™ TPR 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 © 2012 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. Effective operator training should also focus on the owner’s/user’s company policies and operating conditions.
INTRODUCTION General Information Due to ongoing product improvement, some parts have changed, along with operation and trouble shooting methods. This manual describes these changes. For further assistance, please contact: Poweramp Technical Service at 800-643-5424 or techservices@docksystemsinc.
INTRODUCTION Component Identification ION NOITUAC CAUT LLUP PULL R R O NI IN O N N O O OUT N N TUO EERG GREE Y LNO Y L ON Placards 4111-0035 — Feb 2012 Aug 2012 9
INSTALLATION INSTALL ROLLER TRACK PLATE Install roller track plate onto dock face at specified location by welding to an embedded steel plate or by using the fifteen (15) concrete anchors provided in conjunction with welding to pit steel and a leveler frame. If you have questions, contact Systems Technical Support at (800) 643-5424. The roller track plate must be plumb with dock face. If not, use and weld (6) shims 2” wide x 25 5/8” long. If shims are over 1/2” thick use longer anchors.
INSTALLATION WELDING INSTALLATION INSTRUCTIONS If the installation being worked on is a retrofit or replacement situation, the following electrical connections must be disconnected prior to welding: LOCKOUT/TAGOUT the power at the fused disconnect, then remove the motor and limit switch connections from the control harness located in the outside junction box. Once all welding has been completed, reconnect all the wires. NOTES: 1.
INSTALLATION INSTALL VEHICLE RESTRAINT INTO ROLLER TRACK PLATE 1. Attach the four (4) springs to the lower spring bar. 2. Pull springs upward and slide over top spring mount on the track roller plate. Use lifting device (e.g. crane, jack) when lifting carriage (approx. 110 lbs.). Lifting by hand may cause back injury. 3. Install right and left spring cover with clip nuts and flat head screws provided. 4. Slide the carriage assembly into the roller track. 5.
INSTALLATION ! DANGER Make sure that the power source has been locked out and tagged according to OSHA regulations and approved local electrical codes. If the incoming electrical power for the TPR vehicle restraint is taken from a nearby electrical appliance, e.g., overhead door opener, verify that the amperage is in accordance with local and federal codes. The TPR vehicle restraint 1/10 HP motor requires 120V, single phase power, 60 Hz power and 10 amps of current to operate properly.
INSTALLATION Disconnect (supplied by others) Place control box where best suited, within arms reach, at eye level near door opening 5” Inside Caution sign Allow adequate space for seals and shelters Placard Inside light and control box Outside lights 48” Dock Seal Outside Caution Sign 18” 96” 4” Thick Bumpers Junction box mounted on dock face, not to extend out more than 3” (Supplied by others) “TPR” 3/4” Conduit or Diameter per Local Code (Supplied by others) Wire Harness Optional imbed plated
INSTALLATION 4111-0035 — Feb 2012 Aug 2012 15
INSTALLATION 16 4111-0035 — Feb 2012 Aug 2012
INSTALLATION 4111-0035 — Feb 2012 Aug 2012 17
INSTALLATION INTERLOCKING LOAD DATA AND NOTES 18 4111-0035 — Feb 2012 Aug 2012
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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. Only trained personnel should operate the dock leveler and truck restraint.
OPERATION Stored Position / Restraint UNLOCKED Hook is in the STORED position. Inside light is flashing red alerting forklift operator unsafe condition exists. Outside light is flashing GREEN alerting truck driver it is safe to back in. Inside light flashing RED RED GREEN RED GREEN ENGAGE Button Pressed - Restraint ENGAGING Trailer has backed into loading dock and is parked firmly against dock bumpers. Hook rotates from stored position to engage RIG.
