PowerHook Truck Restraint Owner’s/User’s Manual 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 © 2003 Manual No.
Table of Contents Page Safety Recognize Safety Information ............................................................. General Operational Safety Precautions ............................................ Safety Decal’s ........................................................................................ Owner’s/User’s Responsibilities ......................................................... 1 1 5 7 Introduction General Information .....................................................................
SAFETY Recognize Safety Information General Operational Safety Precautions 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. 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 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.
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 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. Its revolutionary hydraulic system efficiently controls and operates every function.
INTRODUCTION Component Identification J A B I C H F E D G 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) I — Hook Lowered Sensor Target 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.
INSTALLATION KS4 INSTALLATION These installation instructions were written for retrofitting a Poweramp® hydraulic dock leveler with integral power pack with a PowerHook® KS4 Vehicle Restraint. If you are not adding the PowerHook® 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.
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 floor Powerhook Pan Vertical Valve Block KS4 Pan Inside view Hook Valve Block 12 4111-0010 — Nov 2010
INSTALLATION KS5 INSTALLATION These installation instructions were written for retrofitting a Poweramp® hydraulic dock leveler with integral power pack with a PowerHook® KS5 Vehicle Restraint. If you are not adding the PowerHook® 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.
INSTALLATION 15. Cut pit for the truck restraint pan as indicated on the Pit Drawing. A 16. 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 17.
INSTALLATION Existing Dock Leveler Length Possible Cause Hoist Cylinder Trunnion Plates CLEAN PIT Model 6,10 or 12 Foot NO 8 Foot NO 6 Foot 8 Foot 10 or 12 Foot YES YES YES Supplied by others available from Systems Inc 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.
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 these items from unit prior to installing unit in pit. DO NOT remove the shipping bands at this time. 2. Remove all debris from the pit. 3.
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.
INSTALLATION Figure 8 18 4111-0010 — Nov 2010
INSTALLATION 4111-0010 — Nov 2010 Figure 4 Figure 5 Figure 6 Figure 7 19
INSTALLATION 8” Allow enough clearance for possible seal or shelter.
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 Red Light -Outside Green Light 3. Visually inspect restraint for proper engagement.
MAINTENANCE Service Dock Leveler/Restraint Safely F E C D A— Tag out Device B — Lockout Device C — Lockout Device D — Tag out Device E — Maintenance Prop F — Header Plate 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 Service Dock Leveler/Restraint Safely A B C 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.
MAINTENANCE Daily Maintenance • Make sure that all the Inside and Outside signal lights work. Weekly Maintenance • Operate the dock leveler and PowerHook through the complete operating cycle to maintain lubrication. • Quarterly Maintenance Lubricate the following areas with white lithium grease: 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.
MAINTENANCE P N Q KS5 or KS6 and KS7 • Check reservoir fluid level (Q): 1. Put the dock leveler platform at the full below-dock position. 2. Turn OFF all electrical power to the leveler. 3. Remove inspection plate. M 4. Remove breather cap (P). 5. 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 N — 2 in.
ADJUSTMENT AND TESTING Testing PowerHook Operating Range NOTE: Test operating range of PowerHook 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 Adjust PowerHook Operating Range Hook cylinder trunnions Hook Cylinder Threaded Eye and Jam Nut Counter clock Wise Clock Wise Hose Port Figure 10 Position cylinder trunnions Figure 11 1. Adjust the upper vertical limit of PowerHook operating range if necessary. A. Locate the hook cylinder assembly and the hold down cylinder assembly. The length of the threaded eye on the hold down cylinder will determine the upper vertical limit of the hook movement. B.
ADJUSTMENTS Adjust PowerHook Operating Range B 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. C A E D 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.
ADJUSTMENTS #3 prox switch Start adjustments at 10o’clock position Figure 13 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 KS6 and KS7 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.
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 B B A A B C E E D 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 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.
OPTIONAL EQUIPMENT ADJUSTMENTS Adjust Auto Return To Dock (ARTD) E F D C 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. B 2. Turn OFF all electrical power to the dock leveler. Attach safety lockout and tag-out devices.
OPTIONAL EQUIPMENT ADJUSTMENTS ARTD Continued 6. Turn ON electrical power to the dock leveler. IMPORTANT Anytime proximity switch and target are adjusted, always check for interference between target and switch before operating the leveler. Damage to switch will occur if the target contacts the switch. The maximum torque for proximity switch lock nuts is 27 N•m (29 lb-ft). Damage to switch will occur if maximum torque is exceeded. B A C E A— 1/4 in. (6.4 mm) Approximate B— Target D 8.
OPTIONAL EQUIPMENT ADJUSTMENTS Full Below-Dock Position Lip Fully Extended Position Lip Keeper Whenever the platform lip is at the full below-dock position, the following conditions will exist for a normally operating ARTD: 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. • Proximity switch senses target. • Proximity switch ON (closed) (signal sent to the control panel).
TROUBLESHOOTING POWERHOOK Always stand clear of the dock leveler lip when working in front of the dock leveler. 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. The maintenance prop MUST be in the service position when working under the dock leveler.
TROUBLESHOOTING POWERHOOK 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. Solution Check for blown fuses at branch circuit disconnect. Replace fuse. Determine cause of blown fuse. Check motor starter as follows: 1.
TROUBLESHOOTING POWERHOOK Symptom Possible Cause Solution Restraint does not fully extend or motor overcurrent device and/ or overload device continuously tripping. Low hydraulic fluid. Add fluid, see Maintenance section for proper fluid level and type. Restraint lowers, fully extends but does not raise. Pump operates in pressure relief. Solenoid “D” valve stuck ON. Locate solenoid (See Parts: Valve Block). Remove coil from cartridge valve and cartridge valve from valve block.
