HYDRAULIC TRUCK RESTRAINT OWNER S MANUAL

Transcription

1 HYDRAULIC TRUCK RESTRAINT OWNER S MANUAL

2 TR TRUCK RESTRAINT Serial Number: Model: Customer: Date Shipped: Options:

3 OWNER S MANUAL Table Of Contents Safety Information Warning... 3 Installation... 3 Maintenance & Troubleshooting... 3 Operation... 3 Installation Procedures Notes... 5 Installation Layout Diagram... 6 Inside Lights Control... 7 Outside Lights... 8 Operating Instructions... 9 Engage Restraint... 9 Lower Restraint... 0 Additional Situations Trouble Shooting Check List... 2 Trouble Shooting... 3 Restraint Does Not Engage ICC Bar... 3 Operate Leveler in Override Mode... 3 Return to Stored Position... 4 Restraint Arm Drifts... 4 Diagrams Hydraulic / Electrical Assembly Replacement Parts... 5 Hydraulic Leveler Remote & Powerpack Repl. Parts... 6 Proximity Switch Replacement Parts... 7 Truck Restraint Assembly Replacement Parts... 8 Standard Electrical Schematic... 9 General Maintenance Daily Weekly Quarterly Lubrication General Maintence Diagram... 2 Service Policy & Warranty... 22

4 SAFETY INFORMATION WARNING: Failure to read and understand the entire contents of this manual may result in damage to the equipment, bodily injury and/or death. NEVER install, maintain or operate this equipment while under the influence of drugs or alcohol. INSTALLATION:. Personnel installing this equipment must be qualified and experienced in safe working procedures. 2. All lifting and slinging devices must be in proper working condition and used in the proper manner. 3. All electrical to be done must be performed by a qualified electrician and must meet all applicable local codes. 4. Concrete must be in excellent condition with no cracks in the mounting face within 4 ft. of the truck restraint and dock leveler. 5. Do not install the truck restraint on brick, concrete block or similar surfaces. MAINTENANCE & TROUBLE SHOOTING:. Lock out the power supply. 2. Barricade in front of the dock leveler on the loading dock area and in the driveway. 3. When replacing parts use only genuine KOKE Inc. parts. OPERATION:. Keep clear of the equipment s operating path. 2. Do not operate with anyone standing in front of the lip of the dock leveler. 3. Do not wear loose clothing or jewelry while operating this equipment. 4. Keep hands, limbs and loose hair clear of the equipment during positioning or storing of the dock leveler and truck restraint. 5. Never attempt to ride on the equipment during the positioning or storing of the dock leveler or truck restraint. 6. Never continue to use the truck restraint or dock leveler if you believe it is in unsafe condition because of damaged understructure, broken welds, oil leaks etc. 3

5 INSTALLATION PROCEDURES STEP MATERIAL INSPECTION:. Open and inspect all of the materials received. 2. Immediately report any damage or material shortages to KOKE Inc. 3. Study all installation instructions and drawings. 4. Determine the proper locations for the signs, controls, truck restraint and exterior lighting system. STEP 2 INSTALLATION OF THE TRUCK RESTRAINT:. Place restraint box in the center of the door opening. 2. Mark the eight (8) hole positions on the face of the foundation wall. 3. Drill eight (8) 5/8 diameter holes approximately 6 deep. 4. Bolt the restraint box to the foundation wall using anchor bolts supplied (5/8 x 5). 5. If possible, weld the top of the back plate to the bottom of the curb angle on the dock leveler. STEP 3 HYDRAULIC CONNECTION TO LEVELER & TRUCK RESTRAINT: See connection diagram found on page 6 for hose routing. Important note: (when connecting to an existing leveler). Drain oil and clean reservoir. 2. Flush hydraulic system. 3. Refill reservoir with new oil. (Failure to do so will cause damage to the unit and Void the warranty) 4. Hydraulic system must be clear of debris / dirt particles and all hoses covered when passing the conduit through. 5. Required hydraulic oil: PETRO-CAN HV22, SHELL TELLUS 27, TEXACO HD22 or an equivalent. STEP 4 MOUNTING:. Select location and mount the exterior sign and light system as shown on page Select location and mount the interior control box and sign as shown on page 6. STEP 5 ELECTRIC PROX. SWITCH INSTALLATION TO EXISTING UNIT:. Mount the limit switch plate behind the leveler lip. 2. The switch plate can be either welded or bolted into place. (See page 7) 4

