TPR® Owner`s/User Manual
Contents
1. LTI DO NOT ENTER P d 122 4111 0035 April 2015 17 INSTALLATION INTERLOCKING LOAD DATA AND NOTES OP TIONAL R E INTERLOCKING OR DRY INTERLOCKED CONTROL CIRCUIT CONTACT RATING 7 5 A GEN USE 9 120 VAC POWERAMP PROVIDES YELLOW COLOR 14 16 AWG CONDUCTORS FOR THIS WIRING LINE 120 9550 LOAD DATA EXTERNAL CONTROL CIRCUIT LOADS ALL LOADS 12 VDC LEGEND AMP RATING 13 4 0 13 12 V EACH COMPONENT LOCATION TABLE COMPONENT LOCATION INDICATED BY PHANTOM LINES A DRAWING SHOWS SYSTEM AT REST WITH POWER OFF amp RESTRAINT FULLY LOWERED REPRESENTS A TERMINAL BLOCK C WRE COLORS NEAR COMPONENT REFER TO COLOR OF WRE SUPPLIED BY THE COMPONENT MFCR D NUMBERS NEAR COMPONENT REFER TO NUMBERS FOUND ON THE TERMINALS OF THE COMPONENT 18 4111 0035 April 2015 Operating Instructions Stay clear of dock leveler when transport vehicle 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 personal2. N i n pom LOW VOLTAGE 12V POWER RED BLK _ WIRE HARNESS Es LED CORD GRIP WHT BLK 7 BLK i BLUE RED RED BLK 32 4111 0035 April 2015 PARTS TRANSFORMER DOES NOT INCLUDE FUSES RED LED MODULE 12 VOLT GREEN LED MODULE 12 VOLT AMBER LED MODULE 12 VOLT OPTIONAL 10 AMBER LENS OPTIONAL I 13 ALARM OPTIONAL SELECTOR SWITCH KEY SWITCH OPTIONAL NOT SHOWN 15 KEY ONLY 4111 0035 April 2015 33 PARTS ITEM QTY DESCRIPTION SCREW 3 8 16 X 1 1 2 HH CAP SCREW 5 16 18 X 1 HH 34 4111 0035 April 2015 PARTS z CAP SCREW 1 4 20 X 1 1 2 SOCKET HEAD BUSHING MACHINERY 1 3 4 OD 1 1 4 ID 1 8 THICK KEY HOOK 1 4 X 1 4 X 1 1 4 NUT NYLOCK 7 16 14 1 1781 0735 DECAL MADEINTHEUSA _ NUN 15 N lt 11 12 13 14 15 16 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 4111 0035 April 2015 35 PARTS 36 4111 0035 April 2015 PARTS WASHER FLAT 1 X 18 GAUGE NUT LOCK 7 16 14 SERRATED FLANGE e 1 ommo SOPEEXENSON SSCS 4111 0035 April 2015 of PARTS OSLA Outside Light Assembly s amos GREEN LED Lens wok 4 Ls 4 4 4 3051 0105 Clips Lens Holding 305
3. 50 IN LBS IN 10 IN LB INCREMENTS USE TIGHTENING SEQUENCE SHOWN AT RIGHT 4111 0035 April 2015 TROUBLESHOOTING Symptom Possible Cause Solution 2 Vehicle restraint lights do p functi Check for blown fuse at branch circuit not flash and the hook does disconnect not raise Verify electrical schematics page 16 TPR vehicle restraint lights are uu flashing but the hook does not Chain is loose or broken Adjust or replace as required raise or lower to full extent Low incoming voltage Verify in coming power at L1 and L2 Drive motor defective Check motor repair or replace verify wiring per electrical schematic break torque should not exceed 42 Incorrect break torque Fale TPR vehicle restraint is opera If brake torque is less than 42 ft lbs tional but hooks drops causing y or chain is loose or broken adjust or lights to change and horn to replace as required sound w hile trailer is being serviced Check motor Repair or replace as Drive motor defective needed TRP vehicle restraint Is opera LED liahte Check and replace Led lights as tional but all lights are out gnis needed TPH vehicle restraint horn does not sound but hook and lights are operational Power horn using 12V DC if does not sound replace horn page 17 Horn is defective Lights not working in correct order Verify all field wiring connections are Incorrect wiring correct page 16
4. Inside Red does not change Defective LS1 Out side lights and inside Green light Defective L2 does not change Broken or weak springs Recommend to replace all springs TPR vehicle restraint carriage does not return to full up posi tion Verify that the roller track plate is straight and damaged Damaged roller track plate Clean debris out of roller track and or Carriage binding in track verify roller bearings are greased and move freely 4111 0035 April 2015 29 TROUBLESHOOTING LIMIT SWITCH TEST PROCEDURE Set multimeter to Ohms Continuity Test Attach multimeter leads to pins B and C of limit switch connector You should have plunger released no meter reading plunger depressed a Full Scale meter reading LIMIT SWITCH MOUNTING BODY BOLT HOLES BODY A 30 NOTE The green ground wire of the limit switch does not have to be tested A continuity test lamp may be used instead of a multimeter HOOK POSITION VIEW A A 151 POSITION 152 POSITION INSIDE OUTSIDE ucHr LIGHT MORN 1 STORED 2 NO HOOK LOWER POS 3 HOOKED 90 CLOSED DEPRESSED CLOSED DEPRESSED OPEN DEPRESSED OPEN RELEASED CLOSED DEPRESSED CLOSED DEPRESSED RED GREEN OFF 4 NO HOOK UPPER POS CLOSED DEPRESSED CLOSED DEPRESSED 4111 0035 April 2015 TROUBLESHOOTING TPR 2
