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Poweramp PowerHook® Manual Feb2011

Contents

1. I 25 204 PB2 ACTIVATES RESTRAINT O cgi 4 MP i I A 205 KSI BYPASS ESTOP E STOP 216 312 312 ala 19 21 08 OPTIONAL 26 112 14 13 DE ENERGIZED WHEN E STOP ACTIVATED MCN amu roa HYDRAULIC FLUID WARMER 207 OPEN FULLY WHEN OFF ON o CLOSED 25 zB a 112 Ox 3 4 Al 2 e DL 852 INDICATES RESTRAINT OPTIONAL 266 NOT FULLY EXTENDED WEN UNE 1 E HYDRAULIC FLUID WARMER CLOSED FULLY EXTENDED OPTIONAL u n I HYDRAULIC FLUID WARMER PRS3 INDICATES RESTRAINT 209 NOT IN WORKING ZONE WHEN ZONE WHEN 553 l I PRSA INDI 210 FULLY WHEN CLOSED NOT FULLY RETRACTED WHEN DRY CONTROL CIRCUIT FOR AIR SHELTER ENGAGED AT IGG EAR MEN A RAISED amp RETRACTING MOMENTARY SIGNAL ONLY I i 22 PB3 RAISES LEVELER I 151 OPTIONAL LANYARD PULL RING RAISES LEVELER I OPTIONAL LS INTER INDICATES LEVELER UP FULLY FOLDED WHEN CLOSED NOT FULLY FOLDED WHEN OPEN CRI I ze OPTIONAL DOOR OPEN CONTACT DOOR OPEN CONTACT USED INDICATES DOOR IN LEVELER 27 OPERATING ZONE WHEN OPEN NOT IN LEVELER OPERATING ZONE WHEN CLOSED DOOR OPEN CONTACT IF USED INDICATES DOOR IN LEVELER ZONE WHEN OPEN 28 NOT IN LEVELER OPERATING ZONE
2. 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 Always post safety warnings and barricade the maintenance prop 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 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 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 egual specification Inside and outside signal Bad Flasher Replace flasher with wire If lights operate lights will lights do not operate not flash replace flasher Controller PLC RUN indicator is on solid not flashing Unit operates as normal Make sure the correct voltages are present at the proper locations inside the control panel s Restrai
3. Do not over tighten valve into block Max Torque 30 40 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 Binding inside positioning Locate positioning cylinder Place pan under hose cylinder 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 4111 0010 Nov 2010 43 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 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 ful
4. the whee dobri 5 8 IN C ug El bl roared peutic antea j j Deck rmn Manufactured by Hema Ine 1 arity DockBystem lne eom Item Quantity Part Number Description A 1 0961 0083 Proximity Switch with Harness INTERLOCK Feature Only B 1 Push Button Controller 9511 0004 J Box Standard 4 x 4 in Metal Box 1 9512 0429 J Box Cold Weather 5 x 5 in Plastic Box x LI Provide dock leveler serial number voltage phase and options when calling or faxing controller orders 50 4111 0010 Nov 2010 PARTS Powerhook Guide Track Components Item Quantity Part Number Description A 1 Guide Track Aluminum B 1 0521 0144 Cable Assembly Powerhook Standard C 1 0521 0173 Sensor Mounting Bracket D 7 2101 0196 Nylon Lock Nut 10 32 UNF E 5 2101 0202 Round Head Machine Screw 10 32 UNF x 1 2 Stainless Steel F 2 2101 0203 Round Head Machine Screw 10 32 UNF x 3 4 Stainless Steel A G 1 0524 0075 Powerhook Guide Track Assembly Complete H 1 0521 0146 Guide Track Pig Tail 46 Long 1 0521 0147 Guide Track Pig Tail 94 Long 26 1 4 a 18 3 4 Standard Length Standard i B O Item Quantity Part Number
5. 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 truck trailer or a ICC bar simulator The simulator must span min of 6 past both sides of pan Press the ENGAGE button Truck restraint hook should lower extend raise and retract until it locks onto the ICC bar Power pack should then shut off 4111 0010 Nov 2010 ADJUSTMENTS Figure 12 A Hook Lowered Sensor C Hook Lowered Sensor Target Bar Bracket B Powerhook Hold Down D Flat Washer Weldment E Trunnion Bolt Check lights Inside Green Outside Red Test dock leveler operation See dock leveler Owner s Manual Checking of Alarm if equipped and Lights for Premature Truck Departure can be accomplished by having a truck 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 Check Lights Inside Light
6. And Testing Testing PowerHook Operating Range 27 Adjust Powerhook Operating Range 28 Pressure Relief Adjustment 11111 121 1 30 Adjust Dock Leveler and Truck Restraint Interlock 32 Adjust Auto Return To Dock ARTD 33 Troubleshooting Troubleshooting Charts eeee nn enne nnns 36 Programing 45 FOrcing Solenoids mme 46 Wiring DIagFallis k RO NO 48 Parts 50 PowerHook Guide Track Components 51 PowerHook Components 52 PowerHook Valve Body 53 Power Pack nn nn 54 Pressure 81 11 111 dudas datu cru a sale 56 Miscellaneous 57 Wairanty Back Cover 4111 0010 Nov 2010 CUS AF ETY Recognize Safety Information 4111 0010 Nov 2010 Genera
7. Description A 1 0521 0123 Powerhook Cylinder Only B 1 7054 0001 Powerhook Arm Weldment C 1 7054 0010 Powerhook Standard length Provide dock leveler and or PowerHook serial number when calling or faxing orders 4111 0010 Nov 2010 o1 PARTS B E un J Item Quantity Part Number Description A 1 8585 0096 Valve Block Assembly Regeneration See Breakdown for Details B 1 7054 0010 Cylinder Assembly PowerHook C 1 9904 0110 Hydraulic Hose Assembly 1 2 100R1 x 20 00 8 JIC D 1 9301 0116 Fitting 90 Degree 8 ORBM 8 JICM E 2 2101 0012 Hex Head Cap screw 5 16 18 UNC x 1 1 4 F 2 2101 0058 Lock Washer 5 16 G 1 0522 0061 Bar Guide Rod H 2 2101 0057 Hex Head Cap screw 5 16 18 UNC x 1 2 J 2 2101 0058 Lock Washer 5 16 K 1 2101 0059 Flat Washer 1 4 L 1 0524 0075 Guide Track Assembly See Guide Track Assembly Breakdown for Details M 1 0526 0005 Positioning Cylinder Assembly With Breather 0526 0006 Positioning Cylinder Assembly With Weep Tube Fitting N 1 2101 0004 Flat Washer 5 8 O 1 2101 0052 Hex Head Cap screw 5 8 11 UNC x 2 1 2 P 1 2101 0042 Hex Nut 5 8 11 UNC Q 2 0522 0062 Trunnion Positioning Cylinder 3 8 x 3 x 4 R 2 2101 0041 Hex Nut 1 2 13 UNC 5 2 2101 0051 Hex Head Cap screw 1 2 13 UNC x 2 1 2 T 2 2101 0055 Lock Washer 1 2 U 1 2101 0058 Lock Washer 5 16 V 1 2101 0059 Flat Washer 1 4 W
8. WHEN CLOSED KSI LIGHTS ONLY NORMAL FAULT RESET BYPASS CIA 0 30194 s KS FAULT RESET iV V 32 20 e OPTIONAL AUTO RETURN TO DOCK FEATURES ONLY THOSE FEATURES THAT AFFECT TRANSFORMER VA_ARE LISTED FLUD WARMER DRAWING SHOWS TI TRANSFORMER WTH DUAL VOLTAGE PRIMARY WIRED FOR 460 V OR NAMEPLATE DATA 35 A 30 A 35 A 15 A 18 15 A AT THE CUSTOMER SUPPLIED VOLTAGE 48 4111 0010 Nov 2010 115 V 1 PHASE 60 HZ 100 V 240 VAC 85 8 8 407 DE ENERGIZED WHEN IN BYPASS 408 410 SOL D DIRECTS FLUID TO RAISE RESTRAINT WHEN DE ENERGIZED RESTRAINT WHEN ENERGIZED 115 V 1 PHASE 60 HZ SOL E OPTIONAL E STOP LEVELER ONLY BLOCKS FLUID FROM LEVELER TO RESERVOIR WHEN ENERGIZED 116 NOT OK TO BACK 412 DIRE OR LIP WHEN ENERGIZED Cw 8 8 i 3 PE2 OPTIONAL DOOR CLOSED CONTACT INDICA Ec TES OVERHEAD DOOR FULL ATTEMPTS TO PULL AWAY WHEE CLOSED WHEN CLOSED OH RESTRANT ENGAGED AT ICC BAR CLOSED OFF ONLY THE CONTROL ASSY IS A UL LISTED PANEL ALL OTHER EQUIPMENT IS REMOTE FROM THE CONTROL 100 101 102 ASSY amp IS NOT PART OF ANY UL LISTED PANEL M ENERGIZES HYDRAULIC COMPONENT LOCATION TABLE COMPONENT LOCATION PUMP MOTOR INDICATED BY PHANTOM LINES OUTSIDE SIGNAL LIGHT ASSY SOL DIRECTS FLUID TO EXTEND
