KOKE HTR-2020 User manual
1
2
K
KOKE INC
HTR2020 & HTR2020C
SERIAL NUMBER:
OPTIONS:
3
Table of Contents
SAFETY INFORMATION
WARNING ..................................................................................................................................4
INSTALLATION...........................................................................................................................4
MAINTENANCE & TROUBLESHOOTING..................................................................................4
OPERATION................................................................................................................................4
INSTALLATION
INSTALL PROCEEDURE............................................................................................................5
INSTALLATION LAYOUT DIAGRAM...........................................................................................7
HYDRAULIC LAYOUT ................................................................................................................8
INTERIOR/EXTERIOR LIGHTS..................................................................................................9
OPERATING INSTRUCTIONS
FOR HYDRAULIC DOCK LEVELER.........................................................................................10
FOR MECHANICAL DOCK LEVELER.......................................................................................10
ADDITIONAL SITUATIONS.......................................................................................................11
OVERRIDE MODE ...................................................................................................................12
TROUBLE SHOOTING
RESTRAINT WILL NOT RISE..................................................................................................13
RESTRAINT ARM DRIFTS......................................................................................................13
RESTRAINT WILL NOT LOWER..............................................................................................13
MANUAL LOWER VALVE..........................................................................................................13
DIAGRAMS & PART LISTS
HYDRAULIC LAYOUT..................................................................................................................8
PROXIMITY SWITCH...............................................................................................................14
TRUCK RESTRAINT ASSEMBLY.............................................................................................15
ELECTRICAL SCHEMATIC.......................................................................................................16
GENERAL MAINTENANCE SCHEDULE............................................................................................17
WARRANTY INFORMATION..............................................................................................................18
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.
DURING INSTALLATION:
1.Personnelinstallingthisequipmentmustbequaliedandexperiencedinsafe
working procedures.
2. All lifting and slinging devices must be in proper working condition and used in
the proper manner.
3.Allelectricaltobedonemustbeperformedbyaqualiedelectricianandmust
meet all applicable local codes.
4.Concretemustbeinexcellentconditionwithnocracksinthemountingface
within 4 ft. of the truck restraint and dock leveler.
5. DO NOT install the truck restraint on brick, concrete block or similar surfaces.
WHILE PERFORMING MAINTENANCE & TROUBLE SHOOTING:
1. Perforn proper lock out/tag out of 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.
DURING 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
storing of the dock leveler and truck restraint.
5. DO NOT attempt to “ride” on the equipment during the positioning or storing of
the dock leveler or truck restraint.
6. DO NOT use the truck restraint or dock leveler if you believe it is in an unsafe
condition due to damaged understructure, broken welds, oil leaks, etc.
5
INSTALLATION PROCEDURES
STEP 1 MATERIAL 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.
4. Determine the proper locations for the signs, controls, truck restraint and
exteriorlightingsystem.
STEP 2 INSTALLATION OF THE TRUCK RESTRAINT:
1.Placerestraintboxinthecenterofthedooropening.
2. Mark the nine (9) hole positions on the face of the foundation wall.
3.Drillnine(9)5/8”diameterholesapproximately6”deep.
4.Bolttherestraintboxtofoundationwallusing5/8”x5”Lanchorbolts
STEP 3 HYDRAULIC CONNECTION TO LEVELER & TRUCK RESTRAINT:
See connection diagram (pg. 7 & 8) for hose routing.
Important notes:
1. Hydraulic system must be clear of debris / dirt particles and all hoses capped/
covered when feeding through the conduit.
2. Drain oil and clean reservoir.
3. Flush hydraulic system.
4.Rellreservoirwithnewoil.
Failure to do items 1-4 above will cause damage to the unit and void the
warranty.
5.Requiredhydraulicoil:MOBILDTE10Excel15orequivalent.
STEP 4 MOUNTING:
1.Selectlocationandmounttheexteriorsignandlightsystemasshownonpg.7.
2.Selectlocationandmounttheinteriorcontrolboxandsignasshownonpg.7.
STEP 5 ELECTRIC PROXIMITY SWITCH INSTALLATION TO EXISTING UNIT:
1. Mount the limit switch plate behind the leveler lip.(See diag. on pg 14)
2. The switch plate can be either welded or bolted into place.(See diag. on pg.14)
STEP 6 ADJUST THE PROXIMITY SWITCH LIMIT ON EXISTING UNIT:
(Seepage14forProximitySwitchdiagram)
1. Adjust the limit switch within 3/16” of the lip.
(NOTE: lip must be tight against its stop (fully retracted position))
6
STEP 7 ELECTRICAL INSTALLATION:
1.Completeallnecessarywiringfromcontrolboxto:
(See Electrical Schematic pg. 16)
A.Exteriorlight.
