Poweramp POWERHOLD User Manual

Download

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

PowerHold

Truck Restraint

Printed in U.S.A. Copyright

Manual No. 4111-0016

November 2008

POWERHOLD & POWERHOLD SC

OWNER’S / USER’S MANUAL

Page

Safety

Recognize Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

General Operational Safety Precautions . . . . . . . . . . . . . . . . . . . . . . 1

Operational Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Maintenance Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Introduction

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Installation

PowerHold Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Operation

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

PowerHook Light Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Maintenance

Service Dock Leveler/Restraint Safely . . . . . . . . . . . . . . . . . . . . . . . 18

Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Adjustment And Testing

Testing PowerHook Operating Range . . . . . . . . . . . . . . . . . . . . . . . . 22

Adjust Dock Leveler and Truck Restraint Interlock . . . . . . . . . . . . . 24

Adjust Auto Return To Dock (ARTD) . . . . . . . . . . . . . . . . . . . . . . . . . 26

Troubleshooting

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Manual Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Parts

Valve Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

PowerHold Break Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Power Pack Assembly Self Contained . . . . . . . . . . . . . . . . . . . . . . . 46

Latch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Power Pack Assembly Remote Mount . . . . . . . . . . . . . . . . . . . . . . . 48

Outside Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Outside lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Miscellaneous

Customer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover

Table of Contents

4111-0016 — November,2008

SAFETY

4111-0016 — November, 2008

Recognize Safety Information

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 decals on the equipment unless replacing them.

General Operational Safety Precautions

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.

The use of the word DANGER signifies the presence of an extreme hazard or unsafe practice which will most likely result in severe injury or death.

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.

The use of the word WARNING signifies the presence of a serious hazard or unsafe practice which may result in serious injury or death.

IMPORTANT

The use of the word IMPORTANT is to draw attention to a procedure that needs to be followed to prevent machine damage.

The use of the word CAUTION signifies possible hazard or unsafe practice which could result in personal injury.

era

tin

peratin

gZon

SAFETY

4111-0016 — November,2008

Learn the safe way to operate this equipment. Read and understand the manufacturer's instructions. If you have any questions, ask your supervisor.

Operational Safety Precautions

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.

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 before using.

Make sure lip overlaps onto trailer at least 4 in. (102 mm).

Keep a safe distance from both side edges.

SAFETY

4111-0016 — November, 2008

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

4111-0016 — November,2008

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.

ALWAYS stand clear of dock leveler lip when working in front of the dock leveler. Failure to do this may result in serious personal injury or death.

DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded

DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present. Stray sparks can ignite spills or leaks near the work area. Always clean up the oil leaks and spills before proceeding with grinding or welding.

Always keep a fire extinguisher of the proper type nearby when grinding or welding.

Failure to follow these instructions may result in serious personal injury or death.

Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the unit before maintenance is complete.

Hydraulic and electrical power must be OFF when servicing the equipment. For maximum protection, use an OSHA approved locking device to lock out all power sources. Only the person servicing the equipment should have the key to unlock the device.

The maintenance prop must be in the upright "service" position when working under the dock leveler. For maximum protection, use an OSHA approved locking device to lock the maintenance prop in the service position. Only the person servicing the equipment should have the key to unlock the device.

SAFETY

4111-0016 — November, 2008

Dock Leveler Safety Decals

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.

1751-0727

DANGER

CRUSH HAZARD

Maintenance propmust support levelerbehind bar. Do notforce maintenance prop forwardof bar to support lip.Refer to owner’s/user’s manualfor proper use.Failure to comply willresult in death orserious injury.

1751-0727

1751-0730 (x2)

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.

! Return the dock leveler to its

Failure to follow posted instructions will result in death or serious injury.

stored position at dock level.

(decal placed in same position on both sides)

SAFETY INFORMATION

Operation

1. Read and follow all instructions and warnings in the owner’s/user’s manual.

2. Use of dock leveler restricted to trained operators

3. Always chock trailer wheels or engage truck restraint before operating dock leveler or beginning to load or unload.

4. Never use hands or equipment to move the ramp or lip

5. Before activating dock leveler: ¥ Ensure trailer is backed in against bumpers.

¥ Remove any end loads if required. ¥ Check trailer alignment to avoid lip

interference. If lip does not lower to trailer bed, reposition vehicle.

6. Ensure that truck bed supports extended lip or the leveler frame

Call262.255.1510 for replacement placards, warning labels, or owner’s/user’s manuals.

1751-0329 (x2)

DO NOT

FORK THIS SIDE

(decal placed in same position on both sides)

1751-0330 (x2)

(decal placed in same position on both sides)

1751-0728

CRUSH HAZARD

Do not removemain springs until leveler issafely supported by maintenance prop. Mainsprings contain stored energy.Be sure springs are fullyunloaded and ends are loosebefore removal. Refer to owner’s/user’s manualfor proper maintenance procedure. Failure to comply willresult in death or seriousinjury.

DANGER

1751-0729

CRUSH HAZARD

Do notwork under dockleveler unless thismaintenance prop hasbeen secured inthe upright position.See owner’s/user’s manualfor proper procedures.Failure to comply will resultin death orserious injury.