9. 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 14 15 16 17 18 19 20 21 22 23 24 25 26 Cut pit for the truck restraint pan as indicated on the Pit Drawing Cut out or chip to accommodate 3 8 x 16 x 16 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 truck 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 truck restraint pan and Hoist cylinder trunnion plates s that to be imbedded in the pit floor in the plate is separate from the pan Allow sufficient time for the concrete to set Assembly truck restraint only required if pan
10. motor level and type overcurrent device and or overload device continuously tripping Restraint lowers fully Solenoid D valve stuck Locate solenoid See Parts Valve Block extends but does not ON Remove coil from cartridge valve and cartridge valve raise Pump operates in from valve block pressure relief 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 Proximity switch on guide Locate switch on end of guide track closest to hook track that senses when tip Observe indicator light at controller input 4 restraint is fully extended is that receives signal from switch Input light should out of adjustment 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 Positio
11. this manual 7 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 8 Use a fork truck or other method to raise and hold the dock leveler platform Remove the maintenance prop 9 Burn or grind all welds where the dock leveler frame is welded to steel imbedded in the pit NOTE frame removal on 10 and 12 long CLEAN PITe units may not be necessary Consult factory INSTALLATION A Lifting Bracket 2 used 10 11 12 13 14 2 222222 520 22922 522902229902 3 Shipping Bands This set up Is only reguired if the dock leveler is a CLEAN PIT 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 owners 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 truck restraint pan unit Set the leveler platform in the cross traffic position the lip fully
12. vehicle shall have the brakes and wheel chocks applied appropriately or all other positive restraining device shall be fully utilized 8 Loading dock safety equipment should never be used outside of its intended use range or capacity Please consult the manufacturer if you have any questions as to the use range or capacity of the equipment 9 When selecting loading dock safety equipment it is important to consider not only present requirements but also future plans and any possible adverse conditions environments or use 4111 0010 Nov 2010 7 INTRODUCTION General Information Congratulations on your choice of a Poweramp PowerHook truck restraint This manual covers the PowerHook Truck restraint operating system Designed by Poweramp to be a marvel of simplicity and efficiency your truck restraint when properly installed will provide many years of trouble free performance with an absolute minimum of maintenance 5 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 truck restraint to seek find and maintain a tight continuous hold on the RIG Rear Impact Guard bar effectively eliminating trailer creep As an optional safety feature the dock leveler and truck restraint can be interlocked preventing oper
13. with Powerhooks are equipped with Interlock unless leveler has option of Auto Return To Dock ARTD l 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 The ARTD allows the platform to automatically return to the cross traffic stored position after the truck 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 position after which the platform will return to the cross traffic position The switch also contains an indicator light Always stand clear of the dock leveler lip when H that can be used for diagnosing and adjusting the working in front of the dock leveler switch The maintenance prop MUST be in the service NOTE The proximity switches has an indicator light position when working under the dock leveler at the back of the housing and some have the For maximum protection use an OSHA approved light at the side of the housing 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 remo
14. 0 INTRODUCTION Component ldentification 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 Magnetic Reed Switch Reed Switches Assembled Replaces Proximity Switch Hook Lowered Sensor Target QUIT New Telemecanique TWIDO Programmable Logic Controller 4111 0010 Nov 2010 9 INSTALLATION This manual covers three models of PowerHook truck restraints KS4 KS5 KS6 See Figures 1 2 and 3 In addition to the hydraulically actuated truck restraint PowerHook has a programmable electronic controller and Dock alert a dock communication systems The installation 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 oweners users manual Fig 1 KS4 PowerHooke The PowerHooke KS4 box type truck 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 truck restraint is an economical retrofit for dock levelers The fully assembled pan ships complete with all the concrete anchors needed to insure a s
15. 1 2101 0068 Hex Head Cap screw X 1 7052 0005 Bar Prox Target 1 2 x 1 1 2 x 1 M 4111 0010 Nov 2010 PARTS PowerHook Valve Body Assembly Itemit Part Description Bock Label Function Part Number 1 Fluid to Powerhook or Dock Leveler if energized 8581 0011 2 5 8 12 14 IDetaCol Activates Cartridge Valve 8581 0004 3 DLS Fluid to Logic Block 9301 0127 4 Cartridge Valve 3 way 2 position Fluid to lower Powerhook if energized with D 8581 0005 6 Tells PLC to stop Powerhook retracting when ICC bar engaged 0963 0004 7 Fluid to retract Powerhook when energized with C1 8581 0005 9 HC2 Fluid to top of Powerhook cylinder via regeneration valve 9301 0120 10 HCI Fluid to base of Powerhook cylinder via regeneration valve 9301 0120 11 HDC Fluid to positioning cylinder 9301 0120 13 Fluid to retract Powerhook when energized with C2 8581 0074 15 Cartridge valve 3 way 2 position D Fluid to hold Powerhook in lowered position when energized 8581 0005 16 Conrols flow to from positioning cylinder 8581 0008 17 Controls flow to from Powerhook dumps excess flow to tank 8581 0089 18 Return line dump line to pump 9301 0127 19 Fluid to dock leveler logic block 9301 0127 20 Incoming hydraulic fluid from pump varies by model 21 CabelAssemby f Wire harness 48 5 wire assembly connects to 5 delta coils 4305 0234 22 Cable individual not shown Individual wire 48 connects to singl
