PowerHold Truck Restraint OWNER’S / USER’S MANUAL POWERHOLD & POWERHOLD SC 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. Copyright © 2008 Manual No.
Table of Contents Page Safety Recognize Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Operational Safety Precautions . . . . . . . . . . . . . . . . . . . . . . Operational Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Decal's . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY Recognize Safety Information Safety-Alert Symbol The Safety-Alert Symbol identifies important safety messages on equipment, safety signs, in manuals, or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message. General Operational Safety Precautions Read and understand the operating instructions and become thoroughly familiar with the equipment and its controls before operating the dock leveler.
SAFETY Operational Safety Precautions Learn the safe way to operate this equipment. Read and understand the manufacturer's instructions. If you have any questions, ask your supervisor. Stay clear of dock leveling device when freight carrier is entering or leaving area. 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.
SAFETY Do not use dock leveling device if freight carrier is too high or too low. Do not overload the dock leveling device. Do not operate any equipment while under the influence of alcohol or drugs. Do not leave equipment or material unattended on dock leveling device.
SAFETY Maintenance Safety Precautions ALWAYS disconnect electrical power source and ground wire before welding on dock leveler. DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler. Always ground to the dock leveler frame. Failure to follow these instructions may result in damage to dock leveler and/or serious personal injury or death. Hydraulic and electrical power must be OFF when servicing the equipment.
SAFETY Dock Leveler Safety Decal's Every 90 days (quarterly) inspect all safety labels and tags to ensure they are on the dock leveler and are easily legible. If any are missing or require replacement, please call 1-800-643-5424 for replacements. DANGER CRUSH HAZARD Maintenance prop must support leveler behind bar. 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.
SAFETY Decal's Every 90 days (quarterly) inspect all safety labels and tags to ensure they are on the dock leveler and are easily legible. If any are missing or require replacement, please call 1-800-643-5424 for replacements. DANGER CRUSH HAZARD Maintenance prop must support leveler behind bar. 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.
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 manufacturer’s recommendations and industry standards.
INTRODUCTION Congratulations on your choice of a Poweramp PowerHold truck restraint. This manual covers the PowerHold 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. Its revolutionary hydraulic system efficiently controls and operates every function.
OPERATION Theory When the engage button (A) is pushed on the control panel this activates an electric motor which, drives a hydraulic pump. The hydraulic pump forces oil into the hydraulic cylinder causes the shoe to raise. The shoe will make contact with the ICC bar. The pump will shut off one the shoe is at 90deg. Once the truck is locked The leveler the raise button will be activated(D). When the release button (B) is pushed the motor will run and lower the shoe.
INSTALLATION PowerHold Installation Overview For comprehensive installation instructions of the PowerHold read and understand the Installation and Operation Manual. POWERPACK LOCATION OPTIONS Coordinate powerpack location and hose length for proper placement. Allow Enough Clearance for Possible Seal or Shelter Dock Face (Self Contained) Appropriate location when the likelihood of flooding, snow removal and damage from trailer/trucks is minimal.
INSTALLATION PowerHold Installation Overview For comprehensive installation instructions read and understand the Installation and Operation Manual. Concrete Dock Face (Standard installation) Wedge Anchors Method Weld Plate Embed Method Using back plate as a guide, drill eight (8) holes for wedge anchors (3/4”x 5 1/4” min.) (Kit #2103-0004) Weld three sides of PowerHold back plate to the optional embed mounting plate (Part #7953-0119) with continuous 1/4” fillet weld.
INSTALLATION Component Identification.
INSTALLATION Component Identification PowerHold manifold with leveler Hose connections.
OPERATION Operating Instructions Stay clear of dock leveler when freight carrier is entering or leaving dock area. DO NOT move or use the dock leveler if anyone is under or in front of leveler. Keep hands and feet clear of pinch points. Avoid putting any part of your body near moving parts. Failure to follow these instructions may result in severe personal injury or death. DO NOT overload the dock leveler. DO NOT operate any equipment while under the influence of alcohol or drugs.
OPERATION SEQUENCE OF OPERATION NORMAL SEQUENCE OF OPERATION BYPASS 1. Check that the truck/trailer is positioned squarely against the dock bumpers. - Inside Red Light - Outside Green Light 1. Check that the truck/trailer is positioned squarely against the dock bumpers. 2. Push ENGAGE button to activate restraint. - Inside Green and Yellow Light - Outside Red Light 3. ENGAGED on Truck Restraint. - Inside Green Light - Outside Red Light 4. Visually inspect restraint for proper engagement.