5. April 2015 27 ADJUSTMENTS DRIVE CHAIN ADJUSTMENT 1 Inspect the drive chain periodically for dirt and chain slack Open the motor enclosure and clean the chain with solvent After cleaning spray with a high quality chain spray type lubricant The drive chain should not have more than 1 4 slack To tighten chain Open motor enclosure and loosen the three 4 motor mounting bolts Pry the motor assembly forward in the slotted holes until the chain is tight with proper alignment between sprockets Hold in this position and tighten the three 4 motor mounting bolts to 5 ft Ibs LUBRICATE DRIVE CHAIN AND LIMIT SWITCH MOUNTING BRACKET USE SPRAY GREASE 2000 OR EQUAL When working with electrical or electronic controls make sure that the power source has been locked out and tagged according to OSHA regulations and approved local electrical codes BRAKE TORQUE ADJUSTMENT 1 Loosen brake adjuster locknut while holding the adjuster screw to prevent inadvertent adjustment 2 Turn adjuster screw clockwise to increase brake torque as needed Fightenagjusterlocknut while holding the adjuster screw to prevent inadvertent adjustment 4 Verify brake torque is greater than 42 ft lbs at the hook shaft readjust as required USE TORQUE WRENCH LOCKNUT BRAKE ADJUSTER SET SCREW LOOKING AT BOTTOM OF MOTOR MOUNTING PLATE 28 T E eu RE 5 ic 4 MOTOR MOUNTING BOLTS
6. clear of obstructions Always operate the vehicle restraint from the top of the dock Inspect all restraint lights daily to make certain they work properly Perform maintenance on restraints in accordance with Maintenance in this manual vehicle restraints should be operated only by authorized personnel who have read and understand the Owner s User s Manual If you have questions Call your local representative or Systems Inc at 800 643 5424 FAILURE TO FOLLOW THESE PROCEDURES COULD RESULT IN SERIOUS INJURY OR DEATH OPERATION Stored Position Restraint UNLOCKED 3 Light System Hook is in the STORED position Inside light is flashing RED alerting forklift operator unsafe condition exists Outside light is flashing GREEN alerting transport vehicle driver it is safe to back in RESTRAINT POSITION cum 1 6 11 GREEN RESTRAINT POSITION RED gt 152 H Y GREEN ENGAGE Button Depressed Restraint ENGAGING 3 Light System Transport vehicle has backed into loading dock and is parked firmly against dock bumpers Hook rotates from stored position to engage Outside light is flashing RED alerting transport vehicle driver not to move Inside light flashing GREEN If YELLOW caution light comes on proceed to FAULT otherwise proceed to Restraint ENGAGED 20 4111 0035 April 2015 OPERATION RELEASE
7. FROM BRANCH CIRCUIT DISCONNECT SWITCH 4 RELEASE 43 551 NORMAL BYPASS ENGAGE GRD TRI DUAL SINGLE SHOT 7 2 1 5 SEC PB2 MIRI 3 3 FLA THERMALLY PROTECTED 551 NORMAL BYPASS 57 DO NOT ENTER 2 FLI 55 FLASHER 1 9 DIO1 R E INTERLOCKING OR DRY INTERLOCKED CONTROL CIRCUIT CR2 NU Be N LT2 ENTER Or X2 OPTIONAL j 1 082 OPTIONAL CRI 61 002 62 14 2 1X LT3 CAUTION OPTIONAL STROBE LT6 200 0104 0105 N RED O BLK LTS RED Q BLK N LT4 RO 16 4111 0035 April 2015 INSTALLATION Li CUSTOMER SUPPLIED N 115 V 1 PHASE 60 HZ FROM BRANCH CIRCUIT DISCONNECT SWITCH amp OVERCURRENT BY OTHERS SELECT DISCONNECT SWITCH amp OVERCURRENT DEMCE PER THE NEC 551 NORMAL BYPASS ENGAGE NL GRD 100 2 3 4 X0 1 101 102 103 PB2 RELEASE MIRI 3 3 1 FLA 43 4 HERMALLY PROTECTED 104 JUMPER 105 106 107 108 109 110 111 112 1 FLASHER 113 99 1M 115 116 117 118 551 NORMAL BYPASS 119 OPTIONAL INTERLOCKING OR DRY INTERLOCKED CONTROL CIRCUIT CRI OPTIONAL 120 200
8. LIGHT SEQUENCE OF OPERATION SWITCHES amp LIGHTS NORMAL OT mestrain In Light Light Alarm Panel Fully Lowered Activated Not Activated OFF R G Not Fully Lowered 8 R FF In Working Zone c Not Activated Activated Fully Raised Activated Activated R R oN BYPASS OT mestrain In Light Alarm Panel Fully Lowered Activated NotActivated R OFF Not Fully Lowered Not In Working Zone p ctvatec Activated R amp G OFF In Working Zone c Not Activated Activated Fully Raised Activated Activated a An Amber light not in the 2 light design b Not Fully Lowered Not at ICC Bar and Not Fully Raised c Not Fully Lowered Supposingly at ICC Bar and Not Fully Raised TPR 3 LIGHT SEQUENCE OF OPERATION SWITCHES amp LIGHTS NORMAL Switches Lights LS1 152 Out Light R 06 Activated BYPASS osition of Restrain n Light Out Light Fully Lowered Activated Not Activated G amp A R Not Fully Lowered In Working Zone b Not Activated Activated G amp A R Fully Raised Activated Activated G amp A R a Not Fully Lowered Not at ICC Bar and Not Fully Raised b Not Fully Lowered Supposingly at ICC Bar and Not Fully Raised 4111 0035 April 2015 31 HARNESS LOW VOLTAGE 12V POWER gt ORG GND WHT BLK
9. NOT LIMITED TO BREACH OF WARRANTY LOSS OF USE LOSS OF PROFIT INTERRUPTION OF BUSINESS OR LOSS OF GOODWILL