16. A Division of Systems Inc PowerHook Truck Restraint Premium Loading Dock POWERAMP Division of Systems Inc W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 255 5917 www docksystemsinc com techservices docksystemsinc com Printed in U S A Manual No 4111 0010 Copyright 2003 February 2011 Page Safety Recognize Safety Information nn nn nn 1 General Operational Safety Precautions 1 5 Owner s User s Responsibilities 7 Introduction General INFORMATION Vu Vu Enid usd 9 Component 2 2 1 111 enne 10 Installation Model identification i lia 11 K54 IAS tall AON 10 KSS INS AN AMON scat icon icon dicey credi cdm du Us 13 KSO ANGNSZ nn 16 Operation Operating InstructloneS 1111 12lx400000xi0120 rice ce toner cu ous de ala a une dania 21 Sequence of nn 22 Maintenance Service Dock Leveler Restraint Safely 24 Periodic 2 nennen nnn 25 Adjustment
17. C 2 2101 0063 Nut Jam 5 16 18 UNC 1 9395 1 Power Pack Complete Includes All Items Except L N and W 1 Provide dock leveler serial number and type of installation when calling or faxing orders 2 Provide dock leveler serial number voltage and phase when calling or faxing orders 4111 0010 Nov 2010 55 PARTS Pressure Differential Valve and Block 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 Description A 1 4305 0563 Cable Assembly 48 B 1 8581 0135 Pressure Differential Switch C 1 8581 0090 Regeneration valve D 3 9301 0116 Fitting Elbow 90 Deg 8 O Ring To 8 Jic E 1 9301 0126 Fitting Union Str F 1 9904 0110 Hose 1 2 17 Lg 8 JicF Swivel Both Ends A F 1 8585 0096 Pressure Differential Valve Complete 56 4111 0010 Nov 2010 Customer Information NOTE Refer to illustration for left right orientation of dock leveler The model serial number decal A is located on the right platform joist near the front lip of dock leveler When you receive your Poweramp product write down the product 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 dam
18. OVERHEAD DOOR BY 08895 T WHEN DE ENERGIZED JOB NUMBER 0540 9 RESTRAIN RETRACT RESTRAINT WHEN ENERGIZED UNT HAS THE ur nuno CHECK THOSE OPTIONS THAT APPL LOAD DATA EXTERNAL LOADS LANYARD EJ up STOP ALL LOADS 110 120 VAC XI LS INTERLOCKING X HYDRAULIC FLUID WARMER X RE INTERLOCKING X DRY CONTROL CIRCUIT OQ02A010V EH m 00 DX AUTO RETURN DX DOOR CLOSED CONTACT SOL EF OPTIONAL 0 21 A 110 V EACH Q XJ E STOP EJ DRY INTERLOCKED CONTROL CIRCUIT 86 0 21 A 0120 V EACH INCANDESCENT STANDARD K uP x STROBE LIGHT 0 025 A 115 V EACH LED OPTIONAL X AUDIBLE ALARM 0 05 A 115 V x DRY INTERLOCKED PUSHBUTTON CONTROL CIRCUIT g 05 A 120 V l 1 A DRAWING SHOWS SYSTEM AT REST WTH POWER OFF amp OVERHEAD DOOR NOT FULLY RAISED O REPRESENTS A TERMINAL BLOCK DOOR CONTACT UNE 216 OTHERS DOOR OPEN CONTACT TO PREVENT OPERATION OF LEVELER UNTIL DOOR CONTACT MAY BE PROVIDED BY POWERAMP IF SPECIFIED DOOR OPEN RAISED HIGH ENOUGH SUCH THAT LEVELER WILL NOT HIT DOOR OPEN DOOR CONTACT TO BE OPEN WEN DOOR IS IN LEVELER OPERATING ZONE DOOR OPEN CONTACT TO CLOSED ON WHEN DOOR IS NOT N LEVELER OPERATING F DOOR OPEN CONTACT IS USED REPLACE JUMPER FO
19. RM TERMINAL BLOCKS 31 MTH DOOR OPEN D PROXIMITY SMTCH PRSS IS USED ONLY IF THE UNIT HAS EITHER THE LS INTERLOCKING OPTION OR THE AUTO RETURN OPTION 5 5 5 F NEITHER OF THE OPTIONS ARE USED CONNECT WIRE 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 LIP OUT STOP OPTION F WRE 64 IF UNIT DOES NOT HAVE E STOP OPTION WIRE 64A IF 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 1 COLORS NEAR COMPONENT REFER TO COLOR OF WIRE SUPPLIED BY THE COMPONENT BRN BROWN BLU BLUE HKS 5 BLK BLACK WHT WHITE RED RED YEL YELLOW amp ORG ORANGE 4 TO MOENS EXAMPLE 5 amp 4 AT PBI LADDER DIAG RAM K DOOR CLOSED CONTACT 401 BY OTHERS DOOR CLOSED CONTACT MAY BE PROVIDED BY POWERAMP IF SPECIFIED DOOR CLOSED CONTACT USED TO AUTOMATICALLY RESET BYPASS MODE 1 TERMINAL BLOCK 21 USED ONLY IF THE UNIT HAS THE HYDRAULIC FLUID WARMER OPTION M 58 40 IE 1 THE 1 AMVADN 4111 0010 Nov 2010 49 PARTS 4 LAT Spee
20. Red Outside Light Green 29 ADJUSTMENTS 3 prox switch adjustments at 100 clock position Powerhook Pressure relief Adjustment The pressure relief on a Powerhook is not adjusted by the relief mounted on the pump The pressure relief is regulated by the relief mounted on the Big block On 56 and 57 restraints the relief is preset from the factory and normally is not touched KS4 and KS5 truck restraints of some SC hooks the relief must be adjusted during installation Locate the hook cylinder assembly and the hold down cylinder assembly See Figure 10 The length of the threaded eye on the hold down cylinder will determine the upper vertical limit of the hook movement A Raise Leveler on to the maintenance prop and lock in place B Remove wire 36 from input 3 on the PLC 30 Figure 13 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 F Re install wire 36 for input 3 on the PLC G Test hook for proper operation 4111 0010 Nov 2010 PTI NAL E IPMENT ADJUSTMENT Adjust Dock Leveler and Truck Restraint Interlock When service un
21. SS mode Pressing the LOCK button a second time will cycle the PowerHook 10 Remove wheel chocks from the truck trailer wheels when truck is ready to depart 4111 0010 Nov 2010 Service Dock Leveler Restraint Safely MAINTENANCE 2m 3 EGGS 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 4111 0010 Nov 2010 A 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 W
22. YPASS 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 truck trailer 5 When loading or unloading is complete return dock leveler to the stored position 6 Release truck restraint and or remove chocks from truck trailer wheels 22 SEQUENCE OF OPERATION BYPASS 1 Check that the truck trailer is positioned squarely against the dock bumpers 2 Push ENGAGE button to activate restraint Inside Red Light Outside Green Light 3 Visually inspect restraint for proper engagement If RIG Rear Impact Guard is damaged or missing dock leveler can be used in BYPASS 4 If RIG Rear Impact Guard is damaged or missing hook will automatically return to the stored position Inside Amber Light for 30 seconds then Red Outside Red Light for 30 seconds then Green 5 Secure truck trailer wheels with wheel chocks 6 Use key to activate BYPASS mode Inside Green Light with Amber Caution Light Outside Red Light and Strobe 7 Position dock leveler onto truck trailer 8 When loading or unloading is complete return dock leveler to the stored position Inside Green Light with Amber Caution Light Outside Red Light 9 Reset BYPASS mode to NORMAL mode by pressing the LOCK button once Inside Red Light Amber turns Off Outside Green Light Pressing the LOCK button during any part of the cycle will end the BYPA
23. a Powerampe hydraulic dock leveler with integral power pack with a PowerHooke KS5 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 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 15 of this manual Review the Field Wiring Drawing 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
