HYDRAULIC TRUCK RESTRAINT - PDF document

HYDRAULIC TRUCK RESTRAINT OWNER’S
HYDRAULIC TRUCK RESTRAINT OWNER’S MANUALTR 2000 - TRUCK RESTRAINTSerial Number:____________________________________Model:____________________________________Customer:____________________________________Date Shipped:____________________________________Options:_____________________________________OWNER’S MANUALTable Of ContentsSafety Information Warning3 Installation .......................................................................................................................3 Maintenance & Troubleshooting3 Operation .........................................................................................................................3Installation Procedures .......................

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........................................................4-5 Notes ................................................................................................................................5 Installation Layout Diagram ..........................................................................................6 Inside Lights Control ......................................................................................................7 Outside Lights ................................................................................................................8Operating Instructions ...................................................................................9 Engage Restraint ...............

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.............................................................................................9 Lower Restraint ............................................................................................................10 Additional Situations10-11Trouble Shooting Check List12 Trouble Shooting 13 Restraint Does Not Engage ICC Bar ...........................................................................13 Operate Leveler in Override Mode ..............................................................................13 Return to Stored Position .............................................................................................14 Restraint Arm Drifts14DiagramsHydraulic / Electri

cal Assembly Replacement Parts15Hydrau
cal Assembly Replacement Parts15Hydraulic Leveler Remote & Powerpack Repl. Parts .....................................................16Proximity Switch Replacement Parts ..............................................................................17Truck Restraint Assembly Replacement Parts18Standard Electrical Schematic .........................................................................................19General Maintenance ...................................................................................20 Daily ...............................................................................................................................20 Weekly20 Quarterly......................................

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..................................................................................20 Lubrication ....................................................................................................................20 General Maintence Diagram ........................................................................................21Service Policy & Warranty22SAFETY INFORMATIONWARNING: Failure to read and understand the entire contents of this manual may result in damage to the equipment, bodily injury and/or death. NEVER or alcohol.INSTALLATION: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 perfo

rmed by a quali�ed electricia
rmed by a quali�ed electrician and must meet all applicable local codes.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:1. Lock out the power supply.2. Barricade in front of the dock leveler on the loading dock area and in the drive-way.3. When replacing parts use only genuine KOKE Inc. parts.OPERATION:1. 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 stor

ing of the dock leveler and truck restra
ing 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.3INSTALLATION PROCEDURESSTEP 1MATERIAL INSPECTION:1. 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.lighting system.STEP 2 INSTALLATION OF THE TRUCK RESTRAINT:2. Mark the eight (8) hole positions on the face of the foundation wall.5. If possible, weld the top

of the back plate to the bottom of the c
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 16 for hose routing.Important note:1. Drain oil and clean reservoir.2. Flush hydraulic system.(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 HV122, SHELL TELLUS 27, TEXACO HD22 or an equivalent.STEP 4 MOUNTING:STEP 5 ELECTRIC PROX. SWITCH INSTALLATION TO EXISTING UNIT:1. Mount the limit switch plate behind the leveler lip.2. The switch plate can be either weld

ed or bolted into place. (See page 17)4
ed or bolted into place. (See page 17)4STEP 6 ADJUST THE PROXIMITY SWITCH LIMIT ON EXISTING UNIT:1. Adjust the limit switch within 3/16” of the lip. (NOTE: lip must be tight against the stop)STEP 7 ELECTRICAL INSTALLATION:4. Hydraulic power pack.STEP 8 FINAL SET-UP ADJUSTMENTS:is completely closed.2. To increase or decrease the time, adjust the electrical timer inside the control 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, �ush and clean the hydraulic sys-tem includin