10. for replacements 4A DANGER CRUSH HAZARD Maintenance prop must support leveler behind bar 1 15 1 0727 Do not force maintenance prop forward of bar to support lip Refer to owner s user s manual for proper use Failure to comply will result in death or serious injury 1751 0730 x2 SAFETY INFORMATION Unsupported dock leveler ramps can lower unexpectedly Before allowing vehicle to leave the dock always e Ensure that no equipment material or people are on the dock leveler e Return the dock leveler to its stored position at dock level Failure to follow posted instructions will result in death or serious injury war 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 DANGER CRUSH HAZARD 1 75 1 0 1 3 8 DO 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 See owner s user s manual for proper procedures Failure to comply will result in death or serious injury 1751 0729 A DANGER CRUSH HAZARD Rotate prop to maintenance positio
11. 1 0104 Screw Lens Holding Clip 7 3 x Conduit Fastener 3 4 x 3 8 Included in Light Package 38 4111 0035 April 2015 ADANGER Read and follow all instructions warnings and maintenance schedules in the manual and on placards Vehicle restraint operation and servicing is restricted to authorized personnel Before using the vehicle restraint Remove any debris snow or ice that may obstruct vehicle restraint operation Alert personnel in the area of potential vehicle restraint operation and ensure area is clear Operate the vehicle restraint through 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 approved lockout tagout procedures Before attempting to restrain a transport vehicle e Verify that transport vehicle is positioned squarely against dock bumpers Inspect the transport vehicle s rear impact guard RIG Damaged or missing RIGs may not allow the vehicle restraint to securely capture the 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 affect trailer height After activating vehicle restraint e Verify that the transport vehicle s RIG has been restrained successfully In the event this cannot be determin
12. 35 April 2015 SAFETY General Operational Safety Precautions Read and understand the Owner s User s Manual 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 SAFETY Operational Safety Precautions Learn the safe way operate this equipment Read and understand the manufacturer s instructions If you have any questions ask your supervisor we ewer Stay clear of dock leveling device when transport Chock restrain all transport vehicles Never remove vehicle is entering or leaving area the wheel chocks until loading or unloading is finished and transport vehicles driver has been given permission to drive away Exe Teu Do not use broken or damaged dock leveling Do not move or use the dock leveling device if device Make sure proper service and maintenance anyone is under or in front of it procedures have been performed before using _ We Keep han
13. 5 9 INSTALLATION INSTALL ROLLER TRACK PLATE Install roller track plate onto dock face at specified location by welding to an embedded steel plate or by using the fifteen 15 concrete anchors provided in conjunction with welding to pit steel and a leveler frame If you have questions contact Technical Support at 800 643 5424 The roller track plate must be plumb with dock face If not use and weld 6 shims 2 wide x 25 5 8 long If shims are over 1 2 thick use longer anchors If shims need to be 1 thick or more contact McGuire Technical Support NOTE Trim roller track plate as necessary up to a maximum of 5 from the bottom NOTE Some mechanical dock levelers have an adjusting nut access hole in the leveler front subframe If the TPR vehicle restraint roller track interferes with the access hole the track plate must be cut to allow access NOTE Some levelers are slightly recessed within the pit and thus require a shim to be inserted between the roller track plate and the leveler front subframe and welded in place Fifteen 15 concrete anchors are provided with each vehicle restraint An anchor must be installed in each roller track plate hole except for those plug welded to embedded steel 10 ACROSSTOP OFTRACK PLUG WELDED FRONT PIT 3 OR MORE CURB ANGLE LACES DRILL 5 8 HOLE 4 5 8 MIN DRILL DEPTH FOR ANCHOR 2 PLACES 2 5 8 MAX GAP
14. 505 5255 ursa essi rss 30 MONTE E 32 Parts Control box Lights Signs c ccceee eec eeeee ee eeeee nn 33 Assembly 34 Roller track and Springs chic pue Uus ss Era Esau RUE UE CORN EUN 36 Carriage Assembly rc 37 Out Side Light Assy 115 1 38 Miscellaneous 1 Orica ees cee ss m 39 Outside Caution signs mirror 2 2 40 Customer Information 0 nnmnnn 41 WU PRETI Back Cover Recognize Safety Information Safety Alert Symbol The Safety Alert Symbol identifies NOTICE 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 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 The use of the word NOTICE is to draw attention to a procedure that needs to be followed to prevent machine damage 4111 00