OPERATION PowerHold Light Sequence CONDITION INSIDE LIGHTS OUTSIDE STORED BEGIN/END (O/9) RED (O/8) GREEN IN MOTION (O/6) AMBER (O/7) (O/6) RED & STROBE HOOKED (O/5) GREEN (O/7) RED OVERRIDE (O/5) (O/6) GREEN/AMBER (O/7) (O/6) RED/STROBE MISSED ICC (O/6) 30sec (O/4) AMBER (TIME) RED (O/7) 30sec (O/8) RED (TIME) GREEN STROBE (O/8) TIMEOUT (FAILURE) (O/9) (O/6) RED/AMBER (O/7) (O/6) RED/STROBE (O/8) AMBER (O/5) (O/8) RED/STROBE TIMEOUT (FAILURE) IN MOTION A NEW LOCK CYCLE OR BYPASS WI
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MAINTENANCE Service Dock Leveler Safely A B Side View A E C A— Lip Maintenance Prop B —Tag Out Device C — Lock Out Device 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.
MAINTENANCE Periodic Maintenance Apply white lithium grease or equivalent Daily Maintenance • Make sure that all the Inside and Outside signal lights work. IMPORTANT Failure to properly lubricate the Truck Restraint will cause abnormal operation of the Restraint Weekly Maintenance • Operate the PowerHold truck restraint through the complete operating cycle to maintain lubrication. NOTE: - position. • Inspect the slide block track and push rod areas. The areas must be kept free of dirt and debris.
MAINTENANCE Periodic Maintenance With Leveler C B A D K On select models an inspection plate is provided in the platform floor for ease of maintenance and pit inspection. Others must be serviced from under the leveler.
MAINTENANCE P Daily Maintenance • Make sure that all the Inside and Outside signal lights work. N Q Weekly Maintenance • Operate the dock leveler and PowerHold through the complete operating cycle to maintain lubrication. NOTE: To thoroughly inspect the platform hinge area, put the platform in the full below-dock position. M • Inspect the platform hinge and the lip hinge areas. The hinge areas must be kept free of dirt and debris.
ADJUSTMENT AND TESTING PowerHold Operating Range NOTE: Test operating range of PowerHold without truck/trailer backed into dock. 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.
ADJUSTMENTS PowerHold Adjustments Install prox flush then back out (CCW) just past flush. Prox Switch PRS 2 INPUT #4 1/16 min 1/8 max Prox Switch PRS 1 INPUT #3 The Operating range is not adjustable on a PowerHold restraint. IMPORTANT: Make sure that the wire from the prox switches are clear of all moving parts. Proximity switch Adjustment and replacement. A. Locate and remove four screws and cover on front of PowerHold assembly. B. Adjust PRS 1.
OPTIONAL EQUIPMENT ADJUSTMENTS Adjust Dock Leveler and Truck Restraint Interlock Dock Leveler and Truck restraint Interlock 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.
OPTIONAL EQUIPMENT ADJUSTMENTS Adjust & Test Dock Leveler and Truck Restraint Interlock 1. The dock leveler should be in the cross traffic position before beginning tests. 2. Back a truck/trailer with RIG bar into dock. A test fixture may be used to simulate the RIG bar. Use care to avoid damage to the equipment or harm to the operator. 3. Press the RAISE push button. The dock leveler should NOT raise. If the leveler did not raise, proceed with step 4.
OPTIONAL EQUIPMENT ADJUSTMENTS Adjust Auto Return To Dock (ARTD) Adjust the ARTD as Follows: B C D E F 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.
OPTIONAL EQUIPMENT ADJUSTMENTS IMPORTANT 6. Turn ON electrical power to the dock leveler. Anytime proximity switch and target are adjusted, always check for interference between target and switch before operating the leveler. Damage to switch will occur if the target contacts the switch. 7. Disengage the maintenance prop. The maximum torque for proximity switch lock nuts is 27 N•m (29 lb-ft). Damage to switch will occur if maximum torque is exceeded. 9.
OPTIONAL EQUIPMENT ADJUSTMENTS Full Below-Dock Position Lip Fully Extended Position Lip Keeper Whenever the platform lip is at the fully extended position, the following conditions will exist for a normally operating ARTD: • Target not in the sensing area of proximity switch. Whenever the platform lip is at the full below-dock position, the following conditions will exist for a normally operating ARTD: • Proximity switch OFF (open) (no signal sent to the control panel).
TROUBLESHOOTING POWERHOLD When service under the dock leveler is required, always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop. Failure to do this may result in serious personal injury or death. Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete. Failure to do this may result in serious personal injury or death.