6 STEP 6 STEP 7 ADJUST THE PROXIMITY SWITCH LIMIT ON EXISTING UNIT: (See page 8 for Proximity Switch diagram). Adjust the limit switch within 3/6 of the lip. (NOTE: lip must be tight against the stop) ELECTRICAL INSTALLATION: Complete all necessary wiring from control box to:. Exterior light. 2. Junction box located at the truck restraint. 3. Electrical proximity switch behind leveler lip (see page 7) 4. Hydraulic power pack. STEP 8 FINAL SET-UP ADJUSTMENTS:. Make sure the exterior lights have not changed back to green until the restraint is completely closed. 2. To increase or decrease the time, adjust the electrical timer inside the control box. 3. If the down speed on the restraint is too slow, adjust the down speed valve on NOTES: * Hydraulic system must be completely clear of dirt particles and all hoses must be covered when passing through conduits. * When connecting to an existing dock leveler, flush and clean the hydraulic system including the reservoir and add new oil. Failure to complete these 2 items will VOID THE WARRANTY. 5

7 INSTALLATION LAYOUT DRAWING 6

8 INSIDE LIGHT CONTROLS FOR COMBINATION DOCK LEVELER / TRUCK RESTRAINT (SEE OPERATING INSTRUCTIONS FOR DESCRIPTION AND SEQUENCE OF LIGHT SIGNALS) LIGHT COMMUNICATION FOR DOCK ATTENDANT / FORK TRUCK OPERATOR WARNING: Read and understand the safety and operating instructions in the manual before operating this equipment. 7

9 OUTSIDE LIGHT LIGHT COMMUNICATION FOR TRUCK DRIVER RED: Warning truck driver his truck is restained, being loaded/ unloaded and must not pull away. GREEN: Truck may back in or depart. 8

10 OPERATING INSTRUCTIONS Read and understand the safety information (see page 3) Inside Lights and Controls (see page 7) Outside Lights (see page 8) ENGAGE RESTRAINT: RESTRAINT IN STORED POSITION: The following conditions must be in place prior to operation.. Over head door is open, closing limit switch (if equipped). 2. Outside green light is on and flashing. 3. Outside red light is off. 4. Inside green and amber lights are off. 5. Inside red light is on and flashing. 6. Dock leveler and lip are in a stored position. STEP Press and hold raise button. Inflatable seal motor turns on (if equipped, 20v / 5 amps) 2. Outside lights change to green light off and red light on and flashing. 3. When restraint arm engages trailer bumper bar, the dock leveler deck rises and extends lip. 4. Inside lights change to red light off and green light on and flashing. STEP 2 Release raise button Dock leveler lowers to trailer floor by gravity. STEP 3 Restraint is now engaged and dock leveler is ready for loading / unloading 9

11 LOWER RESTRAINT: RESTRAINT IN ENGAGED POSITION: The following conditions must be in place prior to operation.. Over head door is open, closing limit switch (if equipped). 2. Outside green light is on and flashing. 3. Outside red light is off. 4. Inside green and amber lights are off. 5. Inside red light is on and flashing. 6. Dock leveler and lip are in a stored position. STEP Press and hold raise button. Dock leveler deck raises, lip retracts to the pendant position for storing. STEP 2 STEP 3 Release raise button. Dock leveler lowers by gravity to a stored position 2. Inside lights change to green light off and red light on and flashing. 3. Truck restraint arm fully lowers. 4. Outside lights change to red light off and green light on and flashing. Dock leveler and truck restraint are now in the stored poistion. Truck or trailer are now free to depart. ADDITIONAL SITUATIONS: OVER NIGHT MODE:. Leave truck restraint engaged. 2. Store the dock leveler. 3. Close the over head door. FROM A STORED POSITION:. Press and hold down the raise button and the truck restraint will engage. 2. As soon as the dock leveler begins to rise, immediately turn the over ride switch to on (continue to hold down the raise button). 3. Then release the raise button before the dock leveler lip extends. 4. The dock leveler will lower to the stored position with the restraint engaged. 0

12 ADDITIONAL SITUATIONS: (continued) FROM ENGAGED / WORKING POSITION:. Turn the over ride switch to the on position. 2. Press and hold down the raise button while dock leveler raises and the lip raises. 3. Release the raise button. 4. The dock leveler lowers by gravity to the stored position. 5. The outside and inside lights will remain red. POWER FAILURE: (Manual Release). Remove the side plate on the truck restaint. 2. Turn the knob on the valve mounted on the hydraulic cyclinder until restraint begins to lower. (see page 5) 3. When the restraint is completely lowered the truck or trailer is free to move away. 4. Close the valve mounted on the hydraulic cyclinder by turning the knob the opposite way. 5. Replace the side plate on the truck restraint.