15. A Division of Systems Inc T R TM Emenee Restraint POWERAMP Division of Systems Inc W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 255 5917 www docksystemsinc com techservices 9 docksystemsinc com Printed in U S A Manual No 4111 0035 Copyright 2015 April 2015 Table of Contents Page Safety Recognize Safety Information eee 1 General Operational Safety Precautions 1 DSC ON c 5 Owner s User s Responsibilities 7 Introduction General 0 8 9 Installation Installation Roller Track 4 10 12 installati n M 14 Electrical Schematics RET 16 Operation Operating Instructions eet 19 Sequence of 000 10 Vui uds 20 Maintenance Service Dock Leveler Restraint Safely 24 Periodic Maintenance ct RSm 27 Adjustment DAVE CDU E E EDD 28 Brake IG c 28 Troubleshooting Troubleshooting Charts E Pacis 29 Limit SWIICDBS 5254 5
16. AD 1751 0034 OUTSIDE SIGN MIRROR IMAGE 1751 0036 OUTSIDE SIGN ENTER ON GREEN ONLY 40 4111 0035 April 2015 MISCELLANEOUS Customer Information The model serial number deal A is located on the Dock Leveler Information right side panel of the restraint When you receive your Poweramp product write down the product model and serial number in the Serial No form provided This will help ensure safe keeping of the numbers in the event the model serial number Systems Inc Job No decal A becomes lost or damaged Also write down Systems Inc s job number the Original Owner Information 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 Address 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 SERIAL NUMBER For service call or contact Address Systems Inc P O Box 309 Germantown WI 53022 Phone 800 643 5424 Fax 262 255 5917 Date of Installation 4111 0035 April 2015 41 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 yearfrom the date of shipment All claims for breach of this warranty must be made wit
17. ALLATION Disconnect supplied by others Place control box where best suited withi arms reach at eye level near door opening Inside Caution sign Allow adequate space for seals and shelter Inside light 4 1 and control 8 box Outside lights Outside Caution Sign Dock Sea AT l gt 2 96 Junction box mounted on dock face not to extend out if AE 3 4 Conduit or more than 3 22550 Di A lameter per Local Code Supplied by 7 Supplied by others others Optional imbed plated 20 20 Center Line of Dock and TPR 55 14 4111 0035 April 2015 INSTALLATION 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 7 4111 0035 April 2015 15 INSTALLATION 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 125 CUSTOMER SUPPLIED 115 V 1 PHASE 60 HZ amp OVERCURRENT DEVICE BY OTHERS SELECT DISCONNECT SWITCH amp OVERCURRENT DEVICE PER THE NEC
18. An alternate means of securing the transport vehicle must be used e g wheel chocks if the hook can not capture the RIG Switch selector switch to BY PASS silences the ALARM Inside lights are flashing RED and GREEN alerting the forklift operator the trailer is secured by other means Outside light is flashing RED alerting the transport vehicle driver not to move To return to STORED turn the BY PASS to NORMAL and press the RELEASE button hook was not STORED already 4111 0035 April 2015 25 MAINTENANCE Service Dock Leveler Restraint Safely When working with electrical or electronic controls make sure that the power source has been locked out and tagged A B according to OSHA regulations Safe operation of the TPR truck restraint requires and approved local electrical codes all lights and the Alarm to be working properly DO NOT use TPR vehicle restraint if parts are broken Post safety warnings and barricade work area at dock or missing level and at ground level to prevent unauthorized use of the dock Use lifting device e g crane jack when lifting car NOTE If a leveler is installed at the TPR vehicle riage approx 110 6 Lifting by hand may cause restraint location it may be necessary to raise the leveler before performing maintenance Raise the leveler insert and secure the maintenance strut C and LOCKOUT TAGOUT A B the power source back injury 26 4111 0035 April 2015 MAI
