage Will Cause Severe Injury or Death 4111 0010 July 2014 INSTALLATION Operating Instructions Stay clear of dock leveler when freight carrier is entering or leaving dock area DO NOT move or use the dock leveler 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 moving parts Failure to follow these instructions may result in severe personal injury or death Only trained personnel should operate the dock leveler and vehicle restraint DO NOT use a broken or damaged dock leveler or vehicle restraint Make sure proper service and maintenance procedures have been performed on equipment before using Transport vehicle wheels must be chocked unless the vehicle restraint is used Never remove the wheel chocks until loading unloading is finished and vehicle driver has been given permission to
42. hipped with the reservoir full However fluid level should be checked before operation unit for the first time to make sure no fluid loss occurred during shipment or installation See the Preventative Maintenance Section 10 11 12 13 14 15 16 17 18 19 20 21 22 Note For Centra Power or remote power pack units see appropriate instructions the electrical installation is to be preformed at a later date use a fork lift to set the unit in the cross traffic position lip fully folded inside the lip keepers and the platform level with the floor 23 4111 0010 July 2014 17 4111 0010 July 2014 5 x7T xi4 G x8 x12 INSTALLATION MODEL KS6 Shown with Single Hoist Cylinder Support 5 x 7 x 1 4 6 x 8 x12 7 112 x 9 1 2 x 1 4 8 x 10 x 1 2 5 x7 x 1 4 6 x 8 x 1 2 MODEL KS7 Shown with Dual Hoist Cylinder Supports 8 x 3 1 2 x 1 4 9 x 4 x 1 2 7 1 2 x 9 4 2 x 1 4 8 x 10 x 1 2 5 x 7 x 1 4 6 X 8 X 1 2 Figure 8 INSTALLATION Maintenance Prop Stored 318 3 Pass 3 All Sides Top View Both Piates Figure 6 Figure 7 Allow enough clearance for possible seal or shelter Ca y ssed T 14 AQ BH Pg O Z7 KS6 Dock Leveler Optional Guide Lights Drive 4111 0010 July 2014 19 DO NOT overload t
43. lding equipment to any hydraulic or electrical components of the dock leveler Always ground welding equipment to the dock leveler frame NEVER to the platform Failure to follow these instructions may damage the motor hoist cylinder wiring and or control panel 7 Pour concrete around the vehicle restraint pan and Hoist cylinder trunnion plates s that is to be imbedded in the pit floor in the plate is separate from the pan 8 Allow sufficient time for the concrete to set 9 Assembly vehicle restraint only required if pan was shipped separately A Remove all trunnion keepers B Grease cylinder trunnions C Install cylinders D Install all trunnion keepers and prox switches See adjustments See page 28 10 Modify dock leveler frame as needed per Dock Leveler Modification Drawing 11 Install all hydraulic hose s and fill system with approved hydraulic oil See page 26 12 Install out side signs and lights 13 Finish all electrical connections 14 Adjust and test leveler and restraint operations 11 KS4 INSTALLATION These installation instructions were written for retrofitting a Powerampe hydraulic dock leveler with integral power pack with a PowerHooke KS4 Vehicle Restraint If you are not adding the PowerHooke to an existing dock leveler some steps may not be needed or additional procedures may be required as follows e When installing in new construction i e new PowerHook and ne
44. ll 4111 0010 July 2014 TROUBLESHOOTING POWERHOOK Restraint does not Solenoid D valve stuck off Locate solenoid See Parts Valve Block lower at all from Remove coil from cartridge valve and cartridge valve stored position Pump from valve block operates in pressure relief restraint does not Check valve for contaminant s and or damage extend Replace valve if damaged Carefully wipe valve with clean rag do not damage O rings on valve Check valve block for contaminant s Replace valve and coil NOTE Do not over tighten valve into block Max Torque 30 40 Ib ft or snug to prevent leakage Tighten coil snug avoid over tightening and causing valve to bind Operate unit Replace valve if problem persists and all other troubleshooting procedures performed Solenoid D coil not Check controller output that sends a signal to receiving signal to energize solenoid Output may have failed OPEN Use A solenoid that is energized meter to check for contact closure when output will act like a magnet ON Place a metal tool on coil of solenoid valve to determine 2 Check all wiring to solenoid for high resistance if coil is receiving signal loose or no connection Solenoid D coil receiving Coil failed OPEN Consult factory for replacement signal but not energizing Obstruction preventing the Remove obstruction check for damage to restraint from lowering components Fluid flow to p
45. ll maintenance props have been properly positioned Side maintenance props must be positioned as shown in figure A below Prop locking pin must be positioned as shown in figure B below Refer to owner s user s manual for proper procedure Failure to do so will result in death or serious injury FIG A Storage Position Maintenance Position Serial Tag will be located next decal 3 on the run off guard Decal Part Numbers 1 1751 0130 Rev A 2 1751 0230 Rev C 8 1751 0397 4 1751 0229 Rev A 5 1751 0490 Rev A 6 1751 0138 Rev A 7 1751 0402 4111 0010 July 2014 A DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is safely supported by maintenance prop Place barriers on drive way and dock floor to indicate service work being performed Refer to owner s user s manual for proper maintenance procedures Failure to comply will result in death or serious injury A DANGER CRUSH HAZARD DO NOT WORK UNDER DOCK LEVELER unless all maintenance props have been properly positioned Side maintenance props must be positioned as shown in figure A below Prop locking pin must be positioned as shown in figure B below Refer to owner s user s manual for proper procedure Failure to do so will result in death or serious injury FIG A Storage Position