13 TROUBLE SHOOTING INITIAL CHECK LISTS PROBLEM: RESTRAINT WILL NOT RISE:. Check the power supply. 2. Check the circuit breakers. 3. Check for any hydraulic leaks. 4. Check the fluid level in the reservoir. 5. Check the power supply to the solenoid valve. 6. Check for loose or damaged wires. PROBLEM: RESTRAINT WILL NOT LOWER:. Check the power supply. 2. Check the circuit breakers. 3. Check the power supply to the solenoid valve. 4. Check for obstructions in the restrainting arm operating path. 5. Check for loose or damaged wires. 2

14 TROUBLE SHOOTING (When unit is not operating properly an alarm will sound) RESTRAINT DOES NOT ENGAGE ICC BAR: The following conditions exist during operation.. Press hold and raise button. 2. Inflatable seal motor turns on (if equipped, 20v / 5 amps). 3. Outside lights change to green light off and red light is on and flashing. 4. The restraint arm will not engage the ICC bar. 5. Inside lights change to red light flashing and the alarm is sounding. 6. Release the raise button. 7. Inside red light remains flashing and alarm is no longer sounding. 8. The restraint arm will fully lower. 9. Outside lights change to red light off and green light on and flashing. 0. Dock leveler and restraint are now in the stored position. OPERATE LEVELER IN OVERRIDE MODE OVERRIDE MODE INSTRUCTIONS NOTE: RESTRAINT IS IN THE STORED POSITION STEPS. Turn the over ride switch to the on position. 2. Outside lights change to green light off and red light on and flashing. 3. The truck restraint is now in over ride mode. WARNING: Restain truck / trailer by some other means such as wheel chocks. 4. Press and hold down the raise button. (Alarm sounds) 5. The inflatable seal motor turns on ( if equipped). 6. The dock leveler deck rises and extends lip. 7. Inside lights change to red light off, green light remains off amber light turns on and flashing. (Alarm stops) 8. Release the raise button and dock leveler will lower by gravity to the trailer floor. 9. Dock leveler is ready for loading or unloading. WARNING: NEVER turn the over ride switch off while loading or unloading truck 3

15 RETURN TO STORED POSITION RESTRAINT ARM LOWERED STEPS TROUBLE SHOOTING Cont.. The overhead door is open. 2. Outside lights change to green light off and red light on and flashing. 3. Inside lights change to green and red lights off and amber light on and is flashing. 4. The dock leveler is in use and the lip is extended and not in the stored position. WARNING: The dock leveler must be in a stored position before turning the over ride switch to off. 5. Press and hold down the raise button. 6. The dock leveler deck rises and lip retracts and hangs in a 90 degree position for storing. 7. Release the raise button. 8. Inside lights change to amber light off, green light remains off and red light turns on and is flashing. 9. The dock leveler lowers by gravity to the stored position. 0. Remove truck or trailer restraining device such as wheel chocks.. Turn off the over ride selector switch. Outside lights change to red light turns off and green light turns on and is flashing. 2. The dock leveler and restraint are now in a stored position and the truck or trailer is free to leave. RESTRAINT ARM DRIFTS: STEPS. The truck restaint is in an engaged position and the overhead door is open. 2. Outside lights are green light off and red light on and flashing. 3. Inside lights are red and amber lights are off and green light is on and flashing.. 4. The dock leveler is is use and the lip is extended (not in a stored position). 5. The restraints arm starts to drift toward a stored position. 6. The restraint arm reaches the drift limit switch. 7. Outside lights change to green light is off and red light remains on and flashing.. 7. Inside lights change to green light off, and red light turns on and flashing. (Alarm sounds) 8. The dock attendant must press and hold the raise button to re-position the restraint arm. 9. Inside lights change to red light off and green light is on and flashing. (Alarm stops sounding) 0. The restraint arm engages the ICC bar of the truck or trailer and deck begins to rise. 4