19. BY PASS from ENGAGING State 2 Light System Hook cannot engage the HIG The restraint must engaged and in the Hook rotated fully up the ALARM will sound Switch the selector to BY PASS The GREEN inside lights will flash ALARM will turn off Proceed with caution Outside light will flash RED RESTRAINT POSITION RED x x 7 YELLOW GREEN 1 1 BY PASS RESTRAINT POSITION GREEN NORMAL BY PASS to STORED State 2 Light System Once loading or unloading complete Switch the selector to NORMAL ALARM will sound Press the RELEASE but ton IF hook is not in the stored position inside light will flash RED Outside light will flash GREEN The transport vehicle can now depart 24 4111 0035 April 2015 OPERATION FAULT from ENGAGING State With OPTIONAL ALARM Hook cannot engage the RIG This could be due to a RIG that is located too far toward the rear axle bent obstructed or missing Inside light is flashing RED and ALARM alerting the forklift operator that the transport vehicle is not locked Outside light is flashing RED alerting the transport vehicle driver not to move If the transport vehicle is parked firmly against the dock bumpers proceed to BY PASS If not press RELEASE to clear the fault have transport vehicle back up and repeat Restraint ENGAGING HED RESTRAINT POSITION RESTRAINT POSITION BY PASS State SWITCH TO BY PASS WITH ALARM After Securing Trailer by Alternate Means
20. Button Depressed Restraint DISENGAGING 3 Light System Hook travels from the ENGAGED position to the STORED position Outside light is flashing RED alerting transport vehicle driver not to move Inside light is flashing RED Once the hook is stored the outside light with flash GREEN alerting the drive it is safe to depart RED RESTRAINT POSITION RESTRAINT POSITION RED YELLOW BY PASS FAULT from ENGAGING State 3 Light System Hook cannot engage the RIG This could be due to a RIG that is located too far toward the rear axle bent obstructed or missing Inside light is flashing RED and YELLOW light is flashing alerting the forklift operator that the transport vehicle is not locked Outside light is flashing RED alerting the transport vehicle driver not to move If the transport vehicle is parked firmly against the dock bumpers proceed to BY PASS If not press RELEASE to clear the fault have transport vehicle back up and repeat Restraint ENGAGING 4111 0035 April 2015 21 OPERATION BY PASS from ENGAGING State 3 Light System Hook cannot engage the HIG Switch the selector to BY PASS The YELLOW and GREEN inside lights will flash Proceed with caution Outside light will flash RED HED RESTRAINT POSITION GREEN RESTRAINT POSITION HED BY PASS to STORED State 3 Light System Once loading or unloading complete Switch the selector to NORMAL Press the RELEASE button
21. IF hook is not in the stored position inside light will flash RED Outside light will flash GREEN The transport vehicle can now depart 22 4111 0035 April 2015 OPERATION FAULT from ENGAGING State 3 Light System Hook cannot engage the RIG This could be due to a RIG that is located too far toward the rear axle bent obstructed or missing Inside light is flashing RED and YELLOW alerting the forklift operator that the transport vehicle is not locked Outside light is flashing RED alerting the transport vehicle driver not to move If the transport vehicle is parked firmly against the dock bumpers proceed to BY PASS If not press RELEASE to clear the fault have transport vehicle back up and repeat Restraint ENGAGING RESTRAINT POSITION 1 1 RESTRAINT POSITION NEA BY PASS BY PASS State SWITCH TO BY PASS 3 Light System After Securing Trailer by Alternate Means An alternate means of securing the transport vehicle must be used e g wheel chocks if the hook can not capture the RIG Switch selector switch to BY PASS Inside lights are flashing YELLOW and GREEN alerting the forklift operator the trailer is secured by other means Outside light is flashing RED alerting the transport vehicle driver not to move To return to STORED turn the BY PASS to NORMAL and press the RELEASE button hook was not STORED already 4111 0035 April 2015 23 OPERATION
22. NTENANCE Service Dock Leveler Restraint Safely DAILY e Remove debris around TPR vehicle restraint e Verify that restraint operates smoothly and inside outside lights and horn are working e Replace damaged or missing light bulbs and lenses e Repair remount or replace outside and inside signs and labels as required e Inspect dock bumpers Missing bumpers must be replaced 180 DAYS e Perform all Daily maintenance e Grease rollers at fittings located on the top and bottom axle with a synthetic oil base moly grease with a temperature range of 40 to 170 e Verify brake torque is greater than 42 ft lbs at the hook shaft rotating the hook from ENGAGED to STORED e Inspect the outside electrical connections junction box conduit power harness and outside communication light Loose or damaged components must be repaired or replaced e gt Check that all concrete anchor bolts are torqued to 100 ft lbs e Perform operational test after all maintenance repairs and adjustments are complete e Inspect dock bumpers Four inches 4 of protection is required Worn torn loose or missing bumpers must be replaced 360 DAYS Perform all Daily and 180 Day maintenance e Check and tighten if necessary motor drive chain To tighten see e Lube chain using chain lube e Lubricate limit switch mounting bracket between drive sprocket and cam with a synthetic oil base moly grease with a temperature range of 40 to 170 F 4111 0035