OPERATION RELEASE Button Pressed - Restraint DISENGAGING Hook travels from the ENGAGED position to the STORED position. Outside light is flashing RED alerting truck driver not to move. Inside light is flashing RED. Once the hook is stored the outside light with flash GREEN, alerting the drive it is safe to depart. RED RED YELLOW FAULT from ENGAGING State Hook cannot engage the RIG. This could be due to a RIG that is located too far toward the rear axle, bent, obstructed or missing.
OPERATION BY PASS from ENGAGING State Hook cannot engage the RIG. Switch the selector to BY PASS. The YELLOW and GREEN inside lights will flash. Proceed with caution. Outside light will flash RED. RED YELLOW GREEN BY PASS RED NORMAL GREEN BY PASS to STORED State Once loading or unloading complete. Switch the selector to NORMAL. Press the RELEASE button, IF hook is not in the stored position, inside light will flash RED. Outside light will flash GREEN, The driver can now depart.
OPERATION FAULT from ENGAGING State With OPTIONAL ALARM Hook cannot engage the RIG. This could be due to a RIG that is located too far toward the rear axle, bent, obstructed or missing. Inside light is flashing RED and ALARM, alerting the forklift operator that the trailer is not locked. Outside light is flashing RED alerting the truck driver not to move. If the trailer is parked firmly against the dock bumpers proceed to BY PASS.
MAINTENANCE Service Dock Leveler/Restraint Safely A B E When working with electrical or electronic controls, make sure that the power source has been locked out and tagged A-B according to OSHA regulations and approved local electrical codes. Post safety warnings and barricade work area, at dock level and at ground level, to prevent unauthorized use of the dock. Safe operation of the TPR truck restraint requires all lights and the Alarm to be working properly.
MAINTENANCE Service Dock Leveler/Restraint Safely Must follow all safety precautions • • • • • • • • • • • • DAILY Remove debris around TPR vehicle restraint. Verify that restraint operates smoothly and inside, outside lights and horn are working. Replace damaged or missing light bulbs and lenses. Repair, remount, or replace outside and inside signs and labels as required. Inspect dock bumpers. Missing bumpers must be replaced. 180 DAYS Perform all Daily maintenance.
ADJUSTMENTS DRIVE CHAIN ADJUSTMENT 1. Inspect the drive chain periodically for dirt and chain slack. Open the motor enclosure and clean the chain with solvent. After cleaning, spray with a high quality chain spray type lubricant. When working with electrical or electronic controls, make sure that the power source has been locked out and tagged according to OSHA regulations and approved local electrical codes. 2. The drive chain should not have more than 1/4" slack.
TROUBLESHOOTING 4111-0035 — Feb 2012 Aug 2012 29
TROUBLESHOOTING LIMIT SWITCH TEST PROCEDURE • Set multimeter to “RX1” scale for “Continuity Test”. • Attach multimeter leads to pins “B” and “C” of limit switch connector. You should have: -plunger released - no metre reading -plunger depressed - a “Full Scale” meter reading 30 NOTE: The green (ground) wire of the limit switch does not have to be tested. A continuity test lamp may be used instead of a multimeter.