46. lly lowered If this does not occur adjust target counterclockwise See Adjustments section Adjust PowerHook Operating Range NOTE Check circuit breaker inside control assembly before replacing switch Make sure breaker is ON Use a screwdriver as a temporary target to test switch Adjust switch closer to target if input light turns on Replace switch if screwdriver is present and input light on controller does not turn on Locate solenoid See Parts Valve Block Remove coil from cartridge valve and cartridge valve from valve block Check valve for contaminant s and or damage Replace valve if damaged Carefully wipe valve with clean rag do not damage O rings on valve Check valve block for contaminants Replace valve and coil NOTE Do not over tighten valve into block Max Torque 30 40 Ib ft or snug to prevent leakage Tighten coil snug avoid over tightening and causing valve to bind Operate unit Replace valve if problem persists and all other troubleshooting procedures performed Pressure switch is factory set Do not attempt to adjust in field replace switch from factory pre set unit Pressure differential switch Pressure differential switch is factory set Switch must be replaced Restraint only partially lowers from stored position Pump operates in pressure relief Restraint does not extend Fluid flow to positioning cylinder blocked Binding inside positioning cylinder Restraint
47. ly eliminating trailer creep As an optional safety feature the dock leveler and vehicle restraint can be interlocked preventing operation of the dock leveler until the hook engages the vehicle RIG bar The vehicle restraint is firmly anchored in the loading dock pit for maximum holding power The hook remains protected behind the pit wall until activated The PowerHook restraint is designed to withstand a pulling force in excess of 35 000 Ibs Due to ongoing product improvement some parts have changed along with operation and trouble shooting methods This manual describes these changes For further assistance please contact Poweramp Technical Service at 800 643 5424 or techservices docksystemsinc com 4111 0010 July 2014 INTRODUCTION Component Identification A Regeneration Valve D Guide Track Slide Rod G Positioning Cylinder J Pressure Differential B Hook Cylinder E Guide Track H Guide Track Harness Includes 4 Magnetic Valve C Hook F Sensor Prox Switches Reed Switches Assembled Hook Lowered Sensor Target Telemecanique TWIDO Programmable Logic Controller 4111 0010 July 2014 9 INSTALLATION This manual covers three models of PowerHooke vehicle restraints 454 455 456 See Figures 1 2 and 3 In addition to the hydraulically actuated vehicle restraint PowerHooke has a programmable Logic controller and Dock Alert communication systems The in
48. maintenance prop 2 ARTD Continued IMPORTANT Anytime proximity switch and target are adjusted always check for interference between target and switch before operating the leveler Damage to switch will occur if the target contacts the switch The maximum torque for proximity switch lock nuts is 27 Nem 29 lb ft Damage to switch will occur if maximum torque is exceeded A 1 4 in 6 4 mm C 1 in 25 4 mm Approximate Approximate B Target D Lock Nuts E Proximity Switch NOTE Distances A and C are typical factory settings Use these dimensions only as a starting point when adjusting the proximity switch and target especially if switch and or target have been replaced When dimensions A and C are obtained the proximity switch and target may need finer adjustments to get the ARTD to operate satisfactorily 3 Loosen lock nuts D Adjust proximity switch E to obtain distance A Tighten lock nuts Whenever the platform lip is at the cross traffic position the following conditions will exist for a normally operating ARTD Target not in the sensing area of proximity switch e Proximity switch OFF open no signal sent to control panel e Proximity switch indicator light is OFF e Platform stays at this position unless the operator activates the leveler 4111 0010 July 2014 4 Bend target B as needed to obtain distance C Recheck distance A and readjust if necessary
49. nants Replace valve and coil NOTE Do not over tighten valve into block Max Torque 30 40 Ib ft or snug to prevent leakage Tighten coil snug avoid over tightening and causing valve to bind Operate unit Replace valve if problem persists and all other troubleshooting procedures performed Proximity switch at trunnion Locate switch on hook trunnion Observe indicator that senses when restraint light at controller input 3 that receives signal lowered target and or switch from switch Input light should only turn ON when out of adjustment restraint fully lowered If this does not occur adjust target counterclockwise See Adjustments section Adjust PowerHook Operating Range Use a screwdriver as a temporary target to test switch Replace switch if screwdriver is present and input light on controller does not turn on Solenoid C1 or C2 coil s Check Controller output that sends the solenoid not receiving signal to signal Output may have failed OPEN Use meter energize A solenoid that to check for contact closure when output ON is energized will act like a magnet Place a metal Check all wiring to solenoids for high resistance tool on coils of solenoids loose or no connection to determine if coils are receiving signal Solenoid C1 or C2 coil s Coil s failed OPEN Consult factory for replacement receiving signal but not coil energizing 42 4111 0010 July 2014 TROUBLESHOOTING POWERH