TROUBLESHOOTING POWERHOOK Symptom Restraint extends from stored position without fully lowering. Possible Cause Solution Proximity switch at trunnion that senses when restraint lowered target out of adjustment. Locate switch on hook trunnion. Observe indicator light at controller input (#3) that receives signal from switch. Input light should only turn ON when restraint fully lowered. If this does not occur, adjust target counterclockwise. See Adjustments section: Adjust PowerHook Operating Range.
TROUBLESHOOTING POWERHOOK Symptom Restraint does not lower at all from stored position. Pump operates in pressure relief (restraint does not extend). Possible Cause Solution Solenoid “D” valve stuck off. 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.
TROUBLESHOOTING POWERHOOK Symptom Restraint only partially lowers from stored position. Pump operates in pressure relief (Restraint does not extend). Restraint fully lowers from stored position but does not extend. Possible Cause Solution Obstruction preventing the restraint from lowering. Remove obstruction. Fluid flow to positioning cylinder blocked. Locate the needle valve that controls fluid flow to the cylinder.
TROUBLESHOOTING POWERHOOK Symptom Possible Cause Solution Restraint engages truck/ Pressure switch trip point trailer RIG bar but does set too high. not automatically shut OFF. Pump operates in pressure relief. Pressure differential switch trip point set too high. Pressure switch is factory set. Do not attempt to adjust in field replace switch with factory. Restraint extends Solenoid “B” valve stuck from RIG bar engaged ON, or solenoid(s) “C1” or position, fully lowers but “C2” stuck OFF.
TROUBLESHOOTING POWERHOOK Symptom Possible Cause Solution Lowered restraint returns to fully retracted position but unit does not automatically shut OFF. Pump Operates in pressure relief. Restraint remains lowered. Proximity switch on rear of (closest to rear pit wall) guide track that senses when restraint fully retracted out of adjustment. Locate switch on rear of guide track. Observe indicator light at controller input (#6) that receives signal from switch.
TROUBLESHOOTING DOCK LEVELER Symptom Platform does not rise. Pump operates in pressure relief mode. Possible Cause Solution Heavy object(s) on platform. Remove object(s) from platform. 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.
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.
TROUBLESHOOTING DOCK LEVELER 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 solenoid valves in the hydraulic block that is on the hook cylinder).
TROUBLESHOOTING DOCK LEVELER To force the Hook in (retract), do the following: 1. Set the dock leveler on the maintenance prop. 2. Turn off the disconnect switch(es) – see WARNING on page 1. 3. Disconnect field wires 60, 61, 62 and 63. Cap off the end of wires 60, 61 and 63 with a wire nut. 4. Connect field wire 62 to the right side of any 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.
ELECTRICAL DIAGRAM, GENERIC 48 4111-0010 — Nov 2010
4111-0010 — Nov 2010 49
PARTS A C Item Quantity Part Number A B 1 1 C 1 0961-0083 * 9511-0004 9512-0429 Description Proximity Switch with Harness (INTERLOCK Feature Only) Push Button Controller J-Box, Standard (4 x 4 in. Metal Box) J-Box, Cold Weather (5 x 5 in. Plastic Box) * Provide dock leveler serial number, voltage, phase, and options when calling or faxing controller orders.
PARTS Powerhook Guide Track Components #3 #6 C D E D E G D F A #4 #5 D E B D E H I Item Quantity Part Number 0521-0143 Description A 1 B C D E F 1 1 7 5 2 0521-0144 0521-0173 2101-0196 2101-0202 2101-0203 Cable Assembly - Powerhook - Standard Sensor Mounting Bracket Nylon Lock Nut, 10-32 UNF Round Head Machine Screw, 10-32 UNF x 1/2, Stainless Steel Round Head Machine Screw, 10-32 UNF x 3/4, Stainless Steel A-G H I 1 1 1 0524-0075 0521-0146 0521-0147 Powerhook Guide Track Assembly C
PARTS A B D C X W U V R T S Q E L N O P H J F G M Item Quantity Part Number A B C D 1 1 1 1 8585-0096 7054-0010 9904-0110 9301-0116 Valve Block Assembly - Regeneration (See Breakdown for Details) Cylinder Assembly - PowerHook Hydraulic Hose Assembly - 1/2” 100R1 x 20.
PARTS PowerHook Valve Body Assembly 1 2 3 4 6 5 7 8 9 20 10 19 21 18 11 15 17 13 12 16 Item# Part Description Bock Label 1 Cartridge Valve - 4-way - 2-position A 2,5,8,12,14 14 Delta Coil DLS Function Part Number Fluid to Powerhook or Dock Leveler if energized 8581-0011 Activates Cartridge Valve 8581-0004 Fluid to Logic Block 9301-0127 3 Elbow 90º Fitting 4 Cartridge Valve - 3-way - 2-position Fluid to lower Powerhook if energized (with D) 8581-0005 6 Pressure Switch Ass
PARTS Power Pack Assembly Vent Tube J L K M H D G E F Pressure Line C AC AB N P Q B AA R Z S Y A W T PR006 X U Return Line T V 54 4111-0010 — Nov 2010
PARTS Power Pack Assembly 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 Description
PARTS Pressure Differential Valve and Block A B C D F E 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.
MISCELLANEOUS Customer Information A 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. Dock Leveler Information Model ___________________________________ Serial No. ________________________________ Systems, Inc., Job No. ______________________ When you receive your Poweramp product, write down the product model and serial number in the form provided.
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.