B.Junctionboxlocatedatthetruckrestraint.
C.Electricalproximityswitchbehindlevelerlip(seepg.14)
D. Hydraulic power pack.
STEP 8 FINAL SET-UP ADJUSTMENTS:
1.Makesuretheexteriorlightsdonotchangebacktogreenuntiltherestraint
is completely closed in its stored postioin.
2. To increase or decrease the time, adjust the electrical timer on the circuit
board inside the control
box.
NOTES:
* Hydraulic system must be completely clear of dirt particles and all hoses must
be covered when passing through conduits.
*Whenconnectingtoanexistingdockleveler,ushandcleanthehydraulicsystem
including the reservoir and add new oil.
Failure to complete these 2 items will VOID THE WARRANTY.
7
INSTALLATION LAYOUT DRAWING
$
'(7$,/$
6&$/(
+75
02817&(17(5('
IN DOOR OPENING
(/(&75,&$/&211(&7,216)520&,5&8,7%5'
62/,12,'
'5,)7/,0,76:,7&+
352;6:,7&+
+<'5$8/,&+26(7&211(&7,21
720$,1/,)7&</,1'(5
,7(0
(;7(5,25
6723*2/,*+7:,7+
6,*1
,7(0
02817+,*+
)520'5,9(:$<
(/(&75,&$/)(('
72352;,0,7<6:ITCH
;
$1&+25%2/76
352;,0,7<%5$&.(76:,7&+
,7(0
,17(5,25&21752/3$1(/
02817+,*+)520%27720
2)3$1(/72)/225
6,=(
':*12
$
5(9
5(9'$7(
.2.(,1&
35235,(7$5<$1'&21),'(17,$/
7+(,1)250$7,21&217$,1(',17+,6'5$:,1*,67+(62/(3523(57<
2)
.2.(,1&
$1<5(352'8&7,21,13$5725$6$:+2/(:,7+287
7+(:5,77(13(50,66,212)
.2.(,1&
,6352+,%,7('
'$7(
':*%<
0$7(5,$/
8
TYPICAL HYDRAULIC DIAGRAM FOR TRUCK
RESTRAINT with KOKE DOCK LEVELER
9
INTERIOR LIGHTS / CONTROL PANEL / SIGN
Control panel operates truck restraint and electric/hydraulic dock leveler.
Control panel also has light communication system for dock attendant and/or forklift
operator.
EXTERIOR LIGHTS / SIGN
Exteriorlightcommunicationsystemfortruckdriver.
10
OPERATING INSTRUCTIONS
Read and understand the safety information (See pg. 4).
Interior Lights and Controls (See pg. 9)
ExteriorLights(Seepg.9)
ProximitySwitch(Seepg.14)
All of the following conditions must be true prior to operation:
1. Over head door is open.
2. Exterior green light is on.
3. Exterior red light is o.
4. Interior green and amber lights are o.
5. Interior red light is on.
6. Dock leveler and lip are in a stored position.
HYDRAULIC DOCK LEVELER:
ENGAGE (RAISE) RESTRAINT:
STEP 1: Press and hold raise button.
1.Exteriorlightchangesfromgreentored.
2. When restraint arm is fully raised, the dock leveler deck rises and
extendslip.
3. Interior light changes from red to green.
STEP 2: Release raise button.
1.Docklevelerlowerstotraileroorbygravity.
Restraint is now engaged and dock leveler is ready for loading/unloading.
DISENGAGE (LOWER) RESTRAINT:
STEP 1: Press and hold raise button.
1. Dock leveler deck raises, lip lowers to the vertical position for storing.
STEP 2: Release raise button.
1.Docklevelerlowersbygravitytoastored(closed)position.(Proximityswitchisactivated.)
2. Interior light changes from green to red.
3. Truck restraint arm fully lowers.
4.Exteriorlightchangesfromredtogreen.
Dock leveler and truck restraint are now in the stored poistion.
Truck or trailer is now free to depart.
MECHANICAL DOCK LEVELER:
ENGAGE (RAISE) RESTRAINT:
STEP 1: Operate mechanical dock leveler.
1. Pull release chain on dock leveler.
2.Exteriorlightchangesfromgreentored
3.AllInteriorlights(redamber&green)ashandalarmsounds.
4. Walk down dock leveler into truck.
STEP 2: Press and hold RAISE button.
1.Interiorlightschangefromallashingtoredonlyandalarmshutso.
2.Whenrestraintarmfullyraised(apprx.6-8sec.),releaseRAISEbutton.
3. Interior light changes to green.
Restraint is now engaged and dock leveler is ready for loading/unloading.
This manual suits for next models
1
Table of contents