g the reservoir and add new oil.Failure
g the reservoir and add new oil.Failure to complete these 2 items will VOID THE WARRANTY.5INSTALLATION LAYOUT DRAWING6INSIDE LIGHT CONTROLSFOR COMBINATION DOCK LEVELER / TRUCK RESTRAINT(SEE OPERATING INSTRUCTIONS FOR DESCRIPTION AND SEQUENCE OF LIGHT SIGNALS)LIGHT COMMUNICATION FOR DOCK ATTENDANT / FORK TRUCK OPERATORWARNING: Read and understand the safety and operating instructions in the manual before operating this equipment.7OUTSIDE LIGHTLIGHT COMMUNICATION FOR TRUCK DRIVERRED:Warning truck driver his truck is restained, being loaded/unloaded and must not pull away.GREEN:Truck may back in or depart.8OPERATING INSTRUCTIONSRead and understand the safety information (see page 3)In

side Lights and Controls (see page 7)Ou
side 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.1. Over head door is open, closing limit switch (if equipped).3. Outside red light is off.4. Inside green and amber lights are off.6. Dock leveler and lip are in a stored position.STEP 1 Press and hold raise button2. Outside lights change to green light off and red light on and �ashing.3. When restraint arm engages trailer bumper bar, the dock leveler deck 4. Inside lights change to red light off and green light on and �ashing.STEP 2 Release raise buttonDock leveler lowers to trailer �oor by gravity.

STEP 3 Restraint is now engaged an
STEP 3 Restraint is now engaged and dock leveler is ready for loading / unloading9LOWER RESTRAINT:RESTRAINT IN ENGAGED POSITION:The following conditions must be in place prior to operation.1. Over head door is open, closing limit switch (if equipped).3. Outside red light is off.4. Inside green and amber lights are off.6. Dock leveler and lip are in a stored position.STEP 1 Press and hold raise buttonSTEP 2 Release raise button1. Dock leveler deck raises, lip retracts to the pendant position for storing.1. Dock leveler lowers by gravity to a stored position2. Inside lights change to green light off and red light on and �ashing.3. Truck restraint arm fully lowers.4. Outside lights cha

nge to red light off and green light on
nge to red light off and green light on and �ashing.STEP 3 Dock leveler and truck restraint are now in the stored poistion. Truck or trailer are now free to depart.ADDITIONAL SITUATIONS:OVER NIGHT MODE:1. Leave truck restraint engaged.2. Store the dock leveler.3. Close the over head door.FROM A STORED POSITION:1. 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 en-gaged.10ADDITION

AL SITUATIONS: (continued)FROM ENGAGE
AL SITUATIONS: (continued)FROM ENGAGED / WORKING POSITION:1. 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)1. 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 15)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 s

ide plate on the truck restraint.11TRO
ide plate on the truck restraint.11TROUBLE SHOOTING INITIAL CHECK LISTSPROBLEM: RESTRAINT WILL NOT RISE:1. Check the power supply.2. Check the circuit breakers.3. Check for any hydraulic leaks.4. Check the �uid 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:1. 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.121. Press hold and raise button.3. Outside lights change to green light off and red light is on and �ashing.4. The restraint arm

will not engage the ICC bar.6. Releas
will not engage the ICC bar.6. Release the raise button.8. The restraint arm will fully lower.9. Outside lights change to red light off and green light on and �ashing.RESTRAINT DOES NOT ENGAGE ICC BAR: OPERATE LEVELER IN OVERRIDE MODETROUBLE SHOOTING(When unit is not operating properly an alarm will sound)OVERRIDE MODE INSTRUCTIONSNOTE: RESTRAINT IS IN THE STORED POSITIONSTEPS1. Turn the over ride switch to the on position.2. Outside lights change to green light off and red light on and �ashing.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 in�

