PowerStop Truck Restraint Owner’s Manual 6 3/8” 11 3/8” 29 ½” 16 7/8” 12” 8” SYSTEMS, INC. • W194 N11481 McCormick Drive • Germantown, WI 53022 800.643.5424 • fax: 262.257.7399 • www.docksystemsinc.com • techservices@docksystemsinc.com Printed in U.S.A. Copyright © 2006 Manual No. 4111-0014 Sept.
Table of Contents Page Safety Recognize Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Operational Safety Precautions . . . . . . . . . . . . . . . . . . . . . . Operational Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 2 4 Introduction General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY Recognize Safety Information General Operational Safety Precautions Safety-Alert Symbol The Safety-Alert Symbol identifies important safety messages on equipment, safety signs, in manuals, or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message. Read and understand the operating instructions and become thoroughly familiar with the equipment and its controls before operating the dock leveler or truck restraint.
SAFETY Operational Safety Precautions Learn the safe way to operate this equipment. Read and understand the manufacturer's instructions. If you have any questions, ask your supervisor. Stay clear of dock leveling device when freight carrier is entering or leaving area. Chock/restrain all freight carriers. Never remove the wheel chocks until loading or unloading is finished and truck driver has been given permission to drive away.
SAFETY Do not use dock leveling device if freight carrier is too high or too low. Do not overload the dock leveling device. Do not operate any equipment while under the influence of alcohol or drugs. Do not leave equipment or material unattended on dock leveling device. 4111-0014 — November 2006 Sept.
SAFETY Maintenance Safety Precautions ALWAYS disconnect electrical power source and ground wire before welding on dock leveler. DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler. Always ground to the dock leveler frame. Failure to follow these instructions may result in damage to dock leveler and/or serious personal injury or death. Hydraulic and electrical power must be OFF when servicing the equipment.
INTRODUCTION General Information PowerStop Stock Specifications PowerStop truck restraints are available in the following models and options: PowerStop M Mechanical PowerStop PowerStop M-ML Mechanical PowerStop Manual Inside and Outside Lights PowerStop M-AL Mechanical PowerStop Automatic Inside and Outside Lights Congratulations on your choice of a Systems, Inc. truck restraint. This manual covers the PowerStop series hydraulic dock truck restraint. Designed by Systems, Inc.
INSTALLATION DETAILS-AUTOMATIC POWERSTOP POWERSTOP STOP-TITE Overview Overview McGuire 11” LEVEL McGuire. POWERSTOP Overview STOP-TITE Powerpack AAL Conduit, flexible or rigid, must be connected between the limit switch on the restraint and the powerpack. Wiring to and from the restraint must be limited to restraint wires only. Do not run high voltage lines through the same conduit as restraint wires.
INSTALLATION DETAILS-AUTOMATIC POWERSTOP Concrete Dock Face (Standard installation) Wedge Anchors Method Wall Embed Method Weld three sides of PowerStop back plate to the optional Using back plate as a guide, drill six (6) holes for wedge anchors (3/4”x 5 1/4” min.) (Kit #2103-0003) embed mounting plate (Part #7953-0119) with ten (10) 4” long 1/4” fillet welds.
INSTALLATION DETAILS-MECHANICAL POWERSTOP Optional DockAlert Communication System POWERSTOPMAL - Manual Restraint/Automatic DockAlert Conduit must be protected from damage.
INSTALLATION DETAILS-MECHANICAL POWERSTOP Concrete Dock Face (Standard installation) Wedge Anchors Method Wall Embed Method Using back plate as a guide, drill six (6) holes for wedge anchors (3/4”x 5 1/4” min.) (Kit #2103-0003) 5 1/4” minimum 18” Optional Embed Plate Weld three sides of PowerStop back plate to the optional embed mounting plate (Part #7953-0119) with ten (10) 4” long 1/4” fillet welds.
INSTALLATION Install Control Panel and Wiring For comprehensive installation instructions of the Automatic POWERSTOP Overview) read and STOP-TITE (STOP-TITE understand the Installation and Operation Manual. AAL The electrical power must be OFF prior to electrical installation. For maximum protection, use an OSHA approved locking device to lock out all power sources. Only the person installing the equipment should have the key to unlock the power source.
OPERATION Operating Instructions 1. Disconnect the external lifting device and lifting brackets. Stay clear of dock leveler and truck restraint 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.
Troubleshooting Mechanical Troubleshooting Problem Restraint weldment (hook) will not raise. Possible Solution(s) 1. Check side release latch for binding, lubricate if needed. 2. Check restraint body for debris. 3. Check for broken extension springs. 4. Check link joints for missing or bent shoulder bolts, pins or excessive wear. 5. Check front pin slot under restraint weldment for damage.
Troubleshooting Hydraulic Troubleshooting Problem Restraint will not raise. Possible Solution(s) 1. Remove excess load from restraint. Unit is designed to raise no more than its own weight as a safety feature. 2. Strainer element plugged. Remove reservoir and clean or replace strainer element. 3. Hydraulic valve may be not be actuating. Locate solenoid coil. Check solenoid valve coil to confirm it is energized when raising restraint.
Troubleshooting Electrical Troubleshooting Problem Restraint does not raise or lower - Motor does not run, inside and outside lights do not work. Possible Solution(s) 1. No voltage at control assembly. Check voltage input. 2. Blown fuse inside control assembly. Use voltmeter to test. Line side of fuse is always hot. Turn off main power supply before removing fuses. Attach proper lockout / tag-out devices. IMPORTANT Do not run motor when valves are removed from valve block.