23. TRACK 4111 0035 April 2015 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 DO NOT connect the vehicle restraint electrical wiring and ground connections until all welding has been completed DO NOT ground welding equipment to any hydraulic or electrical components of the vehicle restraint 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 FRONT PIT CURB ANGLE DOCK FACE ROLLER TRACK SHIM REQUIRED 6 SHIMS 2 WIDE X FULL LENGTH OF TRACK TO MAINTAIN STRAIGHTNESS AND PLUMB 11 INSTALLATION 1 Attach the four 4 springs to the lower spring bar 2 Pull springs upward and slide over top spring mount on the track roller plate Use lifting device e g crane jack when lifting carriage Install right and left spring cover with clip nuts approx 110 106 Lifting by hand may cause back flat head screws provided injury 4 Slide the carriage assembly into the roller track 5 Position and bolt the lower spring bar to the bottom of the vehicle rest
24. c 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 uncontained 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 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 DANGER AY 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 NFPA 706 for PPE requirements This panel may contain more than one power source Hazardous Voltage Will Cause Sever Injury or Death 4111 0035 April 2015 SAFETY Every 90 days quarterly inspect all safety labels and tags to ensure they are on the dock leveler and are easily leg ible If any are missing or require replacement please call 1 800 643 5424
25. d in same position on both sides CRUSH HAZARD Do not remove main springs until leveler is safely supported by maintenance prop Main springs contain stored energy Be sure springs are fully unloaded and ends are loose before removal Refer to owner s user s manual for proper maintenance procedure Failure to comply will result in death or serious injury 17 CRUSH HAZARD Do not work under dock leveler unless this maintenance prop has bi upright position See owner s user s manual for proper will result in death or serious injury DANGER CRUSH HAZARD Open the pin latch and insert through the maintenance 1 15 1 078 9 prop housing and prop completely 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 0726 s manual for proper maintenance procedures Failure to comply will result in death or serious injury 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 6 4111 0035 April 2015 OWNER S USER S RESPONSIBILITIES 1 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 accordanc
26. ds and feet clear of pinch points Avoid Make sure lip overlaps onto transport vehicles bed putting any part of your body near moving parts at least 4 in 102 mm Keep a safe distance from both side edges 2 4111 0035 April 2015 SAFETY wer Do not use dock leveling device if transports vehicles bed is too high or too low Do not overload the dock leveling device Do not operate any equipment while under the influence of alcohol or drugs Do not leave equipment or material unattended on dock leveling device 4111 0035 April 2015 3 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 ALWAYS disconnect electrical power source and ground wire before welding on dock leveler DO NOT ground welding equipment to any hydrauli
27. e with manufacturer s recommendations and industry standards Effective operator training should also focus on the owner s users 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 2 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 grade 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
28. ed use wheel chocks in addition to restraint If equipped with a light communication system load and unload on GREEN light only Maintenance or service must be performed by authorized personnel only Follow approved lockout tagout procedures FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DEATH OR OTHER SERIOUS INJURY Scan to view our owner s user s POWERAMP MCGUIRE manuals online DLM www DockSystemsinc com SYSTEMS INC 1 800 643 5424 Loading Dock Equipment Call for additional placards or manuals or with questions RELEASE BAR RELEASE LATCH RELEASE BAR PLACARD OPERATING INSTRUCTIONS VEHICLE RESTRAINTS ENGAGE RESTRAINT 1 1 Open overhead door and visually check that transport vehicle is positioned squarely against dock bumpers and has a RIG bar Inside light is RED and outside light is GREEN if equipped with lights Powered Restraints Depress the ENGAGE button to activate restraint Manual Restraints Using release bar pull upward on release latch until restraint is released Visually inspect that RIG bar has been restrained successfully In the event this cannot be determined use wheel chocks in addition to restraint e f RIG bar is missing or damaged use wheel chocks to secure transport vehicle at dock e Loading unloading may proceed with caution Automatic Light Controls When RIG is secured inside light is GREEN and outside light is RED Manual Light Contro