50. nder the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death 4111 0010 July 2014 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 Failure to do this may result in serious personal injury or death When maintenance is to be performed on the dock leveler D First lock out the storage prop with the safety pin Second support the platform with maintenance props C Caution The lip may will fold down after the platform has rested on the maintenance prop Whenever servicing the dock leveler lock the electrical power disconnect in the OFF position Use only an OSHA approved lockout device B and tag out device A Only the person servicing the equipment should have the capability to remove the lockout devices The tag out devices must inform that repairs are in process and clearly state who is responsible for the lockout condition Refer to OSHA regulation 1
51. ning em regarding proper use maintenance and repair of dock leveler switch to NORMAL Lights change to RED Loading Dock Equipment www DockSystemsinc com inside GREEN outside Use with PowerHook Powerhold Holdtite and TPR series 1751 0880 ADANG ER d d z De Choa bol 9 rari re 4 DANGER AN Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De energize equipment before working on or inside Do not open cover without appropriate PPE Refer to NFPA 705 for PPE requirements This panel may contain more than one power source Hazardous Voltage Will Cause Severe Injury or Death 0961 0083 Proximity Switch with Harness INTERLOCK Feature Only B 1 Push Button Controller J Box Standard 4 x 4 in Metal Box J Box Cold Weather 5 x 5 in Plastic Box D 1 17510736 Decal Arc Flash Placard Vehicle Restraints Provide dock leveler serial number voltage phase and options when calling or faxing controller orders 50 4111 0010 July 2014 PARTS Powerhook Guide Track Components Prox switches 44 a A me Quantity Part Number Description A 1 0524 0097 Powerhook Guide Track Assembly Complete Replaces 0524 0075 1 7056 0002 Upgrade kit may be required 11 2012 and older Powerhooks 6 0521 0146 Guide Track Pig Tail 46 Long D 1 0521 0147 Guide Track Pig Tail 94 Long 26 1 4 18 3 4
52. nly specifications to those in the following list will result in abnormal operation of the dock leveler and e Check reservoir fluid level Q voiding of warranty 1 Put the leveler in the stored position Lip folded To ensure normal operation of the vehicle restraint 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 Turn OFF all electrical power to the leveler Remove breather cap P B 5 Im Measure fluid level The fluid level should be approximately 2 in 51 mm N from top of reservoir M Ultra Vis HV1 15 Aero Shell Fluid 4 or Fluid 41 Mobile Aero HFA Mil HS606A or Aero HF Texaco Aircraft Hydraulic Oil 15 or 5606 Exxon Univis J13 5 Add hydraulic fluid if necessary Use only recommended fluid a a These fluid brands can be mixed together Mixing with 7 Turn ON electrical power to the leveler fluids that do not meet or exceed MIL H 5606 G may damage the equipment and WILL void warranty Use of hydraulic fluids with equivalent specifications to those listed here are acceptable 26 4111 0010 July 2014 ADJUSTMENT AND TESTING NOTE Test operating range of PowerHook without transport vehicle backed into dock 1 Position the selector switch in the Normal position make sure BYPASS mode has not been activated Red Inside Light No Amber Light Green Outside Light 2 Momentarily press the ENGAG
53. nt did NOT engage proceed with step 7 If the restraint DID disengage move the switch farther from the target or bend the target so that the target is not in the sensing range of the switch as shown in Figure 38 Make adjustments at switch and or target until restraint does not disengage transport vehicle IMPORTANT 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 push button The dock leveler will raise The leveler lip will fold as the platform raises When the lip is fully folded release the RAISE push button The leveler will descend to the cross traffic position 8 Momentarily press the RELEASE button The vehicle restraint will return to the stored position 4111 0010 July 2014 Figure 37 C 1 in 25 4 mm Approximate D Lock Nuts E Proximity Switch A 1 4 in 6 4 mm Approximate B Target 1 The dock leveler should be in the cross traffic position stored in the lip keepers before beginning tests 2 Back a transport vehicle with RIG bar into dock A test fixture may be used to simulate the RIG bar Use care to avoid damage to the equipment or harm to the operator 3 Press the RAISE push button The dock leveler should NOT raise If the leveler did not raise proceed with step 4 If the leveler did raise decrease dimension A or B Figure 37 so that the targe
54. o Fitting Union Ste 9301 0126 Fitting Union Str 9904 0110 Hose 1 2 17 La 8 JicF Swivel Both Ends 8585 0096 Pressure Differential Valve Complete 56 4111 0010 July 2014 MISCELLANEOUS 57 Powerhook Cylinder Dock Leveler Information Serial No Systems Inc Job No Vehical Restraint Information Serial No Systems Inc Job No Original Owner Information Date of Installation Customer Information NOTE Refer to illustration for left right orientation of dock leveler The LEVELER model serial number decal A is located on the right platform joist near the front lip of dock leveler The RESTRAINT model Serial number decal B is located on the right side near The J Box When you receive your new equipment write down the model and serial number in the form provided This will help ensure safe keeping of the numbers in the event the model serial number decal A becomes lost or damaged Also write down Systems Inc s job number the company that installed the dock leveler and the original owner s name This will all help to identify the specific dock leveler if more information is required When ordering use part numbers and description to help identify the item ordered Do not use item numbers These are only for locating the position of the parts Always give dock leveler MODEL NUMBER and or SEHIAL NUMBER For service call or contact S