24. aged 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 SERIAL NUMBER For service call or contact Systems Inc P O Box 309 Germantown WI 53022 Phone 800 643 5424 Fax 262 255 5917 4111 0010 Nov 2010 MISCELLANEOUS Serial No Systems Inc Job No Original Owner Information Name gt Address Name gt Address Date of Installation 57 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 af ter 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 o
25. ap and inspection plate Reservoir 8 Turn ON electrical power to the leveler 9 Return the platform to the cross traffic position KS4 Only IMPORTANT Check reservoir fluid level Use of fluids that do not have equivalent specifications to those in the following list will result in abnormal operation of the dock leveler and 1 Put the leveler in the stored position Lip folded 2 Turn OFF all electrical power to the leveler voiding of warranty 3 Remove breather cap P To ensure normal operation of the truck restraint use only aircraft hydraulic fluid designed to meet or exceed 4 Measure fluid level The fluid level should be military specification MIL L 5606 It is recommended approximately 2 in 51 mm N from top of that the following hydraulic fluids be used reservoir M Flomite 530 ZF Ultra Vis HV1 15 Aero Shell Fluid 4 or Fluid 41 5 Add hydraulic fluid if necessary Use only Mobil Aero HFA Mil HS606A or Aero HF recommended fluid 6 Install breather cap P Texaco Aircraft Hydraulic Oil 15 or 5606 7 Turn ON electrical power to the leveler Exxon Univis J13 These fluid brands can be mixed together Mixing with fluids that do not meet or exceed MIL L 5606 may damage the equipment and WILL void warranty Use of hydraulic fluids with equivalent specifications to those listed here are acceptable 26 4111 0010 Nov 2010 Testing PowerHook Operating Range When service under the
26. assist in fine tuning and or diagnosing the ARTD operation Cross Traffic Position 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 Lip Keeper When dimensions A and C are obtained the proximity switch and target may need finer adjustments to get the ARTD to operate NOTE The platform lip is fully folded when the satisfactorily platform is at the cross traffic stored position lip engaged with keepers or when platform is resting 3 Loosen lock nuts D Adjust proximity switch E to on the maintenance prop obtain distance A Tighten lock nuts Whenever the platform lip is at the cross traffic 4 Bend target B as needed to obtain distance C position the following conditions will exist for a Recheck distance A and readjust if necessary normally operating ARTD NOTE At least two people may be required to e Target not in the sensing area of proximity switch manually move the lip e Proximity switch OFF open no signal sent to 5 After adjusting proximity switch and target slowly control panel move the lip up by hand while observing the target and proximity switch The target MUST Proximity switch indicator light is OFF NOT contact the
27. ate of shipment this watranty specifically applies to the deck section lip section frame rear hinge assembly and front hinge assembly only 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
28. ation of the dock leveler until the hook engages the truck RIG bar The truck 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 When not in use PowerHook stores in a pit concealed and out of the way enabling dock workers to clear the driveway approach of snow or debris The PowerHook truck restraint comes equipped with an electrical control panel which allows push button operation of the truck restraint functions When combining a Poweramp dock leveler with a PowerHook truck 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 truck restraint 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 Nov 201
29. closest to rear pit wall indicator light at controller input 6 that receives position but unit does guide track that senses signal from switch Input light should turn OFF when not automatically shut when restraint fully retracted restraint fully extended If this does not occur OFF out of adjustment Pump Operates in Check switch position loosen two guide track pressure relief mounting bolts tap guide track assembly back Restraint remains towards rear pit wall lowered 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 Restraint fully retracted Solenoid D valve stuck Locate solenoid See Parts Valve Block but does not raise even Remove coil from cartridge valve and cartridge valve when ON OFF switch from valve block turned OFF Check valve for contaminan 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 contaminan s Replace valve and coil NOTE
30. d valves in the hydraulic block that is on the hook cylinder 11 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 0 om 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 set 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 Reconnect field wires 60 through 63 as originally connected Se 4111 0010 Nov 2010 TROUBLESHOOTING DOCK LEVELER To force the Hook in retract do
31. d the hold down cylinder assembly The length of the threaded eye on the hold down cylinder 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 Hook cylinder trunnions Position cylinder trunnions Figure 11 4111 0010 Nov 2010 Adjust PowerHook Operating Range 1 Adjust the lower vertical limit of hook operating range if necessary A Locate 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 he 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
32. der 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 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 truck trailer backed into dock 4111 0010 Nov 2010 Dock Leveler and Truck restraint Interlock The dock leveler can be interlocked with the truck restra
33. dock leveler is reguired 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 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 Follow the installation instructions found in the PowerHook Installation amp Operation 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 Nov 2010 ADJUSTMENT AND TESTING NOTE Test operating rang
34. e 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 that senses when restraint light at controller input 3 that receives signal from switch Input light should only turn ON when restraint fully 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 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 ot