TROUBLE SHOOTING POWERHOLD Symptom Possible Cause Three-phase units only: 3 Phase units only - no Restraint does not voltage is present on one operate. Motor energizes line. but does not run. NOTE: A motor that is If motor hums, but does missing voltage on one line not run, overload device is said to be single-phased. should trip. Combination Leveler and P-Hold Only. Solution Check for blown fuses at branch circuit disconnect. Replace fuse. Determine cause of blown fuse.
TROUBLE SHOOTING POWERHOLD Symptom Restraint does not fully raise or motor overcurrent device and/or overload device continuously tripping. Possible Cause Solution Low hydraulic fluid. Add fluid, see Maintenance section for proper fluid level and type. Debris in Tank Drain and clean tank. I debris cannot be cleaned out replace tank. Restraint does not raise. Solenoid Not energized. Locate solenoid (See Page 40 & 41). Coil must be energized when P-Hold is in engage mode.
TROUBLE SHOOTING POWERHOLD Symptom Restraint will not lower to release truck. Possible Cause Solution Solenoid staying energized. Relay or PLC contact is stuck contacts. Test coil for Magnetism (see page 40,41). Coil must be deenergized to release the truck. Bad Spool Valve. 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).
TROUBLE SHOOTING POWERHOLD Symptom Possible Cause Solution Restraint raises makes contact with ICC bar but does not lock. Then returns to stored position. Improper location of P-Hold Power Hold must have a 4” set back from bumper SEE page 10. Prox switch 1. Check prox switch #1 and #2. When metal is placed in front of prox the led light on the prox will light up. When the led on the prox is lit the inputs#3 and #4 on the plc will also be lit.
TROUBLE SHOOTING DOCK LEVELER Symptom Platform rises slowly. Possible Cause Solution Low hydraulic fluid. Add fluid, see Maintenance section for proper fluid level and type. Contaminated hydraulic system. Clean and inspect valves. Flush contaminated oil from hydraulic system. Fill system with new oil. See Periodic Maintenance in the Maintenance section. Damaged or restricted hydraulic hose(s). Replace damaged hose(s). Remove restriction. Pressure relief set too low. Increase pressure relief.
TROUBLESHOOTING DOCK LEVELER Symptom Platform locks into “safety” as platform lowers. Lip drops to vertical position. Possible Cause Platform lowering speed is too fast. Solution Adjust platform down speed control. See Adjust Cable Weight and Down Speed Control in the Adjustment section. NOTE: Extreme cold weather OR incorrect fluid may cause platform to lock. Adjustment is same. Dock leveler equipped with ARTD: Platform does not automatically return to the cross-traffic position or operates abnormally.
LADDER LOGIC POWERHOLD W/LEVELER #1 Prox Switch See Page 23 #2 Prox Switch See Page 23 36 4111-0016 — Sept 2010
LADDER LOGIC POWERHOLD W/LEVELER 4111-0016 — Sept 2010 37
PROGRAMMING ISSUES FOR PROGRAMMING. - Error light is flashing, PLC is either missing or damaged. - Update to newer program - Installation of new un programmed PLC MATERIAL REQUIRED. You will receive two (2) E-proms - Blank run E-Prom. - 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.
MANUAL RELEASE Shoe Front Cover Slide Block 3/4” Dia Rod Tools required: Large Hammer 3/4” Dia Rod Two Foot Lg. Manual release. - Lock out / tag out leveler. - Remove front cover plate (4 screws) - Remove bolt and washer holding cylinder in place. - Install 3/4’ rod through front opening. Rod will fit in the slide block. - Hammer 3/4 rod (4 to 5 hits) until the slide block travels past the shoe. -The shoe will then drop.
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PARTS Valve Block Combination PowerHold and Leveler Coil De-energized to raise Leveler. Energized to raise or lower the restraint.
PARTS PowerHold Valve Block SC G H E F 4 1 C D 3 2 A B Item Quantity A B C D E F G H 1 2 2 2 1 1 1 1 Part Number 9571-0007 9301-0109 8581-0113 8581-0115 8581-0011 8581-0004 4305-0319 Hydraulic Valve Body Fitting Pipe Plug 1/8 NPT Fitting Conn STR Thread Fitting Elbow 90 Deg #6 ORB x #6 JIC Valve Cartridge Relief Valve Cartridge 4-Way Coil, Delta Cable Assembly 22” Lg Description I 1 8583-0017 Complete Valve Assembly *Provide dock leveler and/or PowerHold serial number when calling or fax
PARTS PowerHold Valve Block E F Coil must be energized to raise restraint. De-energized to lower the restraint.