55. ock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death With the PowerHook installed in the hook pan and power supplied to the pump motor proceed with the PowerHook adjustments Note Test operating range of PowerHook without transport vehicle backed into dock 4111 0010 July 2014 OPTIONAL EQUIPMENT ADJUSTMENTS Adjust amp Test Dock Leveler and Vehicle Restraint Interlock Figure 38 C 1 in 25 4 mm Approximate D Lock Nuts E Proximity Switch A 3 16 in 6 4 mm Approximate B Target 6 Press the RELEASE button The vehicle restraint should NOT disengage from the transport vehicles RIG bar or test fixture If the restrai
56. ock leveler can be interlocked with the vehicle restraint so that the leveler cannot be operated until the restraint has engaged the transport vehicle RIG Rear Impact Guard when the OPERATION switch is in NORMAL and has NOT been switched to BYPASS and Vehicle restraint The vehicle restraint is interlocked with 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 Leveler and restraint interlocking are overridden when the OPERATION switch is in BYPASS This allows the independent operation of the leveler the vehicle restraint cannot be operated in BYPASS Pressing the restraint ENGAGE button when in BYPASS mode will return the leveler to NORMAL operating mode This option is not available on units equipped with the Auto Return to Dock option When service under the dock leveler is required with power on The platform must be on the maintenance prop and locked out The are must be marked with safety cones and sighs Failure to do this may result in serious personal injury or death 31 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 Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the work area at d
57. off when hook is in stored position If motor does not shut off reposition guide track slightly forward of current position 4111 0010 July 2014 Restraint does not fully Low hydraulic fluid extend or motor over current device and or overload device continuously tripping Restraint lowers fully Solenoid D valve stuck extends but does not ON raise Pump operates in pressure relief Proximity switch on guide track that senses when restraint is fully extended is out of adjustment 38 TROUBLESHOOTING POWERHOOK Proximity switch at trunnion Locate switch on hook trunnion Observe indicator that senses when restraint light at controller input 3 that receives signal lowered target out of from switch Input light should only turn ON when adjustment restraint fully lowered If this does not occur adjust target counterclockwise See Adjustments section Adjust PowerHook Operating Range Use a screwdriver as a temporary target to test switch Replace switch if screwdriver is present and input light on controller does not turn on Proximity switch at trunnion Locate switch on hook trunnion Observe indicator that senses when restraint light at controller input 3 that receives signal from lowered target out of switch Input light should only turn ON when restraint adjustment fully lowered If this does not occur adjust target counterclockwise See Adjustments section Adjust PowerHook O
58. ons of loading dock equipment shall only be done with prior written approval from the manufacturer and the same shall be at least as safe as the original equipment was prior to the modification and shall also satisfy all safety requirements of the manufacturer for the particular application of the leveling device When industrial moving devices are being used in the loading or unloading of product from the transportation vehicle this vehicle shall have the brakes and wheel chocks applied appropriately or all other positive restraining device shall be fully utilized It is recommended that trailers with air ride suspension systems shall have its air exhausted prior to performing loading and unloading operation to minimize trailer bed drop Loading dock safety equipment should never be used outside of its intended use vertical working range or capacity Please consult the manufacturer if you have any questions as to the use vertical working range or capacity of the equipment Only properly trained and authorized personnel should operate the equipment When selecting loading dock safety equipment it is important to consider not only present requirements but also future plans and any possible adverse conditions environmental factors or usage 10 4111 0010 July 2014 INTRODUCTION General Information Congratulations on your choice of a Poweramp PowerHook vehicle restraint This manual covers the When not in use PowerHook stores in
59. or serious injury See owner s user s manual for proper procedures 1751 0729 Rev A A DANGER CRUSH HAZARD Rotate prop to maintenance position Open the pin latch 1 75 1 077 3 1 and insert through the maintenance prop housing Close the pin latch to secure prop Use every time dock leveler is serviced Failure to comply will result in death or serious injury 1751 0731 4 DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is 5 7 safely supported by maintenance prop Place barriers on driveway and dock floor to indicate service work being performed Failure to comply will result in death or serious injury Refer to owner s user s manual for proper maintenance procedures 1751 0726 Rev A Note This is a example of dock leveler safety decals See manual for your specific model for correct safety decal sheet or consulate Tech Services 4111 0010 July 2014 5 A Division of Systems Inc POWERAMP Premium Loading Dock Ami www docksystemsinc com A DANGER If for any reason the platform is raised by means other than the hydraulic system i e Fork truck or crane a hazardous condition may exist because the main hoist cylinder will have air on the load bearing end The cylinder will not support the platform which can fall rapidly potentially causing injuries to anyone under the platform Be sure the leveler is restrained per instructions in the owner s user s manual When repairs se