35. e delta coil 4305 0235 4111 0010 Nov 2010 53 PARTS Power Pack Assembly Vent Tube Pressure Line Z Return Line 54 4111 0010 Nov 2010 Power Pack Assembly PARTS Item Quantity Part Number Description A 2 2101 0039 Nylon Lock Nut 5 16 18 UNC B 2 9301 0029 Seal Thread C 1 9302 0014 Reservoir D 1 9301 0199 Breather Cap 3 8 NPT Male E 1 9301 0027 O Ring Reservoir F 2 9302 0012 Tie Rod Reservoir 1 9301 1 Pump Only G 4 2101 0016 Cap Screw 5 16 18 UNC x 3 1 2 in Grade 5 1 9301 0028 Gasket Pump 1 9303 0002 Coupling Assembly H 1 9302 0017 Plate Drive J 1 9904 0001 Hose K 1 0521 0017 90 Elbow 3 8 NPT Male x 8 JIC Male L 1 0521 0007 90 Elbow 1 4 NPT Male x 1 4 Tube M 1 3411 2 Motor Only N 1 0521 0015 Straight Fitting 3 8 NPT Male x 8 JIC Male P 1 0521 0014 Ball Check Q 1 9301 0024 Guide Check Ball R 1 9302 0009 Spring Relief Valve S 1 9303 0003 Screw Adjusting T 2 9301 0014 Washer Nylon 11 16 in OD x 1 2 in ID U 1 9301 0015 Nut Jam 1 2 20 UNF V 1 9301 0016 Nut Acorn 1 2 20 UNF W 1 0521 0016 45 Elbow 3 8 NPT Male x 8 JIC Male X 1 9301 0009 Strainer Suction Y 1 9301 0082 Magnet Z 1 9301 0008 Pipe Nipple 3 8 NPT x 8 in AA 2 9301 0003 Washer Aluminum 9 16 in OD x 3 8 in ID x 1 16 in AB 2 9301 0004 Screw Socket Head 3 8 16 UNC x 1 3 4 in A
36. e of PowerHook without truck trailer 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 ENGAGE 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 Hook In Highest Position Nw 87 9 Upper Limit Alarm Extended Lower Limit J Hook Must 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 ADJUSTMENTS Adjust PowerHook Operating Range 28 Hook Cylinder E Threaded Eye and Jam Nut Clock Wise Hose Port Figure 10 Adjust the upper vertical limit of PowerHook operating range if necessary A Locate the hook cylinder assembly an
37. ecure installation Fig 3 KS6 PowerHooke The PowerHooke 56 free standing frame type truck 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 Nov 2010 KS4 INSTALLATION These installation instructions were written for retrofitting a Powerampe hydraulic dock leveler with integral power pack with a PowerHooke KS4 Vehicle Restraint lf 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 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 15 of this manual Review the 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 contr
38. eld in for too long of a time and this will damage the sensors The Hook will lower rather quickly so it is suggested that the operator apply only a quick momentary push on the RAISE pushbutton thereby allowing the Hook to only lower slightly The operator may have to apply additional quick momentarily pushes on the RAISE pushbutton in order to get the Hook to lower to the desired position If the solenoids are working correctly the Hook will stay lowered until the POWER OFF ON switch is set to OFF Momentary push the RAISE pushbutton If necessary keep momentarily pressing the RA SE pushbutton until the Hook is lowered to the desired position Turn the POWER OFF ON switch to OFF to allow the Hook to raise 9 Turn off the disconnect switch es see WARNING on page 1 10 Reconnect field wires 60 through 63 as originally connected 4111 0010 Nov 2010 47 TO MAKE SURE CUSTOMER SUPPLIED 3 PHASE VOLTAGE MATCHES VOLTAGE ON CONTROL ASSY NAMEPLATE ELECTRICAL DIAGRAM GENERIC CUSTOMER SUPPLIED 208 230 460 575 V 3 PHASE 60 HZ ROM BRANCH CIRCUIT DISCONNECT SWITCH amp OVERCURRENT DEVICE BY OTHERS SELECT DISCONNECT SMTCH amp OVERCURRENT DEMCE PER THE NEC LOCATE DISCONNECT SWITCH ADJACENT TO THE CONTROL ASSY DUAL ELEMENT TIME DELAY 200 FUSES MUST BE USED FOR BRANCH CIRCUIT PROTECTION 2 I i 202 2 i 115 120 VAC i n l 203 PBI ACTIVATES RESTRAINT 1
39. en 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 Pour concrete around the truck 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 Allow sufficient time for the concrete to set Assembly truck restraint only required if pan was shipped separately A Remove all trunnion keepers B Grease oylinder trunnions C Install cylinders D Install all trunnion keepers and prox switches See adjustments See page 28 Modify dock leveler frame as needed per Dock Leveler Modification Drawing 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 INSTALLATION Hoist Cylinder Trunnion Hook Cylinder Keepers Hold down Cylinder Trunnion Hold down Cylinder keepers Pour concrete Around The Truck Restraint Pan Dock Leveler Pit TN KS4 Pan Inside view Vertical Valve Block Hook Valve Block 12 4111 0010 Nov 2010 INSTALLATION KS5 INSTALLATION These installation instructions were written for retrofitting
40. erHook through the complete operating cycle to maintain lubrication Quarterly 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 Yearly Maintenance e Lubricate the following areas with white lithium grease A Hook cylinder trunnions B Position cylinder trunnions C Inspect Prox harness D Inpesct Hoses E Change Hydraulic Oil May be required earlier depending on conditions 4111 0010 Nov 2010 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 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 QU E 49 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 M Reservoir P Breather Cap l 2 in 51 mm From Top of Q Fluid Level 7 Install breather c
41. ese 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 frame 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 truck or other method to raise dock leveler platform 8 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 Rear Imbed Electrical J Box Electical J B
42. et 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 truck trailer 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 truck restraint will return to the stored position 4111 0010 Nov 2010 OPTIONAL EGUIPMENT ADJUSTMENTS Adjust Auto Return To Dock ARTD Adjust the ARTD as Follows 1 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 A Cable E Target prop and locked out The are must be marked with m Switch i 2 safety cones and sighs Failure to do this may result Bracket Platform Lip 6 lock Nuts H Indicator Light in serious personal injury or death Standard leveler
43. f 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 WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SYSTEMS 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 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 d
44. henever maintenance is to be performed under the dock leveler platform support the platform with maintenance prop E Position the maintenance prop behind front header plate F 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 C and Tag out device D 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 1910 147 23 MAINTENANCE Service Dock Leveler Restraint Safely When service under the dock leveler is reguired 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 perso
45. her 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 Incorrect type of hydraulic 1 Drain and re fill system with proper fluid See fluid used Maintenance section for proper fluid level and type 4111 0010 Nov 2010 4111 0010 July 2003 41 TROUBLESHOOTING POWERHOOK Restraint engages truck Pressure switch trip point Pressure switch is factory set Do not attempt to trailer RIG bar but does 56 too high adjust in field replace switch with factory not automatically shut OFF Pump operates in pressure relief Pressure differential switch Pressure differential switch is factory set Switch trip point set too high must be replaced Restraint extends Solenoid 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 contaminant s Replace valve and coil NOTE Do not over tighten valve into block Max Torque 30 40 Ib ft or snug to prevent