1751-0731

DANGER

CRUSH HAZARD

Open thepin latchand insert through themaintenance prop housingand prop completely. Closethe pin latch to secureprop. Use every time dockleveler isserviced. Failure tocomply will result in deathor serious injury.

supports the ramp before driving on ramp.

7. Stay clear of hinges and front and sides of moving dock leveler.

8. Never use damaged or malfunctioning dock leveler. Report problems immediately to supervisor.

Maintenance/Service

1. Read and follow all instructions, warnings and maintenance schedules in the owner’s/user’s manual.

2. Maintenance/Service of dock leveler restricted to trained personnel.

3. Place barriers on the driveway and on dock floor to indicate service work is being performed.

4. DO NOT ENTER PIT unless dock leveler is securely supported by maintenance prop.

5. If electrically powered turn off and use OSHA lockout/tagout procedures.

FORK HERE

1751-0729

1751-0728

1751-0731

1751-0726

DANGER

CRUSH HAZARD

DO NOTENTER PIT unlessdock leveler is safely supportedby maintenance prop.Place barriers ondriveway and dockfloor to indicate service workbeing performed. Referto owner’s/user’s manualfor proper maintenance procedures. Failureto comply willresult in death or seriousinjury.

1751-0726

4111-0016 — November,2008

SAFETY DECALS

1751-0727

DANGER

CRUSH HAZARD

1751-0727

1751-0730 (x2)

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.

! Return the dock leveler to its

Failure to follow posted instructions will result in death or serious injury.

stored position at dock level.

(decal placed in same position on both sides)

SAFETY INFORMATION

Operation

1. Read and follow all instructions and warnings in the owner’s/user’s manual.

2. Use of dock leveler restricted to trained operators

3. Always chock trailer wheels or engage truck restraint before operating dock leveler or beginning to load or unload.

4. Never use hands or equipment to move the ramp or lip

5. Before activating dock leveler: ¥ Ensure trailer is backed in against bumpers.

¥ Remove any end loads if required. ¥ Check trailer alignment to avoid lip

interference. If lip does not lower to trailer bed, reposition vehicle.

6. Ensure that truck bed supports extended lip or the leveler frame

Call262.255.1510 for replacement placards, warning labels, or owner’s/user’s manuals.

1751-0329 (x2)

DO NOT

FORK THIS SIDE

(decal placed in same position on both sides)

1751-0330 (x2)

(decal placed in same position on both sides)

DANGER

CRUSH HAZARD

1751-0138

1751-0729

CRUSH HAZARD

1751-0731

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.

DANGER

CRUSH HAZARD

supports the ramp before driving on ramp.

7. Stay clear of hinges and front and sides of moving dock leveler.

8. Never use damaged or malfunctioning dock leveler. Report problems immediately to supervisor.

Maintenance/Service

1. Read and follow all instructions, warnings and maintenance schedules in the owner’s/user’s manual.

2. Maintenance/Service of dock leveler restricted to trained personnel.

3. Place barriers on the driveway and on dock floor to indicate service work is being performed.

4. DO NOT ENTER PIT unless dock leveler is securely supported by maintenance prop.

5. If electrically powered turn off and use OSHA lockout/tagout procedures.

FORK HERE

1751-0729

1751-0731

DANGER

CRUSH HAZARD

DO NOTENTER PIT unlessdock leveler is

1751-0726

safely supportedby maintenance prop.Place barriers ondriveway and dockfloor to indicate service workbeing performed. Referto owner’s/user’s manualfor proper maintenance procedures. Failureto comply willresult in death or seriousinjury.

1751-0726

4111-0016 — November, 2008

SAFETY DECALS

Page intentionally left blank

4111-0016 — November,2008

INTRODUCTION

Due to ongoing product improvement, some parts have changed, along with operation and trouble shooting methods. For further assistance, please contact:

Poweramp Technical Service at 800-643-5424 or techservices@docksystemsinc.com

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. To obtain maximum performance and longest possible use, a simple program of preventive maintenance is recommended and is outlined in this manual.

The PowerHold truck restraint is designed 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 operation of the dock leveler until the hold engages the truck RIG bar.

The Truck restraint is firmly anchored to the drive way approach or the building wall for maximum holding power. The PowerHold restraint is designed to withstand a pulling force of 30,000 lbs.

The PowerHold 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 PowerHold truck restraint, the control panel will allow for operation of both units in the same control panel.

Each PowerHold, Poweramp Dock Leveler and control panel has been factory prewired 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 PowerHold truck restraint.

Congratulations on your choice of a Poweramp PowerHold truck restraint. This manual covers the PowerHold Truck restraint operating system.

4111-0016 — November, 2008

OPERATION

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. After the shoe is stored the pump will run 10 seconds then will time out and the pump will turn off.

If no ICC Bar is preset Power Hold can be operated in bypass (C)z.

Theory

INSTALLATION

4111-0016 — November,2008

Allow Enough Clearance for Possible Seal or Shelter

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.

Dock Face (Self Contained)

Appropriate location when the likelihood of flooding, snow removal and damage from trailer/trucks is minimal. Also recommended for use with non-hydraulically powered dock levelers.