60. ositioning Locate the needle valve that controls fluid flow to the cylinder blocked cylinder Hook valve block has two needle valves adjust valve adjacent to NV stamped in valve block Turn valve out all the way counter clockwise Turn valve in all the way clockwise Turn valve out 1 1 2 turn counter clockwise Binding inside positioning Locate the positioning cylinder and the hook cylinder weldment Pushing down on the hook weldment should extend the positioning cylinder and releasing the weldment should allow the positioning cylinder to retract Consult factory if this does not occur 40 4111 0010 July 2014 TROUBLESHOOTING POWERHOOK Obstruction preventing the Remove obstruction restraint from lowering Locate the needle valve that controls fluid flow to the cylinder Hook valve block has two needle valves adjust valve adjacent to NV stamped in valve block Turn valve out all the way counter clockwise Turn valve in all the way clockwise Turn valve out 1 1 2 turn counter clockwise Locate the positioning cylinder and the hook weldment Pushing down on the hook weldment should extend the positioning cylinder and releasing the weldment should allow the positioning cylinder to retract Consult factory if this does not occur Proximity switch at trunnion Locate switch on hook trunnion Observe indicator light at controller input 3 that receives signal from switch Input light should only turn ON when restraint fu
61. perating Range Use a screwdriver as a temporary target to test switch Replace switch if screwdriver is present and input light on controller does not turn on Solenoid B valve stuck Locate solenoid See Parts Valve Block OFF Remove coil from cartridge valve and cartridge valve from valve block Check valve for contaminant s and or damage Replace valve if damaged Carefully wipe valve with clean rag do not damage O rings on valve Check valve block for contaminant s Replace valve and coil NOTE Do not over tighten valve into block Max Torque 30 40 Ib ft or snug to prevent leakage Tighten coil snug avoid over tightening and causing valve to bind Operate unit Replace valve if problem persists and all other troubleshooting procedures performed Solenoid B coil is not 1 Check controller output that sends a signal to receiving signal to energize solenoid Output may have failed OPEN Use A solenoid that is energized meter to check for contact closure when output will act like a magnet is ON Place a metal tool on coil of solenoid to determine if coil 2 Check all wiring to solenoid for high resistance is receiving signal loose or no connection solenoid B coil receiving Coil failed OPEN Consult Factory for replacement signal but not energizing part 39 Restraint extends from stored position without fully lowering Restraint extends from stored position without lowering at a
62. position after which the platform will return to the cross traffic position The switch also contains an indicator light H that can be used for diagnosing and adjusting the switch NOTE The proximity switches has an indicator light at the back of the housing and some have the light at the side of the housing 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 Failure to do this may result in serious personal injury or death 4111 0010 July 2014 OPTIONAL EQUIPMENT ADJUSTMENTS 6 Turn ON electrical power to the dock leveler 7 Disengage the maintenance prop 8 Turn the ARTD switch on control panel to the ON position 9 Raise the platform until the lip is fully extended then allow the platform to drift to the below dock position After approximately 6 seconds the platform will return to the cross traffic position Adjust the proximity switch and target as necessary Make small adjustments then operate the dock leveler to check results Do this until satisfied with the ARTD operation Use the following illustrations to assist in fine tuning and or diagnosing the ARTD operations Cross Traffic Position Lip Keeper The platform lip is fully folded when the platform is at the cross traffic stored position lip engaged with keepers or when platform is resting on the
63. rame angle of the dock leveler is tight against the rear curb angle and flush with the dock floor C Make sure there is equal clearance between the sides of the leveler platform and the pit walls 6 Remove the shipping bands from the unit 7 Use fork lift or other method to raise dock leveler platform Electrical J Box Rear Imbed Rear Imbed Electrical J Box KS7 Pit KS6 Pit 16 4111 0010 July 2014 INSTALLATION Position shims under the hinge tubes of the maintenance prop so that the front panel support weldment is level Recommended shim stock sizes see Figure 8 Use fork lift or other method to raise dock leveler platform to a height that will allow use of the maintenance prop The maintenance prop is accessible when the platform is raised The top of the prop should be positioned directly behind the front header plate of the platform See Figure 4 Make sure that the front and rear legs are resting firmly and securely on the shims set on the pit floor Do not weld shims at this time Use a fork lift or other method to raise the leveler platform Remove the maintenance prop Set the platform in the cross traffic position lip fully folded inside the keepers and the platform level with the dock floor See Figure 5 Make sure the dock leveler deck is flush with the dock floor and that the top rear frame angle of the unit is tight against and flush with the rear pit curb angle Raise platform install correct size