HARNESS 4111-0035 — Feb 2012 Aug 2012 31
PARTS ITEM 1 2 3 4 5 6 7 QTY 2 3 1 4 1 1 1 PART NUMBER 2101-0126 2101-0011 9701-0200 9701-0113 9701-0201 0961-0570 0691-0571 8 1 9701-0112 CAM 9 2 9701-0111 BEARING ASSEMBLY 10 1 9701-0202 CAM DECAL 32 DESCRIPTION CAP SCREW 3/8”-16 X 1-1/2” HH CAP SCREW 5/16-18 X 1” HH RING , SNAP ROLLER ASSEMBLY 3/4” CONDUIT NIPPLE LIMIT SWITCH, LS1 LIMIT SWITCH, LS2 4111-0035 — Feb 2012 Aug 2012
PARTS ITEM 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 QTY 1 1 2 8 2 3 2 2 1 1 2 1 2 1 1 6 1 1 1 1 1 1 1 1 1 1 1 1 2 3 1 4111-0035 — Feb 2012 Aug 2012 PART NUMBER 9701-0109 9701-0108 9701-0203 9701-0204 9701-0205 2101-0163 9701-0206 2101-0005 1751-0149 9701-0207 9701-0208 9701-0110 9701-0209 9701-0114 9701-0210 9701-0211 9701-0212 9701-0107 9701-0106 4301-0008 9701-0113 3411-0050 1751-0847 9701-0213 1751-0010 1751-0851 1751-0850 9701-0214 9701-0215 2101-0
PARTS ITEM QTY PART NUMBER 1 1 9701-0101 2 1 9701-0100 3 4 9701-0216 4 4 0941-0016 5 15 2101-0108 6 1 9701-0102 7 4 2101-0089 34 DESCRIPTION SPRING COVER RIGHT HAND ROLLER TRACK NUT CAGE 5/16”-18 EXTENSION SPRING 5/8” X 4 CONCRETE ANCHOR LEFT SPRING COVER SCREW, SOCKET 5/16”-18 1-1/4” FLAT HEAD 4111-0035 — Feb 2012 Aug 2012
PARTS ITEM QTY PART NUMBER 1 2 9701-0217 2 1 9701-0218 3 1 9701-0219 4 1 9701-0105 5 2 9701-0220 6 1 9701-0104 7 1 9701-0103 4111-0035 — Feb 2012 Aug 2012 DESCRIPTION WASHER, FLAT 1” X 18 GAUGE PIN, COTTER PIN, SLOPE EXTENSION PIVOT SPRING MOUNTING PLATE ASSEMBLY NUT,LOCK 7/16”-14 SERRATED FLANGE SLOPE EXTENSION CARRIAGE ASSEMBLY 35
PARTS Inside Caution Sign Placard 11 ITEM QTY PART NUMBER 1 1 3051-0155 2 1 7141-0260 3 1 1841-0137 4 1 0961-0544 5 1 0961-0545 6 1 0961-0566 8 1 0961-0285 9 1 0961-0280 10 1 0961-0305 11 1 1751-0888 12 1 1751-0889 13 1 1751-0036 36 12 DESCRIPTION TIMER FLASHER TRANSFORMER INSIDE RED LED MODULE INSIDE GREEN LED MODULE INSIDE AMBER LED MODULE ENGAGE PUSH BUTTON RELEASE PUSH BUTTON KEY SWITCH PLACARD PLACARD with ALARM SIGN, CAUTION INSIDE 4111-0035 — Feb 2012 Aug 2012
PARTS Item Quantity 1 2 3 4 5 6 7 1 1 1 1 1 4 4 1 4111-0035 — Feb 2012 Aug 2012 Part Number 3055-0011 3051-0063 3051-0147 3051-0148 3051-0068 3051-0105 3051-0104 x Description 12VDC Complete Light Housing, Yellow Plastic, LED Lights Light Housing Only, Yellow Plastic Lens/Housing/Circuit Assembly Red-LED Lens/Housing/Circuit Assembly Green-LED Mounting Gasket Clips, Lens Holding Screw, Lens Holding Clip Conduit Fastener, 3/4” x 3/8” (Included in Light Package) 37
PARTS N N O O I I T T U U AC CA L L L L U U P P R R O O NI IN N N O O T T U U O O N N E E E E R R G G Y L Y L N N O O ITEM QTY PART NUMBER DESCRIPTION 1 1 1751-0033 OUTSIDE SIGN RIGHT READ 2 1 1751-0034 OUTSIDE SIGN MIRROR IMAGE 38 4111-0035 — Feb 2012 Aug 2012
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MISCELLANEOUS Customer Information A The model/serial number deal (A) is located on the right side panel of the restraint. Dock Leveler Information 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 damaged. Model ___________________________________ 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.