29. hin 30 days after the defect is or can with reasonable care be detect ed In no event shall any claim be made more than 30 days after this warranty has expired In orderto be entitled to the benefits ofthis warranty the product musthave been properly installed maintained and operated in accordance with all manufacturer s recommendations and or spec ified design parameters and not otherwise have been subject to abuse misuse misapplica tion acts of nature overloading unauthorized repair or modification application in a corrosive environment or lack of maintenance Periodic lubrication adjustment and inspection in accor dance 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 equip ment or parts bearing the cost for the parts labor and transportation This shall be ex clusive remedy for all claims whether based on contract negligence or strict liability WARRANTY LIMITATIONS THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES WHETHER EX PRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SYSTEMS INC AND ITS SUBSIDIARIES SHALL NOT IN ANY EVENT BE LIABLE TO ANYONE INCLUD ING THIRD PARTIES FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND INCLUDING BUT
30. hocks applied appropriately or all other positive restraining device shall be fully utilized It is recommended that transport vehicles with air ride suspension systems shall have its air exhausted prior to performing loading and unloading operation to minimize transport vehicle bed drop 9 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 10 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 4111 0035 April 2015 7 INTRODUCTION General Information 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 Technical Service at 800 643 5424 or techservices docksystemsinc com 8 4111 0035 April 2015 INTRODUCTION Component Identification QTY 4 ROLLER ASSEMBLY LIGHT BOX p CONTROL BOX INSIDE SIGN OUTSIDE SIGN QTY 4 CARRIAGE RETURN SPRINGS RIGHT SRPING COVER FT SPRING COVER gt LOWER SPRING BAR 4111 0035 April 201
31. information can be found inside the control box 4111 0035 April 2015 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 DO NOT connect the vehicle restraint electrical wiring and ground connections until all welding has been completed DO NOT ground welding equipment to any hydraulic or electrical components of the vehicle restraint 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 CONTROL BOX INSTALLATION GUIDELINES TEMPERATURE CONTROLLED APPLICATIONS Houte the conduit to enter through the side or bottom of the enclosure If the conduit could fill with water a drip leg may be needed Seal the conduit in any location where the conduit crosses over temperature zones that could produce condensation Install spacers between the wall and enclosure to provide temperature insulation and air flow Where indicated all components must be connected to a SAFETY EARTH GROUND that conforms to the 1999 National Electrical Code Section 250 50 section a or section c for a grounding electrode system INST
32. 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 transport driver has been given permission to 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 4111 0035 April 2015 OPERATION DO NOT overload the 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 Before loading or unloading a vehicle at your loading dock while using a TPR vehicle restraint always visually inspect to be sure that the restraint is engaged with the Rear Impact Guard RIG If the restraint is still not engaged after backing the transport vehicle firmly against the dock bumpers secure the transport vehicle by other means Be sure that the area around the RIG assembly is
33. k ANCHOR INSTALLATION INSTRUCTIONS e Put roller track plate in place e hole of 5 8 diameter and minimum of 4 5 8 deep Clean out hole e Insert anchor and drive flush with roller track plate making sure that the threaded wedge is inserted first Do not disassemble anchor prior to installation e Install all anchors and torque to 100 ft lbs 4111 0035 April 2015 WELDING INSTALLATION INSTRUCTIONS If the installation being worked on is a retrofit or replacement situation the following electrical connections must be disconnected prior to welding LOCKOUT TAGOUT the power at the fused disconnect then remove the motor and limit switch connections from the control harness located in the outside junction box Once all welding has been completed reconnect all the wires NOTES 1 NEVER install the TPR vehicle restraint directly onto concrete block or brick dock face 2 When welding the TPR vehicle restraint disconnect power and ground leads to leveler 3 Due to actual conditions total mounting height may be different 4 Plug weld all holes that are in contact with the embedded mounting plate All fifteen 15 holes must be either plug welded or anchored 5 Shims must be the full length of the roller track mounting plate Minimum electrode must be 1 8 7018 or better ACROSSTOP OFTRACK FRONT PIT CURB ANGLE EMBEDDED PLATE CONCRETE 3 PLACES x ROLLER