64. rvice is complete unit must be operated in the raised direction only until visible movement of platform indicates cylinder is full If alternate liffing means are still available use to return platform to original lowered position and then raise unit hydraulically ATTENTION INSTALLER Replace rear plug with breather cap Do not overfill Oil should fill 72 site glass Use ULTRA VIS HVI 15 or MIL SPEC 5606 Questions Call 800 643 5424 ADANGER CRUSH HAZARD DO NOT REMOVE hydraulic cylinder until leveler is safely supported by maintenance prop Refer to owner s user s manual for proper maintenance procedure Failure to comply will result in death or serious injury A Division of Systems Inc MP VS Series www DockSystemsinc com 1 800 643 5424 800 643 5424 POWE Decal 2 will have two positions one on the left outside beam as shown and one on the right outside beam in the same position Decal 3 will be positioned on the upper most corner of the right outside beam mirror position of decal 7 Dock Leveler Safety Decal s A DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is safely supported by maintenance prop Place barriers on drive way and dock floor to indicate service work being performed Refer to owner s user s manual for proper maintenance procedures Failure to comply will result in death or serious injury A DANGER CRUSH HAZARD DO NOT WORK UNDER DOCK LEVELER unless a
65. shims Check for equal clearance between the sides of the platform and the pit walls Weld the top rear frame angle to the rear pit curb angle Weld behind each hinge tube of the leveler platform See Figure 6 Powerhook KS6 units only Tack weld the shims under the front legs to the legs the plates imbedded in the pit floor and to the pit front curb angle This should be done from outside the pit prior to raising platform See Figure 6 Repeat step 9 Finish weld all shims to unit and where possible to plates or pit curb angles Weld shims together where stacked Refer to Figure 8 A On levelers with single hoist cylinder shim the hoist cylinder support so that the center channels are level Weld shims in place B On levelers with dual hoist cylinders shim under the cylinder supports so that the side channels are level In addition shim under the center beam support so that the center beam is level Weld all shims in place Weld fish plates to the center channels of the leveler and to the plate imbedded in the rear pit wall Refer for recommended fish plate sizes and location Figure 7 Clean and paint all welds Weld and or bolt bumpers in place on face of dock Refer to certified Pit Drawing If leveler is part of a Centra Power system or if the power pack is located remotely connect the hydraulic hoses to the dock leveler as indicated in the Centra Power manual instructions Check the hydraulic fluid level Standard units are s
66. spect all safety labels and tags to ensure they are on the dock leveler and are easily legible If any are missing or require replacement please call 1 800 643 5424 A DANGER CRUSH HAZARD Maintenance prop must fo r re p l ace m e nts support leveler behind bar 1 751 0727 Do not force maintenance prop forward of bar to support lip Failure to comply will result in death or serious injury Refer to owner s user s manual for proper use 1751 0730 x2 SAFETY INF instructions and sides of mc L 8 N Unsupported dock leveler ramps can lower unexpectedly Before allowing vehicle to leave the dock always e Ensure no equipment material or people are on dock leveler e Return dock leveler to its stored position at dock level Failure to follow posted instructions will result in death or serious injury decal placed in same position on both sides 1751 0329 x2 decal placed in same position on both sides 1751 0330 x2 decal placed in same position on both sides A DANGER CRUSH HAZARD 1 7 5 1 0 1 3 8 DO NOT REMOVE hydraulic cylinder until leveler is safely supported by maintenance prop Refer to owner s user s manual for proper maintenance procedure Failure to comply will result in death or serious injury 1751 0729 ADANGER CRUSH HAZARD Do not work under dock leveler unless this maintenance prop has been secured in the upright position Failure to comply will result in death
67. stallation instructions are to be used as basic guide lines for proper installation There may be different techniques to install the levelers but installation must conform to the correct welding and shimming as shown in the owners users manual Fig 1 KS4 PowerHooke The PowerHooke KS4 box type vehicle restraint is ideally suited for Vertical Leveler installations The larger box form with insulated lid is fully assembled and ready to be poured in place during the construction process Fig 2 KS5 PowerHooke The PowerHooke KS5 pan type vehicle restraint is an economical retrofit for dock levelers The fully assembled pan ships complete with all the concrete anchors needed to insure a secure installation Fig 3 KS6 PowerHooke The PowerHooke KS6 free standing frame type vehicle restraint is fully installed and integrated into full height leveler stand It s easy to install just weld it into position and run power to it 10 4111 0010 July 2014 INSTALLATION Post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before installation has been completed Failure to follow the installation instructions can result in damage to dock leveler the facilities and or serious personal injury or death IMPORTANT DO NOT connect the dock leveler electrical wiring and ground connections until all welding has been completed DO NOT ground we
68. t Interlock 31 Adjust Auto Return To Dock ARTD 32 Troubleshooting Troubleshooting 36 POG ATAU PS T 45 FOFCMO 47 Wining P e REED 48 Parts e P 50 PowerHook Guide Track Components 51 PowerHook Components Lecce eere erae nena nena aan 52 PowerHook Valve Body Assembly 53 Power Pack 0500 uui deucc usu uus o xao ESR 54 e 56 Miscellaneous Customer Information ci n sss ss cesses ecce se essen ennenen Qu ME m 57 MU EE a a Back Cover 4111 0010 July 2014 SAFETY General Operational Safety Precautions Read and understand the operating instructions and become thoroughly familiar with the equipment and its controls before operating the dock leveler Never operate a dock leveler while a safety device or guard is removed or disconnected Never remove DANGER WARNING or CAUTION signs or Decal s on the equipment unless replacing them Do not start the equipment until all unauthorized personnel in the area have been warned and have moved outside the operating zone Remove any tools or foreign objects from the operating zone before starting Keep the operating zone free of obstacles that could cause a person to trip or fall Recognize
