PowerStop Vehicle Restraint Owner’s/User’s Manual Systems, Inc. • W194 N11481 McCormick Drive • Germantown, WI 53022 800.643.5424 • fax: 262.255.5917 • www.docksystemsinc.com • techservices@docksystemsinc.com Printed in U.S.A. Copyright © 2013 Manual No.
Table of Contents Page Safety Recognize Safety Information.............................................................. General Operational Safety Precautions............................................. Operational Safety Precautions............................................................ Maintenance Safety Precautions.......................................................... Safety Decals.......................................................................................... Placard installation.
SAFETY Recognize Safety Information 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. General Operational Safety Precautions 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 the transport vehicle is entering or leaving area. Chock/restraint all transport vehicles. Never remove the wheel chocks until loading or unloading is finished and transport vehicles driver has been given permission to drive away.
SAFETY Do not use dock leveling device if transport vehicle 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 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. 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.
SAFETY Safety Decals 5.06" DANGER 1751-0727 CRUSH HAZARD Maintenance prop must support leveler behind bar. Do not force maintenance prop forward of bar to support lip. Failure to comply will result in death or serious injury. Refer to owner’s/user’s manual for proper use. 2.40" 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.
SAFETY Safety Decals 5.06" DANGER 1751-0727 CRUSH HAZARD Maintenance prop must support leveler behind bar. Do not force maintenance prop forward of bar to support lip. Failure to comply will result in death or serious injury. Refer to owner’s/user’s manual for proper use. 2.40" 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.
PLACARDS Placard Installation Instructions • Owner is responsible for the installation and placement of product placards. • Make sure placard is in plain view of dock leveler operations. • Suggested placement of placard is near control box attached to electrical conduit by using nylon tie. If there is no control box present, mount placard on wall to the immediate left of leveler at eye level. Control Box Placard Nylon Tie (Placard placement shown as reference only.
OWNER’S/USER’S RESPONSIBILITIES 1. The owner/ user should recognize the inherent dangers of the interface between the loading dock and the transportation vehicle. The owner/ user should, therefore, train and instruct all operators in the safe operation and use of the loading dock equipment in accordance with manufacturer’s recommendations and industry standards. Effective operator training should also focus on the owner’s/user’s company policies and operating conditions.
INTRODUCTION Manual PowerStop Vehicle Restraint General Information Specification Sheet and PowerStop Stock Specifications Submittal PowerStop vehicle restraints are available in the following models and options: 3 1/2” 5 1/2” PowerStop M Mechanical PowerStop Control Panel, Lights and Signs are part of the optional Dock Alert™ Communication System 73 ½” PowerStop M-ML 8” Mechanical PowerStop Manual Inside and Outside Lights 8” PowerStop M-AL Mechanical PowerStop Automatic Inside and Outside Lights Po
INSTALLATION DETAILS-AUTOMATIC POWERSTOP POWERSTOP Overview STOP-TITE Overview For comprehensive installation instructions of the Automatic STOP-TITE (STOP-TITE ) read and understand the Installation and Operation Manual. AAL Poweramp McGuire Powerpack Location Options Coordinate powerpack location and hose length for proper placement. Dock Face Appropriate location when the likelihood of flooding, snow removal and damage from trailer/trucks is minimal. 11” LEVEL McGuire.
INSTALLATION DETAILS-AUTOMATIC POWERSTOP Automatic PowerStop Installation Overview Concrete Dock Face (Standard installation) Wedge Anchors 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 Wall Embed Method 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.
Manual PowerStop Installation Overview INSTALLATION DETAILS-MECHANICAL POWERSTOP For comprehensive installation instructions of the Manual PowerStop M (PowerStop ) read and understand the Installation and Operation Manual.
INSTALLATION DETAILS-MECHANICAL POWERSTOP Manual PowerStop Installation Overview For comprehensive installation instructions read and understand the Installation and Operation Manual. Concrete Dock Face (Standard installation) Wedge Anchors Method Using back plate as a guide, drill six (6) holes for wedge anchors (3/4”x 5 1/4” min.
STOP-TITE (STOP-TITE ) read and understand the Installation and Operation Manual. AAL McGuire INSTALLATION Install Control Panel and Wiring Powerpack Location Options Coordinate powerpack location and hose length for proper placement. POWERSTOP Overview 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 11” the equipment LEVEL to unlock the power source.
OPERATION Operating Instructions 1. Disconnect the external lifting device and lifting brackets. Stay clear of dock leveler and vehicle 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. 2.
Troubleshooting Discharge capacitor before attempting a capacitor test. Symptom Line side of fuse is always hot. Turn off main power supply before removing fuses. Attach proper lockout / tag-out devices. Possible Cause Solution Restraint will not raise or Debris lower. Remove Bellows check for Debris jammed in scissor mechanism. Restraint will not raise or lower Mechanical or Hydraulic Lubrication - Lubricate latch release leveler. - Lubricate pivot points scissors mechanism.