46. in latch and insert through the maintenance 1751 0789 acne 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 DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is 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 1751 0728 6 4111 0010 Nov 2010 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 accordance with manufacturers recommendations and industry standards Before operation of the equipment all operators shall read understand and be familiar with all functions of equipment as described in the owner s user s manual 2 The manufacturer shall provide to the initial purchaser all necessary information with regards to Safety Information Operation Installation and Safety Precautions Recommended Initial and Periodic Inspections Procedures Planned Maintenance Schedule Product opecifications Troubleshooting Guide Parts Break Down Warranty Information and Ma
47. int so that the leveler cannot be operated until the restraint has engaged the truck trailer RIG Rear Impact Guard when the OPERATION switch is in NORMAL and has NOT been switched to BYPASS The truck 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 Thie allows the independent operation of the leveler the 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 OPTIONAL EGUIPMENT ADJUSTMENTS Adjust 8 Test Dock Leveler and Truck Restraint Interlock Figure 37 A 1 4 in 6 4 mm Approximate B Target C 1 in 25 4 mm Approximate D Lock Nuts E Proximity Switch 1 The dock leveler should be in the cross traffic position stored in the lip keepers before beginning tests 2 Back a truck trailer with RIG bar into d
48. l 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 Operational Safety Precautions Learn the safe way to operate this equipment Read and understand the manufacturer s wee Stay 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 instructions If you have any questions ask your supervisor 1 009 Chock restrain all freight carriers Never remove the wheel chocks until loading or unloading is finished and truck driver has been given permission to drive away Do not use a broken or damage dock leveling device Make sure proper service and maintenance procedures have been performed bef
49. l 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 Helief 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 including 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 ma
50. 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 2010 TROUBLESHOOTING POWERHOOK Lowered restraint Proximity switch on rear of Locate switch on rear of guide track Observe returns to fully retracted
51. n 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 15 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 38 4111 0010 Nov 2010 TROUBLESHOOTING POWERHOOK Restraint extends from stored position without fully lowering Restraint extends from stored position without lowering at all 4111 0010 Nov 2010 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 Operating Ra
52. n 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 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 First install the SAFETY bolt in the storage prop Second support the platform with maintenance props D 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 tagout device A Only the person servicing the equipment should have the capability to remove the lockout devices The tagout devices must inform that repairs are in process and clearly state who is responsible for the lockout condition Refer to OSHA regulation 1910 147 4111 0010 Nov 2010 Daily Maintenance Make sure that all the Inside and Outside signal lights work Weekly Maintenance Operate the dock leveler and Pow
53. nge 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 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 coil receiving failed OPEN Consult Factory for replacement signal but not energizing part 39 TROUBLESHOOTING POWERHOOK Restraint does not Solenoid D valve stuck off Locate solenoid See Parts Valve Block lo
54. nt does not Motor overload device Reset overload relay 3 phase or replace fuse 1 phase or reset breaker 1 phase new models Determine cause of device tripping operate Motor does not tripped energize NOTE If replacing fuse use fuse with equal specification Motor starter 3 phase or motor relay 1 phase not energizing 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 36 4111 0010 Nov 2010 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 Dperete MOLON enengizes Check motor starter as follows but does not run 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 Check all wiring to motor for high resistance or no connection Replace motor Three phase units only Phase reversed Heverse any two legs at
55. nuals 44 4111 0010 Nov 2010 PROGRAMMING ISSUES FOR PROGRAMMING e Error light is flashing PLC 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 30 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 complete flashing Run light should be 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 Nov 2010 45 TROUBLESHOOTING DOCK LEVELER 46 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 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 solenoi
56. nufacturers Contact Information The owner user shall be responsible to verify that this information is available and received as well as proper instructions training and familiarity of the equipment for all operators has been completed Owner s User s shall actively maintain update and re train all operators on safe working habits and operations of the equipment Itis recommended 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 4 Name plates placards decals instructions and posted warnings shall not be obscured from the 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 requested 6 Any modifications or alterations of loading dock equipment shall only be done with prior written approval from the original equipment manufacturer 7 f When industrial moving devices are being used in the loading or unloading of product from the transportation vehicle this
57. ock 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 target 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 truck restraint is not engaged at truck trailer HIG bar 4 Momentarily press the ENGAGE button The truck restraint will be activated and the restraint will engage the truck trailer 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 truck trailer 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 Figure 38 A 3 16 in 6 4 mm Approximate B Target C 1 in 25 4 mm Approximate D Lock Nuts E Proximity Switch 6 Press the RELEASE button The truck restraint should NOT disengage from the truck trailer HIG bar or test fixture If the restraint did NOT engage proceed with step 7 If the restraint DID disengage move the switch farther from the targ