69. t Main Pressure Relief in the Adjustment section NOTE The pressure relief valve must not be set at a level that causes the motor operating current to exceed the full load amp value at any time including when operating in pressure relief The full load amp value can be found on the inside cover of the control panel Platform rises slowly Low hydraulic fluid Add fluid see Maintenance section for proper fluid level and type Contaminated hydraulic Clean and inspect valves Flush contaminated oil system from hydraulic system Fill system with new oil See Periodic Maintenance in the Maintenance section Damaged or restricted Replace damaged hose s Remove restriction hydraulic hose s Pressure relief set too low Increase pressure relief See Adjust Main Pressure Relief in the Adjustment section NOTE The pressure relief valve must not be set at a level that causes the motor operating current to exceed the full load amp value at any time including when operating in pressure relief The full load amp value can be found on the inside cover of the control panel Pump motor loads down Pressure relief set too high Decrease pressure relief See Adjust Main Pressure when platform reaches Relief in the Adjustment section the full raised position NOTE The pressure relief valve must not be set at a level that causes the motor operating current to exceed the full load amp value at any time incl
70. t damage when level is removed Review the Field Wiring Drawing and the certified pit drawing attached to this manual 3 Reconnect hoses to the logic block 4111 0010 July 2014 15 INSTALLATION Powerhook 456 and KS7 Installation instructions Additional installation procedures not given in this manual may be required See the CENTRAPOWER manual for more information Preparation 1 Some units are shipped with the control assembly bumpers and outside light assembly attached to the unit Remove these items from unit prior to installing unit in pit DO NOT remove the shipping bands at this time 2 Remove all debris from the pit 3 Check the pit dimensions with the certified pit drawing attached to this manual Make sure that the walls of the pit are plumb and square with no bulges Check dock height location of imbed plates and J box Installing unit in pit 4 Place the shims for the front and rear of the leveler on the imbed plates in the pit floor Position the shims so that the legs will rest firmly on the shims when the unit is lowered into the pit Shim so that dimension from top of shims to dock floor is as shown Recommended shim stock sizes see Figure 8 5 Install the leveler into the pit with the lifting brackets on the side of the platform Perform the following checks before setting leveler into pit A Make sure the front and rear legs will rest securely on the shims set on the pit floor B Make sure the top rear f
71. t is in the sensing range of the switch Typical factory settings for A and B are approximately 3 4 and 1 8 respectively Make adjustments at switch dimension B and or target dimension A until leveler does not raise when the vehicle restraint is not engaged on transport vehicles HIG bar 4 Momentarily press the ENGAGE button The vehicle restraint will be activated and the restraint will engage the transport vehicles RIG bar 5 Raise the dock by pressing the RAISE button until the lip is fully extended Release the RAISE button The leveler will drop to the floor of the transport vehicle If a RIG test fixture is used it should allow the leveler to drop to the full below dock position without the contact between the lip and test fixture 32 OPTIONAL EQUIPMENT ADJUSTMENTS Adjust the ARTD as Follows Raise platform fully and engage the maintenance prop in the service position Allow platform to rest on the prop so the lip will fully fold until it contacts the lip stops 2 Turn OFF all electrical power to the dock leveler Attach safety lockout and tag out devices When service under the dock leveler is required with power on The platform must be on the maintenance prop and locked out The are must be marked with safety cones and sighs Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized
72. uding when operating in pressure relief The full load amp value can be found on the inside cover of the control panel Trouble shooting Levelers see appropriate manuals 44 4111 0010 July 2014 PROGRAMMING ISSUES FOR PROGRAMMING e Error and or run light is flashing PLC program is either missing or damaged e Update to newer program e Installation of new un programmed PLC MATERIAL REQUIRED You will receive two 2 E proms e Blank run E Prom e Program Specific E Prom INSTALLATION 1 Turn power off power remove existing E Prom if present 2 Insert new Blank Run E Prom 3 Turn power on for 60 seconds 4 Turn power off for 10 seconds repeat cycle 3 times Prom Location e Insert program chip program specific Repeat steps 1 3 and 4 Allow light sequence to IM Pos complete flashing Run light should be on STEADY not flashing Error light should NOT be on Check for proper input and out put lights on the PLC If not repeat steps 3 and 4 until PLC responds properly If the PLC does not accept the program or if questions contact the Tech Service Department at 800 643 9424 Note The PLC will maintain the program even if the power is turned off E Prom 4111 0010 July 2014 45 TROUBLESHOOTING POWERHOOK This is for standard Powerhooks only This is for Powerhooks that have a Telemecanique Twido computer PLC only This is for Powerhooks that have the new style valving only