066006C;atable seal motor turns on ( if
066006C;atable 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 8. Release the raise button and dock leveler will lower by gravity to the trailer �oor.9. Dock leveler is ready for loading or unloading.WARNING: NEVER turn the over ride switch off while loading or unloading truck 13TROUBLE SHOOTING Cont.1. The overhead door is open.2. Outside lights change to green light off and red light on and �ashing.3. Inside lights change to green and red lights off and amber light on and is �ashing.4. The dock leveler is in use and the lip is extended and not in the store

d position.WARNING: The dock leveler
d 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 9. The dock leveler lowers by gravity to the stored position.11. Turn off the over ride selector switch. Outside lights change to red light turns off 12. The dock leveler and restraint are now in a stored position and the truck or trailer is free to leave.STEPSRETURN TO STORED POSITIONRESTRAINT ARM LOWEREDRESTRAINT ARM DRIFTS: STEPS1. The tru

ck restaint is in an engaged position an
ck restaint is in an engaged position and the overhead door is open.2. Outside lights are green light off and red light on and �ashing.3. Inside lights are red and amber lights are off and green light is on and �ashing..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 �ashing..7. Inside lights change to green light off, and red light turns on and �ashing. (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
arm.9. Inside lights change to red light off and green light is on and �ashing. (Alarm stops sounding)10. The restraint arm engages the ICC bar of the truck or trailer and deck begins to rise.14 PART PART # SOLENOID VALVE C/W COIL & VALVE BODY WIRE CONNECTOR 90-CONNECTOR 11 STRAIGHT ELECTRICAL CONNECTOR SOLENOID VALVE COIL CARTRIDGE FILTER VALVE BODY LIMIT SWITCH HYDRAULIC / ELECTRICAL ASSEMBLY REPLACEMENT PARTS15REPLACEMENT PARTS CONNECTION TO TYPICAL HYDRAULIC DOCK LEVELERREMOTE AND SELF CONTAINED POWER PACK PART PART# SWIVEL TEE

16ITEM1234PARTPROXIMITY SWITCH
16ITEM1234PARTPROXIMITY SWITCH BRACKETPROXIMITY SWITCHJUNCTION BOX COVERJUNCTION BOXQTY1111PART NO.TR-515915-0023915-0025915-0024REPLACEMENT PARTS FOR PROXIMITY SWITCH17TRUCK RESTRAINT ASSEMBLY REPLACEMENT PARTSITEM123456789101112131415161718192021PARTSIDE COVERHOUSING ASSEMBLYCOVERCAP SCREWHITCH PIN CLIPROLLER PINROLLERNYLON STRAPRETAINING RINGACTIVATING ARM PINUPPER ARM ASSEMBLYARM ASSEMBLY PINBOLTMAIN SHAFTEXTENSION SPRINGCYLINDER PINNUTHYDRAULIC CYLINDERBOLTTENSION SPRINGLOWER ARM ASSEMBLYPART NO.TR-108TR-200 .1TR-100920-0024920-0019TR-520131-2009131-2005920-0001TR-122231-2007TR-123TR-106940-0004TR-107TR-121QTY1112222121111121

1112118STANDARD ELECTRICAL SCHEMAT
1112118STANDARD ELECTRICAL SCHEMATIC19GENERAL MAINTENANCEDAILYWEEKLYQUARTERLYLUBRICATION- 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- Check full operation of the truck restraint and dock leveler to ensure there is no hesitation in the hydraulic system- Any loss of �uid will affect the safe operation of the equipment - Inspect the hydraulic cylinder, valve and hose for any �uid loss- Inspect structural members for failures (bending or broken welds)- Add lubrication on a quarterly basis20GENERAL MAINTENANCE DIAGRAM21CAUTION:INSERT 1/2 “O” ROD WHEN MAINT

AINING RESTRAINTDO NOT OIL OR GREASE
AINING RESTRAINTDO NOT OIL OR GREASE STRAP OR SERVICE POLICY & WARRANTYKOKE Inc. warrants that each KOKE manufactured product shall be free from defects in materials and workmanship. Any part of this-product which under normal and proper use, maintenance proves defective in material and workmanshipwithin (12) twelve months on 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 PERSO
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.22Koke Inc.582 Queensbury AveQueensbury, NY 12804Koke 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