16 HYDRAULIC / ELECTRICAL ASSEMBLY REPLACEMENT PARTS ITEM PART QTY PART # ELBOW KTR HYDRAULIC CYLINDER TR-2 3 SOLENOID VALVE C/W COIL & VALVE BODY KTR BULKHEAD FITTING HOSE C/W FITTINGS ADAPTER KTR WIRE CONNECTOR 8 PVC BOX 9 PVC COVER 0 90-CONNECTOR STRAIGHT ELECTRICAL CONNECTOR 2 SOLENOID VALVE COIL 3 CARTRIDGE 4 FILTER 2 5 VALVE BODY LIMIT SWITCH

17 REPLACEMENT PARTS CONNECTION TO TYPICAL HYDRAULIC DOCK LEVELER REMOTE AND SELF CONTAINED POWER PACK ITEM PART QTY PART# HOSE C/W FITTINGS KHD407 2 HOSE C/W FITTINGS KTR-60 3 O-RING FITTING 4 SWIVEL TEE BULK HEAD FITTING

18 REPLACEMENT PARTS FOR PROXIMITY SWITCH ITEM PART PROXIMITY SWITCH BRACKET PROXIMITY SWITCH JUNCTION BOX COVER JUNCTION BOX QTY PART NO. TR

19 TRUCK RESTRAINT ASSEMBLY REPLACEMENT PARTS ITEM PART SIDE COVER HOUSING ASSEMBLY COVER CAP SCREW HITCH PIN CLIP ROLLER PIN ROLLER NYLON STRAP RETAINING RING ACTIVATING ARM PIN UPPER ARM ASSEMBLY ARM ASSEMBLY PIN BOLT MAIN SHAFT EXTENSION SPRING CYLINDER PIN NUT HYDRAULIC CYLINDER BOLT TENSION SPRING LOWER ARM ASSEMBLY QTY PART NO. TR-08 TR-200. TR TR TR TR-23 TR TR-07 TR-2 8

20 STANDARD ELECTRICAL SCHEMATIC 9

21 GENERAL MAINTENANCE DAILY - Check inside and outside lights for burnt bulbs - Replace burnt out bulbs immediately - Remove debris on or around truck restraint - Remove snow and ice on truck restraint WEEKLY - Check full operation of the truck restraint and dock leveler to ensure there is no hesitation in the hydraulic system - Any loss of fluid will affect the safe operation of the equipment QUARTERLY - Inspect the hydraulic cylinder, valve and hose for any fluid loss - Inspect structural members for failures (bending or broken welds) LUBRICATION - Add lubrication on a quarterly basis - Oil SAE 0W30 motor oil 20

22 GENERAL MAINTENANCE DIAGRAM CAUTION: INSERT /2 O ROD WHEN MAINTAINING RESTRAINT DO NOT OIL OR GREASE STRAP OR 2

23 SERVICE POLICY & WARRANTY KOKE Inc. warrants that each KOKE manufactured product shall be free from defects in materials and workmanship. Any part of thisproduct which under normal and proper use, maintenance proves defective in material and workmanshipwithin (2) twelve months on mechanical components `(90) days on electrical components and (60) months on structural components, provided that notice of any such defects and satisfactory proof of defects is given by the buyer to the seller, with transportation prepaid, and seller s examination proved such part to be defective. KOKE S OBLIGATION UNDER THIS WARRANTY IS LIMITED TO THE RE- PLACEMENT OF DEFECTIVE COMPONENTS AT THE FACTORY, OR, AT THE DISCRETION OF KOKE INC., AT A LOCATION DESIGNATED BY THE COM- PANY. KOKE INC. WILL NOT BE LIABLE FOR ANY LOSS, INJURY OR DAMAGE TO PERSONS OR PROPERTY, NOR FOR DAMAGES OF ANY KIND RESULT- ING FROM FAILURE OR DEFECTIVE OPERATION OF ANY MATERIALS OR EQUIPMENT. NO OTHER WARRANTIES EXIST EXCEPT AS STATED HEREIN KOKE INC. is constantly striving to improve the equipment we produce. Improvements and necessary design changes will be made whenever KOKE Inc. believes performance or operation of the equipment will be improved with no obligation to incorporate any improvements to any equipment that may be in service. 22

24 Koke Inc. 582 Queensbury Ave Queensbury, NY 2804 Phone: (800) Fax: (888) Koke Inc. is constantly striving to make a better product. As a result, the company reserves the right to make changes and upgrades at any time without notice. Copyright 2006 Koke Incorporated