58. ol 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 Install storage props on both side of the leveler and the safety pin on the maintenance prop Shut off all power to dock leveler control assembly 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 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 Nov 2010 10 11 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 be
59. ore using Make sure lip overlaps onto trailer at least 4 in 102 mm Keep a safe distance from both side edges 4111 0010 Nov 2010 Do not use dock leveling device if freight carrier is too high or too low m _ 3 111 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 Nov 2010 SAFETY III HY Maintenance Safety Precautions 4 4111 0010 2010 Dock Leveler Safety Deca s Every 90 days guarterly 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 75 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 A DANGER Unsupported dock leveler ramps can lower unexpectedly Before allowing vehicle to leave the dock always Ensure that no equipment material or people are on the dock leveler iny end loads if required Return the dock leveler to its stored position at dock level Failure to follow posted instructions will result in death or
60. ox Rear Imbed 16 4111 0010 Nov 2010 INSTALLATION 9 Use fork truck 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 10 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 11 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 12 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 shims Check for equal clearance between the sides of the platform and the pit walls 13 Weld the top rear frame angle to the rear pit curb angle Weld behind each hinge tube of the leveler platform See Figure 6 14 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 15 Repeat step 9 16 Finish weld all shims to unit and where
61. ped 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 Nov 2010 TROUBLESHOOTING POWERHOOK 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 fully lowers from stored position but does not extend 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 truck 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 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 clockwis
62. possible to plates or pit curb angles Weld shims together where stacked 17 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 18 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 19 Clean and paint all welds 20 Weld and or bolt bumpers in place on face of dock Refer to certified Pit Drawing 21 If leveler is part of a Centrapower system or if the power pack is located remotely connect the hydraulic hoses to the dock leveler as indicated in the Centrapower manual instructions 22 Check the hydraulic fluid level Standard units are shipped 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 Note For Centrapower or remote power pack units see appropriate instructions 23 If 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 pla
63. rial unattended on Keep hands and feet clear of pinch points Avoid the dock leveler putting any part of your body near moving parts Failure to follow these instructions may result in Failure to follow these instructions may result in personal injury and or damage to equipment severe personal injury or death Only trained personnel should operate the dock leveler and truck restraint DO NOT use a broken or damaged dock leveler or truck restraint Make sure proper service and maintenance procedures have been performed on equipment before using Truck trailer wheels must be chocked unless the truck restraint is used Never remove the wheel chocks until loading unloading is finished and truck driver has been given permission to leave Make sure platform lip rests on the truck trailer 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 0010 Nov 2010 21 OPERATION SEGUENCE OF OPERATION NORMAL 1 Check that the truck trailer is positioned squarely against the dock bumpers Inside Red Light Outside Green Light 2 Push ENGAGE button to activate restraint Inside Red Light Outside Green Light 3 Visually inspect restraint for proper engagement If RIG Rear Impact Guard is damaged or missing dock leveler can be used in BYPASS IF B
64. rs ln POWERHOOK VEHICLE RESTRAINT CONTROL ENTER ON ENGAGE GREEN ONLY e LIGHT RELEASE N A 2 A O FAULT BYPASS RESET service maybe required when LIGHTS ONLY Fault light is on DOCK LEVELER CONTROL Check that truckitraiier Push RAISE bulion raise positioned squarcy dack leurlar against dock bumpers z Push ENGAGE buttan to aclivabe restrairri Inside light green cou aed Release RAISE button in b inapect resiraint eer dock Ieveler for proger engagement j bo Lip will extend when dock laveler is Fully raised IF BYPASS MODE Z REQUIRED Chock truck trallsr Yhes Inside green light accompanied by amber Caution ight outside light ned Manual reset Bypass is accomplished by pushing ENGAGE bution after loading cycha complete Position mack bewekar onto truckHraillar 5 When loading ar uninading is complete rezurn dock leveler ta the shored position l Release ruck restraint andlor remote chacks from ck redler wheels ADANGER INK POWERAMP HAZARDU YL Tete TE DLM Tin s 5 1 1 a ur 6 2 er i eg eet te dl n v c 272 4 8 2 ond 56 5 Das dod mil ce 286 zr 8 88 hep Coreen Tani coe po Doom ope cored ere 5121 rudem mecnurwd zo dock
65. s 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 A DANGER CRUSH HAZARD Maintenance prop must support leveler behind bar 1 75 61 0727 Do not force maintenance prop forward of bar to support lip Refer to owners user s manual for proper use Failure to comply will result in death or serious injury 1751 0730 x2 AADANGER SAFETY INFORMATION Unsupported dock leveler ramps can lower unexpectedly ta Before allowing vehicle to leave the dock always e Ensure that no equipment material or people are on the dock leveler 00 vyjde 000 go O VZES 1751 0330 x2 decal placed in same position on both sides 2 A DANGER 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 1751 0728 7 DANGER 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 0788 4 DANGER CRUSH HAZARD Open the p
66. 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 75 1 0 1 38 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 A DANGER 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 position Open the pin latch 1751 0731 Scone 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 pros DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is 1 75 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 1751 0729 4111 0010 Nov 2010 5 SAFETY Dock Leveler Safety Deca s Every 90 days guarterly inspect all safety labels and tag