Under The Dock Leveler

When combined with hydraulic leveler pump or remotely mounting under leveler, make certain to locate the powerpack where leveler will not interfere in below dock conditions. The routing of hydraulic and electrical lines from the powerpack to the restraint are best placed through min. 3” PVC (hydraulic) and 3/4”

conduit (electrical) chase during pit

construction.

POWERHOLD REMOTE MOUNT POWERPACK

Inside Building (Remote Mount)

Locate powerpack to minimize obstruction potential. Hydraulic and electrical lines from the powerpack to the restraint are best placed through min. 3” PVC (hydraulic) and 3/4” (electrical) chase during pit construction.

IO PH PR 06/04

INSTALLATION

PowerHold Installation Overview

33”

10”

4111-0016 — November, 2008

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)

For comprehensive installation instructions read and understand the

Installation and Operation Manual.

Weld three sides of PowerHold back plate to the optional embed mounting plate (Part #7953-0119) with continuous 1/4” fillet weld.

20”

Embed

Plate

located 2”

above grade

5 1/4” minimum

20”

3/8”

Cantilevered Dock (For bumper projection >4” or cantilevered dock or Edge-of-Dock leveler)

To determine size offset required, take total effective bumper projection (bumper size plus any cantilever) and subtract 4”.

Offset Formula

Dim. A Dim. B

Bumper Projection Cantelever

Offset

4" + Dim B 6" + Dim B

10" + Dim B

-4" = Offset

15" + Dim B

Dim. B

Driveway Mount Wall Mount

Dim. A

Dim. B

Determine offset then proceed with “Driveway Mount” instructions below.

Dim. A

Dim. B

8” Min.

48”

Dim. B

For filler requirements from 1 ½”to 7 ½” use cantilever bracket #94140054

and anchor cantilever bracket to the dock face or

embedded mounting plate (Part #7953-0119)

For filler requirements for 8 3/4” to 13 3/4” use cantilever bracket #9414-0055 and anchor cantilever bracket to the dock face (3/4” Dia. X 5 1/4” min.) (Kit #2103-0004) or

weld to embedded mounting Plate (Part #7953-0119).

weld to

Driveway Mount (Recommended when dock face is unsuitable for PowerHold Mounting)

Wedge Anchors Method Drive Embed Method

48”

A continuing product improvement process is in effect at Systems, Inc. We reserve the right to make product changes without prior notice.

Poweramp • Division of Systems, Inc. • W194 N11481 McCormick Dr. • Germantown, WI 53022

(Kit #2103-0005)

Driveway mount requires attachment to a concrete drive greater than 8” thick. For asphalt drive, pour 48”x48”x8” (min.) concrete pad and include six (6) 3/4” dowels into foundation wall. Then proceed with adhesive anchors or weld plate embed.

8” Min.

Install nine (9) 3/4” Dia. x 5 1/4” min. wedge anchors at the base of the PowerHold.

48”

800.643.5424 • fax: 262.255.4199 • www.DockSystemsInc.com

Weld method

Properly locate and level the drive embed weld plate (Part#7953-0132) in the drive approach. Observe Cantilever conditions for proper positioning. Weld restraint to embed plate with a continuous ¼” filet weld.

14”

36”

INSTALLATION

Component Identification.

A —Weldment B —Latch Assembly C —Hydraulic Cylinder D — Power Pack SC Only

E — Valve Block F — Shoe G — Rack Weldment

H — Slide Block I — Push Rod J — Spring

“TWIDO” Programmable Logic Controller

4111-0016 — November,2008

PowerHold manifold with leveler Hose connections.

INSTALLATION

Component Identification

4111-0016 — November, 2008

Diverter valve, When coil is energized directs fluid to the PowerHold

Return From PowerHold

Pressure To Logic Block

Return To Pump

Pressure From Pump

Pressure to Powerhold

Return To Logic Block

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.

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.

DO NOT overload the dock leveler.

DO NOT operate any equipment while under the influence of alcohol or drugs.

DO NOT leave equipment or material unattended on the dock leveler.

Failure to follow these instructions may result in personal injury and/or damage to equipment.

4111-0016 — November,2008

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

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.

If RIG (Rear Impact Guard) is damaged or missing, dock leveler can be used in BYPASS

IF BYPASS MODE IS REQUIRED

SEE: SEQUENCE OF OPERATION - BYPASS

FOR NORMAL OPERATION AFTER TRAILER RIG IS ENGAGED CONTINUE WITH: STEP 4

5. Position dock leveler onto truck/trailer.

6. When loading or unloading is complete, return dock leveler to the stored position.

7. Release truck restraint and/or remove chocks from truck/trailer wheels.

1. Check that the truck/trailer is positioned squarely against the dock bumpers.

2. Push ENGAGE button to activate restraint.

- Inside Green Light, Red Outside 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, Shoe will automatically return to the stored position.

- Inside Amber Light and LED will flash for 30

seconds, then Flash Red (Do Not Enter).

- Outside Red Light will flash for 30 seconds, then

flash 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

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 BYPASS mode

- Pressing the LOCK button a second time will

cycle the PowerHold.

10.Un-chock the truck/trailer wheels when truck is ready to depart.