Troubleshooting Electrical Troubleshooting Continued Problem Possible Solution(s) Restraint does not lower-motor runs in pressure relief, inside and outside lights work. 1. Solenoid valve mechanically stuck ON. Remove solenoid valve from hydraulic block. Inspect block for contaminants. Test. Replace if necessary. IMPORTANT Do not run motor when valves are removed from valve block. Do not over tighten coil on valve: 15 inch lbs max which is just over finger tight.
MAINTENANCE Periodic Maintenance A L K B J C H G F E D L A— Scissors Assembly B— Hook Weldment C— Rear Vertical Track D— Rear Track Assist Spring E— Platform Hinge Area F— Bottom Slide Track Before performing any maintenance under the dock leveler or truck restraint lock the electrical power source in OFF position using an approved locking device. Failure to follow these instructions may result in serious personal injury or death.
MAINTENANCE Daily Maintenance • Daily patrol truck restraint area and clear any debris to prevent operation issues. • Check inside and outside lights for proper operation Q P N Weekly Maintenance • Operate the truck restraint through the complete operating cycle to maintain lubrication of parts of both mechanical and hydraulic restraints. • Inspect the rear vertical track area (C). The track area must be kept free of dirt and debris.
PARTS PowerStop M (Mechanical) Parts Breakdown 26 14 12 11 24 6 30 21 19 17 29 15 18 25 13 28 8 3 2 16 27 20 7 22 10 4 5 23 2 9 18 4111-0014 — November 2006 Sept 2007
PARTS PowerStop M (Mechanical) Parts Breakdown Item Quantity Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16* 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 1 1 1 1 1 2 8 1 8 2 2 1 8 2 0191-0025 0941-0015 0615-0037 1751-0444 1751-0010 1751-0135 2101-0009 2101-0084 2101-0085 2101-0143 2101-0150 2101-0151 2101-0165 2101-0189 2101-0212 1 2 2 1 2 1 2 2 1 1 1 1 1 1 5455-0005 9202-0042 9202-0043 9411-0028 9412-0161 9412-0201 9412-0202 9412-0215 9413-0049 9413-0062 9413-0068 9413-0070 9413-0087 9414-0046 B
PARTS PowerStop A (Hydraulic) Parts Breakdown 20 4111-0014 — November 2006 Sept 2007
PARTS PowerStop A (Hydraulic) Parts Breakdown Item Quantity Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21@ 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 * 1 1 1 1 1 1 2 1 8 1 8 2 2 1 1 1 1 8 2 2 1 2 2 1 1 2 1 2 1 1 1 2 1 1 1 1 1 1 0191-0025 0524-0063 0524-0064 0615-0037 1751-0444 1751-0010 2101-0009 2101-0039 2101-0084 2101-0098 2101-0143 2101-0150 2101-0151 2101-0163 2101-0165 2101-0187 2101-0188 2101-0189 2101-0202 2101-0212 @ @ Description 9202-0042 9202-0043 9411-0024 9411-
PARTS Power Pack Assembly Amp Draw 4.8- 5.
PARTS Power Pack Assembly Item Quantity Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 3 2 2 2 1 1 1 1 1 1 REF 1 2 1431-0011 1431-0086 2101-0017 2101-0140 2401-0001 2751-0016 3051-0058 9301-0164 9391-0009 9391-0012 9391-0013 9904-0119 R513-0050 R598-0090 * Description Connector-2 Screw, 3/8 Insulated Terminals, 16-14 AWG HHCS-Grad 2-Zinc Plated, 3/8-16 UNC X 1 Lock Washer, 3/8 Grommet, 1-3/8 OD X 3/4 ID J-Box Cover, 4 X 4 Capacitor-Motor Start, 66-77mf-330V Fitting Connector Straight Thread, #4 ORB #
PARTS Power Stop Valve Combined With Leveler 24 4111-0014 — November 2006 Sept 2007
NOTES 4111-0014 — November 2006 Sept.
PARTS Outside Signs A B Item Quantity Part Number A 1 1751-0133 B 1 1751-0134 26 Description SIGN,PULL IN/OUT ON GREEN ONLY RIGHT READING,16-7/8x8x3/32 SIGN,PULL IN/OUT ON GREEN ONLY MIRROR IMAGE,16-7/8x8x3/32 4111-0014 — November 2006 Sept 2007
PARTS OSLA (Outside Light Assembly) Item 1-7 1-7 1 2 3 * * 2 3 4 5 6 7 Quantity 1 1 1 1 1 2 2 1 1 1 4 4 1 Part Number 3055-0008 3055-0002 3051-0002 3051-0064 3051-0065 3051-0085 3051-0066 3051-0102 3051-0103 3051-0068 3051-0105 3051-0104 x 4111-0014 — November 2006 Sept.
NOTES This Page Intentionally Left Blank 28 4111-0014 — November 2006 Sept 2007
MISCELLANEOUS Customer Information A NOTE: Refer to illustration for left/right orientation of Dock Leveler and Truck Restraint. The model/serial number decal (A) is located on the right platform joist near the front (lip) of dock leveler. The Truck Restraint serial number is located on the left side of the bellows shroud. When you receive your PowerStop Truck Restraint, write down the Truck Restraint and Dock Leveler serial number (if applicable) in the form provided.
Systems, Inc. WARRANTY POWERSTOP SERIES TRUCK RESTRAINT Systems, Inc., guarantees the materials, components, and workmanship in your Systems, Inc. truck restraint to be of the highest quality and to be free of defects in material and workmanship for a period of One (1) Year from date of shipment. Specifically this includes the frame and all mechanical components. Systems, Inc., further guarantees the hydraulic components (where equipped) on all Systems, Inc.