67. switch otherwise damage to switch will occur Readjust switch and or target if e Platform stays at this position unless the operator necessary then recheck for interference activates the leveler 34 4111 0010 Nov 2010 OPTIONAL EGUIPMENT ADJUSTMENTS Full Below Dock Position Lip Fully Extended Position p 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 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 Proximity switch indicator light is ON e f the platform lip is resting on the truck bed the e Platform will automatically rise after approximately a plattorm will stay at this position unless the six second delay then returns to the cross traffic operator activates the leveler position 4111 0010 Nov 2010 35 TROUBLESHOOTING POWERHOOK 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
68. te two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop 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 Failure to follow these instructions may result in serious personal injury or death 4111 0010 Nov 2010 33 OPTIONAL EQUIPMENT ADJUSTMENTS ARTD Continued 6 Turn ON electrical power to the dock leveler IMPORTANT 7 Disengage the maintenance prop Anytime proximity switch and target are adjusted 8 Turn the ARTD switch on control panel to the ON always check for interference between target and position switch before operating the leveler Damage to switch will occur if the target contacts the switch 9 Raise the platform until the lip is fully extended then allow the platform to drift to the below dock The maximum torque for proximity switch lock nuts position is 27 Nem 29 lb ft Damage to switch will occur if maximum torque is exceeded 10 After approximately 6 seconds the platform will return to the cross traffic position 11 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 12 Use the following illustrations to
69. tform level with the floor 4111 0010 Nov 2010 17 INSTALLATION MODEL KS6 Shown with Single Hoist Cylinder Support 5 x 7 x 14 67x8 x12 7 1 2 x 9 1 2 x 1 4 8 10 x 1 2 5 x 7 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 5 x 7 11a 7 12 x 9 12 x 1 4 8 x 10 x 1 2 5 x 7 x 1 4 6 X 8 x 1 2 Figure 8 18 6 8 x 4111 0010 Nov 2010 Maintenance Prop Stored Fig 19 Maintenance Prop In Position Figure 4 Rear Pit Rear Curb Angie Frame Angle Top View Figure 6 4111 0010 Nov 2010 INSTALLATION Fig 20 Dock Leveier In Cross Traffic Position Figure 5 Fish Plate AS D 73 8 3 Pass All Sides Both Piates Figure 7 INSTALLATION gt 8 4 2 96 20 4111 0010 Nov 2010 Allow enough clearance for possible seal or shelter x U pg LN SSS Limit PHA O O Optional MI Guide Lights KS6 Dock Leveler Drive OPERATION Operating Instructions Stay clear of dock leveler when freight carrier is DO NOT overload the dock leveler entering or leaving dock area DO NOT operate any eguipment while under the DO NOT move or use the dock leveler if anyone 5 influence of alcohol or drugs under or in front of leveler DO NOT leave equipment or mate
70. 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 lv 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 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 Damage or blocked Replace damaged hose s Check and remove hydraulic hose s and or blockage from hose s and or valve s valve s 4111 0010 Nov 2010 37 TROUBLESHOOTING POWERHOOK Restraint does not Low hydraulic fluid Add fluid see Maintenance section for proper fluid fully extend or
71. 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 set the OPERATION SWITCH to BYPASS Push and hold the RAISE pushbutton Release the RAISE 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 urn 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 4 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 5 Turn on the disconnect switch es 6 Set the POWER OFF ON switch to ON 7 Set the OPERATION SWITCH to BYPASS 8 In this step it is very important that the operator does not allow the Hook to lower to a position that will cause any of the sensors on the guide track to come into contact with the positioning cylinder The sensors will contact the cylinder if the RAISE pushbutton is h
72. 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 Raise the platform following instructions in the dock leveler owner s users manual and support with the maintenance prop Attached lifting plates supplied by others to the outboard joists on both sides of the dock leveler Use front hole on one side and rear hole on the other 4111 0010 Nov 2010 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 4 Shut off all power to dock leveler control assembly 5 Disconnect all wires at the junction box located on the rear pit wall 6 Modify the underside of the dock leveler platform as indicated on the Dock Leveler Modification Drawing s attached to
73. was shipped separately A Remove all trunnion keepers B Grease oylinder truinons 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 Nov 2010 Existing Dock Leveler Possible Cause Length CLEAN PIT Model 6 10 or 12 Foot Supplied by others available from Systems lnc at extra costs 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 6 Foot YES ben 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 INSTALLATION Hoist Cylinder Trunnion Plates 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 8 Foot YES plate s is supplied by Systems Inc Attached to pan Dispose of old e
74. wer 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 contaminan 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 oolenoid 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 positioning 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 stam
75. xisting 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 10 or 12 Foot YES Existing plate s to be reused Installation Instructions for KS5 when dock leveler is power by a Centrapower 1 Following step 1 4 of normal retrofit instructions page 13 A Disconnect and label the hydraulic hoses attached to the Centrapower Hydraulic valve assembly B Cap off all open fittings to prevent contamination 2 Step 21 reinstall leveler 3 Step 25 See VS KS4 manual on how to purge hydraulic system Additional instructions for KS5 when dock leveler is powered by a remote power pack 1 Draln power pack 2 Disconnect and label hydraulic hoses that are attached to the logic block The logic block is attached to the underside of the dock leveler platform A Cap Off all open fittings to prevent contamination B Tie off hoses to prevent damage when level is removed Review the Field Wiring Drawing and the certified pit drawing attached to this manual 3 Step 23 reconnect hoses to the logic block 4111 0010 Nov 2010 INSTALLATION Powerhook Ks6 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 th

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