4111-0016 — November, 2008

OPERATION

PowerHold Light Sequence

CONDITION LIGHTS

INSIDE OUTSIDE

(O/9) (O/8)

STORED BEGIN/END RED GREEN

(O/6) (O/7) (O/6)

IN MOTION AMBER RED & STROBE

(O/5) (O/7)

HOOKED GREEN RED

(O/5) (O/6) (O/7) (O/6)

OVERRIDE GREEN/AMBER RED/STROBE

(O/6) 30sec (O/4) (O/7) 30sec (O/8)

MISSED ICC AMBER (TIME) RED RED (TIME) GREEN

STROBE (O/8)

(O/9) (O/6) (O/7) (O/6)

TIMEOUT (FAILURE) RED/AMBER RED/STROBE

(O/8) (O/5) (O/8) TIMEOUT (FAILURE) AMBER RED/STROBE IN MOTION

A NEW LOCK CYCLE OR BYPASS WILL OVERRIDE MISSED ICC

TIMEOUT FAILURE OVERRIDE MISSED ICC

EMERGENCY STOP (Where Equipped) OVERRIDES EVERY OTHER CONDITION

(O/4) (O/5) WHEN E-STOP IS DEPRESSED RED RED

4111-0016 — November,2008

4111-0016 — November, 2008

This page intentionally left blank

MAINTENANCE

Service Dock Leveler/Restraint Safely

Whenever 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 tagout 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 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.

A— Tagout Device B — Lockout Device C — Lockout Device D — Tagout 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 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.

4111-0016 — November,2008

MAINTENANCE

Periodic Maintenance

Daily Maintenance

• Make sure that all the Inside and Outside signal lights work.

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. Build-up of foreign material in the track areas will cause abnormal operation.

Quarterly Maintenance

• Clean and Lubricate slide block track and push rod areas. Lubricate pins for the “Z” bar. Inspect and clean Prox switches.

IMPORTANT

Failure to properly lubricate the Truck Restraint will cause abnormal operation of the Restraint

Apply lubricant

Apply white lithium grease or equivalent

4111-0016 — November, 2008

MAINTENANCE

Periodic Maintenance With Leveler

To ensure normal operation of the dock leveler, use only aircraft hydraulic fluid designed to meet or exceed military specification MIL-L-5606. It is recommended that the following hydraulic fluids be used:

• Flomite 530 ZF

• Aero Shell Fluid 4 or Fluid 41

• Mobile Aero HFA Mil-H5606A or Aero HF

• Texaco Aircraft Hydraulic Oil 15 or 5606

• 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.

A— Lip Hinge Area B— Valve Lever Pivot on Logic

Block

C— Inspection Plate

D— Dual-Lanyard Lever Pivot E— Platform Hinge Area F— Platform Cylinder Trunnion

G — Toe Guard Hinges H— Platform Cylinder-to-Platform Pin J— Lip Cylinder-to-Platform Frame Pin

K— Lip Lifter and Lift

Cylinder Pin

L — Toe Guard Pivots

IMPORTANT

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 voiding of warranty.

Before performing any maintenance under the dock leveler, lock the electrical power source in OFF position and lock the maintenance prop in the service position using an approved locking device. (See Service Dock Leveler Safely in this section.)

Failure to follow these instructions may result in serious personal injury or death.

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.

4111-0016 — November,2008

MAINTENANCE

Daily Maintenance

• Make sure that all the Inside and Outside signal lights work.

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.

• Inspect the platform hinge and the lip hinge areas. The hinge areas must be kept free of dirt and debris. Build-up of foreign material in the hinge areas will cause abnormal operation.

Quarterly Maintenance

• Lubricate the following areas with light weight machine oil:

(A)— Lip hinge area unless equipped with grease

fittings (apply oil to the top of the entire length of lip hinge when platform is at the full

below-dock position and lip is folded). (D)— Dual-lanyard lever pivot. (E)— Platform hinge area (apply oil to top of all

platform hinges when platform is at the full

below-dock position). (G)— Toe guard hinges (along full length of top and

bottom hinges). (H)— Platform cylinder-to-platform frame pin. (J)— Lip cylinder-to-platform frame pin. (K)— Lip lifter and lift cylinder pin.

• Lubricate the following areas with white lithium grease:

(B)— Valve lever pivot and top of logic block spool

valve. (F) — All platform cylinder trunnions. (L)— Toe guard pivots (where toe guard strut

contacts pivot).

NOTE: Apply grease to lip hinge grease fittings if

equipped.

M — Reservoir N — 2 in. (51 mm) (From Top of

Reservoir)

P — Breather Cap Q — Fluid Level

• 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 (C).

4. Remove breather cap (P).

5. Measure fluid level. The fluid level should be approximately 2 in. (51 mm) (N) from top of reservoir (M) with platform at the below-dock position.

6. Add hydraulic fluid if necessary. Use only recommended fluid.

7. Install breather cap and inspection plate.

8. Turn ON electrical power to the leveler.

9. Return the platform to the cross-traffic position.

IMPORTANT

Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler.

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.

4111-0016 — November, 2008

NOTE: Test operating range of PowerHold without truck/trailer backed into dock.