PARTS A X E X B P Q C N D K I L M O J V F U S T Q G H R Q W *Provide dock leveler and/or PowerHold serial number when calling or faxing orders.
PARTS PowerHold Break Down Item Quantity Part Number A B C D 1 1 1 1 E 1 F G H I J K L M N O P Q R S T U 1 1 1 1 1 1 1 1 2 4 1 14 1 1 1 1 V W X 4 1 1 9414-0064 9412-0030 9414-0021 9411-0005 8583-0017 8583-0016 9414-0065 2101-0118 2101-0119 9414-0073 9904-0059 9904-0155 9412-0095 2101-0045 9412-0063 2101-0009 9411-0046 2101-0099 9411-0012 9411-0007 0192-0016 2753-0001 2753-0002 2101-0074 9414-0063 8581-0137 4111-0016 — Sept 2010 Description Restraint Shoe Pin 1-1/2 X 8 LG Rack Weldment Spring,
PARTS PowerHold SC Power Pac D A C G F B Item Quantity Part Number A B C D F 1 1 1 2 7 9301-0199 9411-0047 9301-0085 9904-0051 2101-0009 Breather Cap Cover, Power Pac Filter 3/8 NPT Hose, 16.00” LG 3/8 NPTM / #6 Jic Swivel Female Bolt 5/16-18 UNC 3/4 Lg.
PARTS PowerHold SC Prox Switch #2 INPUT #4 A D E Prox Switch #1 INPUT #3 B C Item Quantity Part Number A B C D E F F 2 1 1 1 1 1 1 0963-0073 0941-0008 0941-0009 2101-0012 2101-0202 2101-0203 9414-0065 4111-0016 — Sept 2010 Description Prox Switch Spring Spring Bolt 5/16-18 UNC Nut, Hex 5/16-18 UNC Latch Weldment Latch Assembly (Complete With Prox Switches) 47
PARTS Power Pack Assembly Remote Mount J L K M H D C G E F AC AB B Q AA R Z Y A N P W X S T U T V 48 4111-0016 — Sept 2010
PARTS Power Pack Assembly Remote Mount Item Quantity Part Number A B C D E F 2 2 1 1 1 2 1 4 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 2 2 1 2101-0039 9301-0029 9302-0014 9301-0199 9301-0027 9302-0012 9301-____ 1 2101-0016 9301-0028 9303-0002 9302-0017 9904-0001 0521-0017 0521-0007 3411-____ 2 0521-0015 0521-0014 9301-0024 9302-0009 9303-0003 9301-0014 9301-0015 9301-0016 0521-0016 9301-0009 9301-0082 9301-0008 9301-0003 9301-0004 2101-0063 9395-____ 1 G H J K L M N P Q R S T U V W X Y Z AA AB AC 1 2
PARTS Outside Signs A Item Quantity Part Number A 1 1751-0033 B 1 1751-0034 50 B Description SIGN,PULL IN/OUT ON GREEN ONLY RIGHT READING,16-7/8x8x3/32 SIGN,PULL IN/OUT ON GREEN ONLY MIRROR IMAGE,16-7/8x8x3/32 4111-0016 — Sept 2010
PARTS OSLA (Outside Light Assembly) Item Quantity Part Number 1 3055-0008 Complete Light Housing, Yellow Plastic, LED Lights 1 1 3055-0002 3055-0009 Complete Light Housing, Yellow Plastic, Incandescent Lights Complete Light Housing, Clear Charcoal, LED Lights, Strobe 1 3055-0007 Complete Light Housing, Clear Charcoal, Incandescent Lights, Strobe 1 3051-0063 Light Housing Only, Yellow Plastic 1 3051-0100 Light Housing Only, Clear Charcoal 2 1 3051-0102 Lens/Housing/Circuit Assembly Red-
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MISCELLANEOUS Customer Information A PR052 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 PR dock leveler, write down the dock leveler model and serial number in the form provided. This will help ensure safe keeping of the numbers in the event the model/serial number decal (A) becomes lost or damaged. Also, write down Systems, Inc.
STANDARD PRODUCT WARRANTY SYSTEMS, INC. warrants that its products will be free from defects in design, materials and workmanship for a period of one (1) year from the date of shipment. All claims for breach of this warranty must be made within 30 days after the defect is or can with reasonable care, be detected. In no event shall any claim be made more than 30 days after this warranty has expired.