34. loading and unloading process 4 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 5 Manufacturer s 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 6 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 7 Any modifications or alterations 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 8 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 c
35. ls Once HIG is secured turn switch to SERVICE TRAILER Inside light is GREEN and outside light is RED LEASE RESTRAINT Powered Restraints To release restraint depress the RELEASE button When safely stored inside light is RED and outside light is GREEN Manual Restraints To release restraint push down on restraint arm with release bar until restraint is completely stored Note Restraint is completely stored when release latch engages restraint arm Automatic Light Controls When safely stored inside light is RED and outside light is GREEN Manual Light Controls When safely stored turn switch to DO NOT SERVICE TRAILER Lights change to RED inside and GREEN outside BY PASS 1 3 If restraint is unable to secure transport vehicle s RIG use wheel chocks to secure transport vehicle at the dock Turn switch to BY PASS Inside light is GREEN and outside light is RED Loading unloading may proceed with caution BY PASS RESET RETURN TO NORMAL OPERATION 1 When loading or unloading is completed and wheel chocks are removed manual reset of BY PASS is accomplished by turning switch to NORMAL Lights change to RED inside and GREEN outside regarding proper use maintenance and repair of dock leveler 17510830 Use PowerStop and StopTite series PART NUMBER DESCRIPTION 1751 0880 TPR PLACARD 4111 0035 April 2015 39 PARTS ITEM PART NUMBER DESCRIPTION 1751 0033 OUTSIDE SIGN RIGHT RE
36. n Open the pin latch 1 751 0731 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 A DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is 1 15 1 072 6 safely supported by maintenance prop Place barriers on driveway 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 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 0035 April 2015 5 SAFETY Dock Leveler Safety Decal s Every 90 days quarterly inspect all safety labels and tags to ensure they are on the dock leveler and are easily leg ible If any are missing or require replacement please call 1 800 643 5424 for replacements 4 DANGER CRUSH HAZARD Maintenance prop must support leveler behind bar 1 15 1 0727 Do not force maintenance prop forward of bar to support lip Refer to owner s user s manual for proper use Failure to comply will result in death or serious injury 1751 0730 x2 ADANGER 1751 0329 x2 decal placed in same position on both sides NN yz 4 1751 0330 x2 AN Zab 1228 decal place
37. raint carriage 6 Install the motor cover and spring covers 7 Install slope extension 12 4111 0035 April 2015 Make sure that the power source has been locked out and tagged according to OSHA regulations and approved local electrical codes If the incoming electrical power for the TPR vehicle restraint is taken from a nearby electrical appliance e g overhead door opener verify that the amperage is in accordance with local and federal codes The TPR vehicle restraint 1 10 HP motor requires 120V single phase power 60 Hz power and 10 amps of current to operate properly If you have questions contact Technical Support at 800 643 5424 When drilling access hole in the control box DO NOT penetrate too deep components may be damaged DO NOT turn control upside down to drill any access holes To prevent damaged to electrical components from debris cover components prior to drilling Seal all conduit entrances to prevent moisture from entering the control box DO NOT use compressed air to clean control box Hecommended to vacuum debris from inside The TPR vehicle restraint assembly includes a 63 long flexible wiring harness the control box with lights and the outside signal light box The outside junction box conduit fittings and wire are provided by others be sure to use a qualified installer utilizing quality materials Hefer to component location information Electrical schematics for wiring
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