1. Make sure the selector switch is in Normal and BYPASS mode has not been activated.

- Red Inside Light, No Amber Light

- Green Outside Light

2. Momentarily press the ENGAGE button. The PowerHold restraint will raise to 90 deg. NO trailer the restraint will lower back to the stored position. The motor will run additional 6 to 10 seconds in the stored position.

- Inside Amber Light for 30 seconds, then Red

*Alarm will sound if equipped

- Outside Red Light for 30 seconds, then Green Operating range Refer to page 10.

PowerHold Operating Range

ADJUSTMENT AND TESTING

Follow the installation instructions found in the PowerHold Installation & Operation Manual prior to attempting any adjustments.

Always stand clear of the dock leveler lip when working in front of the dock leveler.

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.

4111-0016 — November,2008

ADJUSTMENTS

PowerHold Adjustments

The Operating range is not adjustable on a

PowerHold restraint.

Proximity switch Adjustment and replacement.

A. Locate and remove four screws and cover on

front of PowerHold assembly.

B. Adjust PRS 1. With the “Z’” bar rotated

directly over the prox switch. The prox switch distance should between 1/16” and 1/8”.

C. Adjust PRS 2. The #2 prox switch must be

threaded in until flush with the latch block. Turn prox switch out (CCW) until switch is no longer flush with the latch block.

IMPORTANT: Make sure that the wire from the prox switches are clear of all moving parts.

1/16 min 1/8 max

Install prox flush then back out (CCW) just past flush.

Prox Switch PRS 1 INPUT #3

Prox Switch PRS 2 INPUT #4

4111-0016 — November, 2008

OPTIONAL EQUIPMENT ADJUSTMENTS

Always stand clear of the dock leveler lip when working in front of the dock leveler.

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.

Adjust Dock Leveler and Truck Restraint Interlock

Dock Leveler and Truck restraint Interlock

The dock leveler can be interlocked with the truck restraint 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. The 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.

4111-0016 — November,2008

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. If the leveler did raise, decrease dimension “A” or “B”, 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 RIG bar.

4. Momentarily press the ENGAGE button. The truck restraint automatic engage cycle 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.

6. Press the RELEASE button. The truck restraint should NOT disengage from the truck/trailer RIG 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 target or bend the target so that the target is not in the sensing range of the switch as shown in Figure

37. 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.

4111-0016 — November, 2008

OPTIONAL EQUIPMENT ADJUSTMENTS

Standard PR levelers are equipped with the Auto Return To Dock (ARTD) unless leveler is interlocked with a truck restraint.

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 proximity switch 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 (H) that can be used for diagnosing and adjusting the switch.

NOTE: Some proximity switches have an indicator

light at the back of the housing and some have the light at the side of the housing.

A— Cable B— Proximity Switch C— Bracket D— Lock Nuts

E— Target F— Lip Hing e Tube G—Platform Lip H— Indicator Light

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.

Always stand clear of the dock leveler lip when working in front of the dock leveler.

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.

4111-0016 — November,2008

OPTIONAL EQUIPMENT ADJUSTMENTS

6. Turn ON electrical power to the dock leveler.

7. Disengage the maintenance prop.

8. Turn the ARTD switch (on control panel) to the ON position.

9. Raise the platform until the lip is fully extended, then allow the platform to drift to the below-dock position.

After approximately 6 seconds, the platform must return to the cross-traffic position.

10. 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.

Use the following illustrations to assist in fine tuning and/or diagnosing the ARTD operation.

Cross-Traffic Position

NOTE: The platform lip is fully folded when the

platform is at the cross-traffic (stored) position (lip engaged with keepers) or when platform is resting on the maintenance prop.

Whenever the platform lip is at the cross-traffic position, the following conditions will exist for a normally operating ARTD:

• Target not in the sensing area of proximity switch.

• Proximity switch OFF (open) (no signal sent to control panel).

• Proximity switch indicator light is OFF.

• Platform stays at this position unless the operator activates the leveler.

A— 1/4 in. (6.4 mm)

Approximate

B— Target

C— 1 in. (25.4 mm)

Approximate 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.

When dimensions (A and C) are obtained, the proximity switch and target may need finer adjustments to get the ARTD to operate satisfactorily.

3. Loosen lock nuts (D). Adjust proximity switch (E) to obtain distance (A). Tighten lock nuts.

4. Bend target (B) as needed to obtain distance (C). Recheck distance (A) and readjust if necessary.

NOTE: At least two people may be required to

manually move the lip.

5. After adjusting proximity switch and target, slowly move the lip up by hand while observing the target and proximity switch. The target MUST NOT contact the switch, otherwise, damage to switch will occur. Readjust switch and/or target if necessary, then recheck for interference.

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.

Lip Keeper

4111-0016 — November, 2008

OPTIONAL EQUIPMENT ADJUSTMENTS

Whenever the platform lip is at the full below-dock position, the following conditions will exist for a normally operating ARTD:

• Proximity switch senses target.

• Proximity switch ON (closed) (signal sent to the control panel).

• Proximity switch indicator light is ON.

• Platform will automatically rise after approximately a six-second delay, then returns to the cross-traffic position.