73. use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death 33 Adjust Auto Return To Dock ARTD A Cable E Target B Proximity Switch F Lip Hinge Tube C Bracket G Platform Lip D Lock Nuts H Indicator Light Standard leveler with Powerhooks are equipped with Interlock unless leveler has option of Auto Return To Dock ARTD The ARTD allows the platform to automatically return to the cross traffic stored position after the vehicle departs The ARTD uses a proximity switch B located under the platform and a piece of angled steel called the target E that is attached to the lip hinge tube F The PLC provides a six second delay after the platform has lowered to the full below dock
74. w Poweramp hydraulic leveler in a newly prepared pit skip steps 1 through 5 Platform modifications step 5 were completed prior to shipment When installing PowerHook with a Poweramp hydraulic dock leveler which is powered by remote power pack or a Centra Powere system refer to the manuals provide with those units as well as to page 15 in this manual When installing Powerhook with a mechanical dock leveler or a hydraulic dock leveler manufactured by another company the PowerHook must be equipped with a remote hydraulic power pack See page 53 of this manual 1 Reviewthe Field Wiring Drawing and the certified pit drawing attached to this manual The PowerHook KS4 vehicle restraint with a hydraulic dock leveler requires two separate 3 4 conduit runs from the control assembly to the junction box located at the rear pit wall An additional conduit if required may be run either in a trench dug in the concrete or in a space between the pit walls and the dock leveler 2 Install storage props on both side of the leveler and the safety pin on the maintenance prop 3 Shutoff all power to dock leveler control assembly 4 Modify the underside of the dock leveler platform as indicated on the Dock Leveler Modification Drawing s attached to this manual 5 Remove hydraulic fluid To do so locate the return port at the drive plate for the hydraulic pump Set a catch vessel below the port Remove the hose at the return port and
75. will determine the upper vertical limit of the hook movement B Disconnect the Hydraulic hose from the hold down cylinder Cap off the open fittings to prevent fluid loss and to prevent contamination from entering the system C Remove the keepers from the hold down cylinder trunnion D Lift up on the hook cylinder This will allow the hold down cylinder to exit the trunnion E Support hook cylinder loosen the jam nut that is on the threaded eye of the hold down cylinder 28 at 10 O clock ADJUSTMENTS 3 prox switch Start Adjustments Position Figure 12 A Hook Lowered Sensor C Hook Lowered Sensor Target Bar Bracket B Powerhook Hold Down D Flat Washer Weldment E Trunnion Bolt 4 Check lights Inside Green Outside Red 5 Test dock leveler operation See dock leveler Owner s Manual 6 Checking of Alarm if equipped and Lights for Premature Vehicle Departure can be accomplished by having a vehicle attempt to pull away from an engaged hook It is not recommended due to potential damage to RIG bars that may not be up to current strength standards Press RELEASE button The PowerHook should disengage from the RIG bar and restore behind the dock wall Power pack should then shut off 8 Check Lights Inside Light Red Outside Light Green 29 Adjust PowerHook Operating Range 1 Adjust the lower vertical limit of hook operating range if necessary A Lo
76. y 2014 37 TROUBLESHOOTING POWERHOOK Add fluid see Maintenance section for proper fluid level and type Locate solenoid See Parts Valve Block Remove coil from cartridge valve and cartridge valve from valve block Check valve for contaminant s and or damage Replace valve if damaged Carefully wipe valve with clean rag do not damage O rings on valve Check valve block for contaminant s Replace valve and coil NOTE Do not over tighten valve into block Max Torque 30 40 Ib ft or snug to prevent leakage Tighten coil snug avoid over tightening and causing valve to bind Operate unit Replace valve if problem persists and all other troubleshooting procedures performed Locate switch on end of guide track closest to hook tip Observe indicator light at controller input 4 that receives signal from switch Input light should turn OFF when restraint fully extended If this does not occur Check switch position loosen two guide track mounting bolts tap guide track assembly back towards rear pit wall Switch should be positioned approximately 1 4 from the inside wall of the track Make sure that the switch face does not extend further than the guide track mounting bars welded to the cylinder Position switch so that face will not come into contact with guide rod Tighten nuts to secure switch DO NOT over tighten nuts Maximum tightening torque is 25 Ib ft Run restraint Make sure motor shuts
77. ystems Inc P O Box 309 Germantown WI 53022 Phone 800 643 5424 Fax 262 255 5917 4111 0010 July 2014 STANDARD PRODUCT WARRANTY SYSTEMS INC 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 In no event shall any claim be made more than 30 days after this warranty has expired In order to be entitled to the benefits of this warranty the product 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 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 INC covered by this warranty SYSTEMS INC shall remedy such defect by repairing or replacing any defective equipment or parts bearing the cost for the parts labor and transportation This shall be exclusive remedy for all claims whether based on contract negligence or strict liability WARRANTY LIMITATIONS THE ABOVE WAR

PowerHook® Owner`s/User Manual

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PowerHook&reg; Owner`s/User Manual

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PowerHook® Owner`s/User Manual