Troubleshooting 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. Do not over tighten valve into block: 15 foot lbs max which is enough to compress the washer and prevent leakage. Symptom Restraint move in one direction only. Possible Cause 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 vehicale 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 clear any debris to prevent operation issues. • Check inside and outside lights for proper operation Q P N Weekly Maintenance • Operate the vehicle 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 (Mechanical) Parts Breakdown 26 14 12 11 24 6 30 21 19 17 29 15 18 25 13 28 8 3 1 16 27 20 7 22 10 4 5 23 2 9 20 4111-0014 — July 2013
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 1 1 1 1 1 1 2 8 1 8 2 2 1 8 2 16 1 17 18 19 20 21 22 23 24 25 26 27 28 29 30 * 1 2 2 1 2 1 2 2 1 1 1 1 1 1 1 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 2103-0006 2103-0003 5455-0005 9202-0042 9202-0043 9411-0028 9412-0161 9412-0201 9412-0202 9412-0215 9413-0049 9413-0062 9413-0068 9413-
PARTS PowerStop A (Hydraulic) Parts Breakdown 18 31 29 30 13 12 35 34 23 20 26 16 22 37 2 9 14 10 33 15 1 36 28 4 27 24 25 21 7 22 11 5 6 32 3 19 8 17 4111-0014 — July 2013
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 1 1 1 1 1 1 2 1 8 1 8 2 2 1 1 1 1 8 2 2 21 1 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 * * 2 2 1 1 2 1 2 1 1 1 2 1 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 2103-0006 2101-0003 9202-0042 9202-0043 9411-00
PARTS PowerStop Scissor Breakdown 2 1 9 4 8 6 7 5 Rear of Restraint 3 S Y S L o a d i n SCIS MATERIAL DRAWN BY NMW TOLERANCES (UNLESS OTHERWISE NOT FRACTIONAL: 1/32" DECIMAL: .00 = .01" .000 = .005" ANGULAR: 1 This print is the property of Systems, Inc. and of use and/or manufacture and/or sale.
PARTS PowerStop Valve Combined With Leveler 3 2 5 LR 4 LP 5 1 Leveler coil De-Energized leveler Energized restraint 6 6 R 9 P 5 7 RC BC Restraint Coil LP De-Energized Lower Energized to raise P R LP LP LR P P RR Item Description P R LP LR BC RC Pressure From Pump Return To Tank Presure To Logic Block Return From Logic Block Blind End of Powerstop Cylinders Rod End Of Powerstop Cylinder BC BC RC RC LR LR Item Quantity Part Number 1 2 3 4 5 6 7 2 1 1 1 3 2 1 8581-0011 8581-0112
PARTS Power Pack Assembly 10 BC RC 4 10 11 12 3 6 8 5 7 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 2 2 2 1 1 1 1 1 1 REF 1 1 1 2101-0017 2101-0140 2401-0001 2751-0016 3051-0058 9301-0221 9391-0040 9391-0012 9391-0013 9904-0119 8581-0117 8581-0118 1751-0149 * 14 Description 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 45 Deg, #4 ORB #4 JIC Powerppac-PStop, 1PH-115V-1/4HP-1GPM Powerppac Mounting Weldment Cove
Electrical Control Box Generic Drawings shown Provide serial number for specific drawings 28 4111-0014 — July 2013
Electrical Ladder Diagram Generic Drawings shown Provide serial number for specific drawings 4111-0014 — July 2013 29
PARTS Outside Signs A Item Quantity Part Number A 1 1751-0033 B 1 1751-0034 30 B 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 — July 2013
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 4111-0014 — July 2013 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 Description Complete Light Housing, Yellow Plastic, LED Lights Complete Light Housing, Yellow Plastic, Incandescent Lights Light Housing Only, Yellow Plastic Lens Red, for use with incandescent bulbs Lens Green, for use with incandescent bulbs L
NOTES A O P E R AT I N G ! DANGER INSTRUCTIONS Read and follow all instructions, warnings and maintenance schedules in the manual and on placards. Vehicle restraint operation and servicing is restricted to trained personnel. Before using the vehicle restraint: Remove any debris, snow or ice that may obstruct vehicle restraint operation. Alert personnel in the area of potential vehicle restraint operation and ensure area is clear.
MISCELLANEOUS Customer Information A NOTE: Refer to illustration for left/right orientation of dock leveler and vehicle restraint. The model/serial number decal (A) is located on the right platform joist near the front (lip) of dock leveler. The Vehicle Restraint serial number is located on the left side of the bellows shroud. When you receive your PowerStop Vehicle Restraint, write down the Vehicle Restraint and Dock Leveler serial number (if applicable) in the form provided.
STANDARD PRODUCT PRODUCT WARRANTY WARRANTY STANDARD SYSTEMS, INC. INC. warrants warrants that that its its products products will will be be free free from from defects defects in in design, design, materials materials and and workmanship workmanship SYSTEMS, for a period of one (1) year from the date of shipment. All claims for breach of this warranty must be be for a period of one (1) year from the date of shipment.