Full Below-Dock Position

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 OFF (open) (no signal sent to the control panel).

• Proximity switch indicator light is OFF.

• If the platform lip is resting on the truck bed, the platform will stay at this position unless the operator activates the leveler.

Lip Fully Extended Position

Lip Keeper

4111-0016 — November,2008

TROUBLESHOOTING POWERHOLD

Symptom Possible Cause Solution

Inside and outside signal lights do not operate. Controller (PLC) RUN indicator is on solid (not flashing). Unit operates as normal.

Bad Flasher.

Replace flasher with wire. If lights operate (lights will not flash), replace flasher.

Restraint does not operate. Motor does not energize.

Motor overload device tripped.

Reset overload relay (3 phase) or replace fuse (1 phase) or reset breaker (1 phase-new models). Determine cause of device tripping.

NOTE: If replacing fuse, use fuse with equal

specification .

Motor starter (3 phase) or motor relay (1 phase) not energizing. Combination Leveler and P-Hold Only.

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.

• Check all fuses inside the control panel(s). Replace any blown fuse(s) with a fuse of equal specification.

• Make sure the correct voltages are present at the proper locations inside the control panel(s).

Before performing the detailed troubleshooting procedures, check the following items first:

Always stand clear of the dock leveler lip when working in front of the dock leveler.

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.

4111-0016 — November, 2008

TROUBLE SHOOTING POWERHOLD

Symptom Possible Cause Solution

Three-phase units only: Restraint does not operate. Motor energizes but does not run.

If motor hums, but does not run, overload device should trip.

Combination Leveler and P-Hold Only.

3 Phase units only - no voltage is present on one line.

NOTE: A motor that is missing voltage on one line is said to be single-phased.

Check for blown fuses at branch circuit disconnect. Replace fuse. Determine cause of blown fuse.

Check motor starter as follows:

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.

5. Line-side and load-side voltages should be approximately the same. Replace starter if voltage values are considerably different from one another.

Check all wiring to motor for high resistance or no connection.

Replace motor.

Three-phase units only: Restraint does not operate. Motor runs in reverse

Phase reversed. Reverse any two legs at the branch circuit

disconnect.

Single-phase units only: Restraint does not operate.

Motor energizes, but does not run.

Line voltage too low. Check wiring to motor for high resistance. Check for

loose or corroded connections. Check if gauge of wires to motor are of correct size and specification for load requirement. Replace if necessary.

Defective motor centrifugal switch.

Replace motor.

Defective motor capacitor. Replace motor.

Low hydraulic fluid. Add fluid, see Maintenance section for proper fluid

level and type.

Restraint operates slowly.

Low hydraulic fluid. Add fluid, see Maintenance section for proper fluid

level and type.

Pressure relief valve set too low.

(combination unit only)

See pressure relief adjustments on page 48.

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.

Power Hold raises Slow or Slow to release (SC Power Hold Only)

-Pressure Relief cartridge adjusted per max amp

draw.

Damage or blocked hydraulic hose(s) and/or valve(s).

Replace damaged hose(s). Check and remove blockage from hose(s) and/or valve(s).

4111-0016 — November,2008

Symptom Possible Cause Solution

Restraint does not fully raise or motor overcurrent device and/or overload device continuously tripping.

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.

-Check valve for Magnetism at the coil

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).

NOTE: Do not over tighten valve into block. Max Torque: 10-15 lb/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.

Restraint does not raise but leveler raises. (combination unit only)

Solenoid Not energized. Locate solenoid (See Page 39).

Coil Must be energized when P-Hold is in engage mode.

-Check valve for Magnetism at the coil.

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).

NOTE: Do not over tighten valve into block. Max Torque: 10-15 lb/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.

TROUBLE SHOOTING POWERHOLD

4111-0016 — November, 2008

Symptom Possible Cause Solution

Restraint will not lower to release truck.

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).

NOTE: Do not over tighten valve into block. Max Torque: 10-15 lb/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.

Restraint will not lower but leveler raises. (combination unit only)

Solenoid not Energized. Locate solenoid (See Page 48).

Coil must be energized when P-Hold is in engage or disengaged.

-Check valve for Magnetism at the coil

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.

-Check valve block for contaminant's.

-Replace valve and coil.

NOTE: Do not over tighten valve into block. Max Torque: 10-15 lb/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.

TROUBLE SHOOTING POWERHOLD

4111-0016 — November,2008

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.

-Shorted or open prox switch

-open or shorted wires

-Bad prox switch.

Activation of #1 prox switch Input 4 must come on first. The restraint shoe must

make contact with the ICC bar. The restraint shoe will rotate as the hydraulic extends. The Slide block on the hydraulic cylinder push The rod. The rod will make contact with the Z bar. The Z bar will pass over the #1 prox switch. Input #3 will light on the PLC. The power hold then shut off.

-Frozen or rusted push rod

-Bend or damaged Z bar

-adjustment to prox maybe required

Activation of #2 prox switch The restraint shoe must make contact with the ICC

bar. The restraint shoe will rotate the ratchet will pass in front of the #2 prox switch, input #4

Platform does not rise. Pump operates in pressure relief mode.

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.

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.

4111-0016 — November, 2008

Symptom Possible Cause Solution

Platform rises slowly. 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. 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 when platform reaches the full raised position.

Pressure relief set too high. Decrease 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.

Shoe does not rise to full height.

Low hydraulic fluid. Add fluid, see Maintenance section for proper fluid

level and type.

Platform DOES rise to full height, but lip DOES NOT extend or extend fully.

Low hydraulic fluid. Add fluid, see Maintenance section for proper fluid

level and type.

Logic block (valve) lever cable weight too low on cable.

Adjust cable weight. See Adjust Cable Weight and Down Speed Control in the Adjustment section.

TROUBLE SHOOTING DOCK LEVELER

4111-0016 — November,2008

TROUBLESHOOTING DOCK LEVELER

Symptom Possible Cause Solution

Platform locks into “safety” as platform lowers. Lip drops to vertical position.

Platform lowering speed is too fast.

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.

The auto return proximity switch not sensing target correctly.

Adjust proximity switch and target as necessary. See Adjust Auto Return To Dock (ARTD) in the Adjustment section.

Defective proximity switch. Replace switch.

Broken wire. Loose or corroded wire connections.

Repair or replace wires and connections as necessary.

4111-0016 — November, 2008

LADDER LOGIC POWERHOLD W/LEVELER

4111-0016 — November,2008

#1 Prox Switch

See Page 23

#2 Prox Switch

See Page 23

LADDER LOGIC POWERHOLD W/LEVELER

4111-0016 — November, 2008

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.

- Insert program chip (program specific)

Repeat steps 1,3 and 4. Allow light sequence to complete flashing. Run light should be on 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.

Twido PLC

E-Prom

Prom Location

4111-0016 — November,2008

MANUAL RELEASE

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.

3/4” Dia Rod

Front Cover

4111-0016 — November, 2008

Shoe

Slide Block

4111-0016 — November,2008

This page intentionally left blank

PART S

Item Quantity Part Number Description

A 1 8581-0011 4 Way Cartridge Valve B 2 9301-0113 Fitting Elbow 90 Deg STR Thread #6 ORB x #6 JIC C 1 9301-0115 Fitting Elbow 90 Deg STR Thread #6 ORB x #8 JIC E 1 8581-0016 Fitting Elbow 90 Deg STR Thread #8 ORB x #8 JIC

F 1 8583-0115 Complete Valve assembly

G 1 8581-0004 Coil, Delta

H 1 4301-0001 Cable Assembly 48” Lg

Valve Block Combination PowerHold and Leveler

4111-0016 — November, 2008

Coil De-energized to raise Leveler. Energized to raise or lower the restraint.

Item Quantity Part Number Description

A 1 Hydraulic Valve Body B 2 9571-0007 Fitting Pipe Plug 1/8 NPT C 2 9301-0109 Fitting Conn STR Thread D 2 8581-0113 Fitting Elbow 90 Deg #6 ORB x #6 JIC E 1 8581-0115 Valve Cartridge Relief

F 1 8581-0011 Valve Cartridge 4-Way

G 1 8581-0004 Coil, Delta H 1 4305-0319 Cable Assembly 22” Lg

I 1 8583-0017 Complete Valve Assembly

*Provide dock leveler and/or PowerHold serial number when calling or faxing orders.

PowerHold Valve Block SC

PART S

4111-0016 — November,2008

PART S

*Provide dock leveler and/or PowerHold serial number when calling or faxing orders.

PowerHold Valve Block

Item Quantity Part Number Description

A 1 Valve Manifold B 2 9301-0109 Fitting Connection STR #6 ORB TO 36 JIC C 2 9301-0113 Fitting Elbow 90 Deg STR Thread #6 ORB x #6 JIC D 1 8581-0011 Valve Cartridge 4-Way E 1 8581-0004 Coil, Delta F 1 4305-0319 Cable Assembly 22” Lg

G 1 8583-0016 Complete Valve assembly

4111-0016 — November, 2008

Coil must be energized to raise restraint. De-energized to lower the restraint.

*Provide dock leveler and/or PowerHold serial number when calling or faxing orders.

PART S

4111-0016 — November,2008

PART S

PowerHold Break Down

Item Quantity Part Number Description

A 1 9414-0064 Restraint Shoe B 1 9412-0030 Pin 1-1/2 X 8 LG C 1 9414-0021 Rack Weldment D 1 9411-0005 Spring, Rack Weldment

E 1

8583-0017 Valve Block SC 8583-0016 Valve Block with leveler

F 1 9414-0065 Latch Block Assembly (Includes Prox Switches) G 1 2101-0118 Bolt 3/4-10 UNC X 1-1/2 LG

H 1 2101-0119 Bushing

I 1 9414-0073 Cylinder Complete (Includes Slide Block and Hoses)

J 1 9904-0059 Hose, 35” Lg.#6 Jic Swivel Both Ends

K 1 9904-0155 Hose, 21” Lg. #6 Jic Swivel Both Ends

L 1 9412-0095 Push Rod M 1 2101-0045 Cotter Pin, 1/8 x 1.00 N 2 9412-0063 Removable Track Stop O 4 2101-0009 Bolt 5/16-18 P 1 9411-0046 Access Cover, Top Q 14 2101-0099 Screw 1/4-20 UNC x 3/8 R 1 9411-0012 Cover, Front S 1 9411-0007 Weather Seal, Hold Down T 1 0192-0016 Weather Seal, Ratchet U 1 2753-0001 J-Box, Cover and Gasket SC (includes screws)

2753-0002 J-Box, Cover and Gasket Remote (includes screws)

V 4 2101-0074 Screw, Allen Head 1/2-20 UNC x 1-1/2 Lg.

W 1 9414-0063 Base Weldment

X 1 8581-0137 One Way Check Valve

4111-0016 — November, 2008

Item Quantity Part Number Description

A 1 9301-0199 Breather Cap B 1 9411-0047 Cover, Power Pac C 1 9301-0085 Filter 3/8 NPT D 2 9904-0051 Hose, 16.00” LG 3/8 NPTM / #6 Jic Swivel Female F 7 2101-0009 Bolt 5/16-18 UNC 3/4 Lg.

G 1 9395-0022 Power Pac Complete, SC

PowerHold SC Power Pac

PART S

4111-0016 — November,2008

PART S

PowerHold SC

Item Quantity Part Number Description

A 2 0963-0073 Prox Switch B 1 0941-0008 Spring C 1 0941-0009 Spring D 1 2101-0012 Bolt 5/16-18 UNC E 1 2101-0202 Nut, Hex 5/16-18 UNC F 1 2101-0203 Latch Weldment F 1 9414-0065 Latch Assembly (Complete With Prox Switches)

Prox Switch #1 INPUT #3

Prox Switch #2 INPUT #4

4111-0016 — November, 2008

PART S

Power Pack Assembly Remote Mount

4111-0016 — November,2008

PART S

Power Pack Assembly Remote Mount

Provide dock leveler serial number and type of installation when calling or faxing orders.

Provide dock leveler serial number, voltage, and phase when calling or faxing orders.

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-____

Pump Only 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-____

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 3 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. AC 2 2101-0063 Nut, Jam 5/16-18 UNC

1 9395-____

Power Pack Complete (Includes All Items Except L, N, and W)

4111-0016 — November, 2008

PART S

Outside Signs

Item Quantity Part Number Description

A 1 1751-0033

SIGN,PULL IN/OUT ON GREEN ONLY RIGHT READING,16-7/8x8x3/32

B 1 1751-0034

SIGN,PULL IN/OUT ON GREEN ONLY MIRROR IMAGE,16-7/8x8x3/32

4111-0016 — November,2008

PART S

OSLA (Outside Light Assembly)

Item Quantity Part Number Description

1 3055-0008 Complete Light Housing, Yellow Plastic, LED Lights

1 3055-0002 Complete Light Housing, Yellow Plastic, Incandescent Lights 1 3055-0009 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-LED

3 1 3051-0103 Lens/Housing/Circuit Assembly Green-LED

* 2 3051-0085 Lamp, 25W,120V,Incandescent, BAY (Rated 1000 Hours)

* 2 3051-0066 Socket Harness for Incandescent Lamp

2 1 3051-0064 Lens, Red

3 1 3051-0065 Lens, Green

4 1 3051-0068 Mounting Gasket

5 4 3051-0105 Clips, Lens Holding

6 4 3051-0104 Screw, Lens Holding Clip

7 1 x Conduit Fastener, 3/4” x 3/8” (Included in Light Package)

4111-0016 — November, 2008

4111-0016 — November,2008

MISCELLANEOUS

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 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.’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

Dock Leveler Information

Model ___________________________________

Serial No. ________________________________

Systems, Inc., Job No. ______________________

Original Owner Information

Name ___________________________________

Address _________________________________

________________________________

Installer Information

Name ___________________________________

Address _________________________________

_________________________________

Date of Installation ________________________

PR052

4111-0016 — November, 2008

POWERAMP WARRANTY

PowerHold Truck Restraint

All PowerHold vehicle restraints feature a full Two (2) year base warranty on all structural, hydraulic and electrical parts, including freight and labor charges in accordance with Systems, Inc’s Standard Warranty Policy. Structural components carry an additional full three (3) year extended warranty with parts and labor. Systems, Inc. warrants all components to be free of defects in materials and workmanship, under normal use, during the warranty period. This base warranty period begins upon the completion of installation or the sixtieth (60th) day after shipment, whichever is greater.

In the event of any defect covered by this guarantee, Systems, Inc., will remedy said defect by repairing or replacing all defective parts, bearing all of the costs for parts, labor, and transportation.

All guarantee claims will be settled on a timely basis when defects are found to be from other than improper installation, operating contrary to instructions or beyond rated load capacities, abuse, careless or negligent use, or failure to maintain the unit as recommended by the owner's manual.

There are no guarantees, either expressed or implied, including any implied guarantees of merchantability or fitness for a particular purpose which shall extend beyond the guarantee periods indicated above. This guarantee is valid only if the unit(s) is unaltered from original condition as delivered from the factory and a survey is completed by a Poweramp representative.

Poweramp POWERHOLD User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual