SYSTEMS, INC. • W194 N11481 McCormick Drive • Germantown, WI 53022
800.643.5424 • fax: 262.257.7399 • www.docksystemsinc.com • techservices@docksystemsinc.com
PowerStop
Truck Restraint
Owner’s Manual
Printed in U.S.A.
Copyright
© 2006
Manual No. 4111-0014
Sept. 2007
6 3/8”
29 ½”
12”
8”
11 3/8”
16 7/8”
Page
Safety
Recognize Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General Operational Safety Precautions . . . . . . . . . . . . . . . . . . . . . . 1
Operational Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Introduction
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation
Install Control Panel and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operation
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Troubleshooting
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Troubleshooting
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Parts
Mechanical PowerStop Components . . . . . . . . . . . . . . . . . . . . . . . . 18
Hydraulic PowerStop Components . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Powerpack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Power Stop with Leveler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Outside Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Outside Light Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Miscellaneous
Customer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
Table of Contents
4111-0014 — November 2006
Sept 2007
1
SAFETY
4111-0014 — November 2006
Sept.2007
Recognize Safety Information
Read and understand the operating instructions and
become thoroughly familiar with the equipment and
its controls before operating the dock leveler or truck
restraint.
Never operate a dock leveler or truck restraint while a
safety device or guard is removed or disconnected.
Never remove DANGER, WARNING, or CAUTION
signs or decals on the equipment unless replacing
them.
General Operational Safety
Precautions
Do not start the equipment until all unauthorized
personnel in the area have been warned and have
moved outside the operating zone.
Remove any tools or foreign objects from the
operating zone before starting.
Keep the operating zone free of obstacles that could
cause a person to trip or fall.
The use of the word DANGER signifies the
presence of an extreme hazard or unsafe practice
which will most likely result in severe injury or
death.
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.
The use of the word WARNING signifies the
presence of a serious hazard or unsafe practice
which may result in serious injury or death.
IMPORTANT
The use of the word IMPORTANT is to draw
attention to a procedure that needs to be followed
to prevent machine damage.
The use of the word CAUTION signifies possible
hazard or unsafe practice which could result in
personal injury.
Op
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2
SAFETY
4111-0014 — November 2006
Sept 2007
Learn the safe way to operate this equipment. Read and understand the
manufacturer's instructions. If you have any questions, ask your supervisor.
Operational Safety Precautions
Stay clear of dock leveling device when freight
carrier is entering or leaving area.
Do not move or use the dock leveling device if
anyone is under or in front of it.
Keep hands and feet clear of pinch points. Avoid
putting any part of your body near moving parts.
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.
Do not use a broken or damage dock leveling
device. Make sure proper service and
maintenance procedures have been performed
before using.
Make sure lip overlaps onto trailer at least 4 in.
(102 mm).
Keep a safe distance from both side edges.
3
SAFETY
4111-0014 — November 2006
Sept.2007
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.
4
SAFETY
4111-0014 — November 2006
Sept 2007
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.
ALWAYS stand clear of dock leveler lip when
working in front of the dock leveler. Failure to do
this may result in serious personal injury or death.
DO NOT grind or weld if hydraulic fluid or other
flammable liquid is present on the surface to be
ground or welded
DO NOT grind or weld if uncontained hydraulic fluid
or other flammable liquid is present. Stray sparks
can ignite spills or leaks near the work area.
Always clean up the oil leaks and spills before
proceeding with grinding or welding.
Always keep a fire extinguisher of the proper type
nearby when grinding or welding.
Failure to follow these instructions may result in
serious personal injury or death.
Always post safety warnings and barricade the
work area at dock level and ground level to
prevent unauthorized use of the unit before
maintenance is complete.
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.
Access under the dock leveler may be required to
service the truck restraint. The maintenance prop
must be in the upright "service" position when
working under the dock leveler. For maximum
protection, use an OSHA approved locking device
to lock the maintenance prop in the service
position. Only the person servicing the equipment
should have the key to unlock the device.
5
4111-0014 — November 2006
Sept.2007
INTRODUCTION
General Information
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
PowerStop A-ML
Automatic PowerStop
Manual Lights
PowerStop A-AL
Automatic PowerStop
Automatic Inside and Outside Lights
Note:
All PowerStop models with the standard two level
restraint hook have the same service range of 12” to
29-1/2” (304.8 mm to 749.3 mm)
With the optional Low Profile restraint hook the
service range is 10” to 27-1/2” (254 mm to 698.5 mm)
Call Systems, Inc. to discuss available options to
meet your specific needs.
The Automatic (hydraulic) PowerStop series truck
restraint comes equipped with an electrical control
panel, which allows push button operation of the
truck restraint functions. Each PowerStop dock truck
restraint unit and control panel has been factory
prewired and tested to ensure satisfactory operation.
To illustrate which connections are to be made in the
field at installation, electrical drawings are included
with each order or by contacting Systems, Inc.
Technical Services.
Once again, thank you and congratulations on your
purchase of a Systems, Inc. truck restraint.
PowerStop Stock Specifications
Congratulations on your choice of a Systems, Inc.
truck restraint. This manual covers the PowerStop
series hydraulic dock truck restraint.
Designed by Systems, Inc. to be a marvel of
simplicity and efficiency, your truck restraint, when
properly installed, will provide many years of troublefree performance with an absolute minimum of
maintenance. To obtain maximum performance and
longest possible use, a simple program of preventive
maintenance is recommended.
6
4111-0014 — November 2006
Sept 2007
INSTALLATION DETAILS-AUTOMATIC POWERSTOP
POWERSTOP Overview
POWERSTOP Overview
STOP-TITE Overview
McGuire
LEVEL
11”
McGuire.
STOP-TITE Powerpack
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. Conduit and associated hardware to complete wiring and mounting of powerpack are to be supplied by others.
712 89 1414 6
A
11 10
AAL
3
4 1
5
SECTION "A-A"
DESCRIPTIONNOTE
CONNECT TO BASE END OF RELEASE CYL.BC
A
QTYITEM DESCRIPTIONPART NO. SIZE
1431-0011
11
1431-0086
23
2101-0017
32
2101-0140
42
2751-0016
51
3051-0058
61
6431-0001
72
9301-0164
82
9391-0009
91
9392-0045
10 1
9393-0025
11 1
9904-0097
12 2
R513-0050
13 1
R598-0090
14 2
BILL OF MATERIAL
Connector - 2-Screw 3/8
Insulated Terminial 16-14 AWG
Hex Head Capscrew 3/8-16 UNC X 1
Lock Washer 3/8
Cover - J-Box 4X 4
Capacitor - Motor Start 64-77mF- 330V
Grommet 1-3/8 OD X 3/4 ID
Fitting Conn Str Thrd #4 ORB X #4 JIC
STOP-TITE
Powerpac - PowerStop 1PH- 115V - 1/4 HP - 1 GPM
STOP-TITE
Cover - PowerStop B CAD
Powerpac Mounting Weldment B CAD
Hyd Hose Assy - 1/4"100R1 X 24.00 #4 JICF SWIVEL BOTH ENDS
Wire 16 GA RED X 5.00"
Split Flex Conduit 1/4" X 9.00"
Motor Blue
Motor Red
Capacitor Wiring Detail
13
2
6
RC BC
M
105
HYDRAULIC SCHEMATIC
R.V.SET @
650PSI
RC CONNECT TO ROD END OF RELEASE CYL.
7
4111-0014 — November 2006
Sept.2007
INSTALLATION DETAILS-AUTOMATIC POWERSTOP
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)
18”
Optional
Embed
Plate
27”
Low Pit Floor (Distance from pit floor to drive under 24”)
Anchor pit floor mounting plate (minimum 3/8” x 20”W x 8” D)
(Part #9414-0056) with four (4) (3/4”x 5 1/4” min.) wedge anchors.
Weld mounting plate to curb steel and back plate of PowerStop with
a continuous 1/4” fillet weld. Anchor back plate of PowerStop to
dock face with a minimum or (4) 3/4” x 5 1/4” wedge anchors
(Kit#2103-0003).
If <24”
5 1/4” minimum
Weld three sides of PowerStop back plate to the optional
Wall Embed Method
embed mounting plate (Part #7953-0119) with ten (10)
4” long 1/4” fillet welds.
20”
3/8”
20”
Cantilevered Dock (For bumper projection >4” or cantilevered dock or Edge-of-Dock leveler)
To determine size offset required, take total effective
bumper projection (bumper size plus any cantilever) and
subtract 4”.
Offset Formula
Dim. A Dim. B
Bumper Projection Cantelever
Offset
4" + Dim B
6" + Dim B
10" + Dim B
-4" = Offset
15" + Dim B
Dim. A
Dim. B
Driveway Mount Wall Mount
Determine offset
Dim. B
then proceed with
“Driveway Mount”
instructions below.
Dim. A
Dim. B
8” Min.
48”
Offset
For filler requirements from 1 ½”to 7
½” use cantilever bracket #9414-0052
and anchor cantilever bracket to the
dock face or
mounting plate (Part #7953-0119)
For filler requirements for 8 3/4” to 13
3/4” use cantilever bracket #94140053 and anchor cantilever bracket to
the dock face (3/4” Dia. X 5 1/4” min.)
weld to embedded
(Kit #2103-0004) or weld to
embedded mounting plate
(Part #9414-0052).
Driveway Mount (Recommended when dock face is unsuitable for PowerStop Mounting)
Adhesive Anchors Method Drive Embed Method
(Kit #9414-0058)
Install two (2) 1” Dia. adhesive
anchors into 1-1/8” Dia. x 7”
deep hole at rear of PowerStop.
Install two (2) 3/4”
Dia. x 5 1/4” min.
wedge anchor at
front of PowerStop.
Weld method
Properly locate and level the drive embed weld plate (Part#7953-
0059) in the drive approach. Observe Cantilever conditions for
proper positioning. Weld restraint to embed plate with a
continuous ¼” filet weld.
Bolt on Method
Properly locate and level the
drive embed plate
(Part#9414-0057) in the drive
approach. Observe cantilever
conditions for proper positioning.
Using the bolts included, bolt
the restraint to the embed plate.
(Rear)
1” Dia. X 6” min.
bolt
48”
Driveway mount requires
attachment to a concrete
drive greater than 8”
thick. For asphalt drive,
pour 48”x48”x8” (min.)
concrete pad and include
six (6) 3/4” dowels into
foundation wall. Then
proceed with adhesive
anchors or weld plate
embed.
8” Min.
27”
(Front)
3/4” Dia. X 6” min.
bolt
14”
8
4111-0014 — November 2006
Sept 2007
INSTALLATION DETAILS-MECHANICAL POWERSTOP
Optional DockAlert Communication System
POWERSTOP - Manual Restraint/Automatic DockAlert
Conduit must be protected from damage.
Conduit & connections must be liquid tight
if in area where liquid can be present
Conduit must be protected from damage.
Conduit & connections must be liquid tight
if in area where liquid can be present
MAL
Field wires:
L1,L2-115VacControl
Ground
Control assembly (by Poweramp)
1
L1 L2
Junction box at face of dock
Truc k re str ai nt
Limit switch (option)
Proximity switch
115
Vac
47
Common
Multiconductor cable
13
Ground
11 46
14
4722
11
Proximity Switch
Proximity Switch
Limit Switch (option)
Field wires:
11, 46 - Proximity - 115 Vac Control
47, 55 - Limit Switch Option - 115 VacControl
Ground
46
11
Blue
Brown
55
51
55
5048
Red Light
Green Light
Limit Switch (option)
Wires 47 & 55
(if used)
Ground
Field wires:
47, 55 - Limit Switch Option
- 115 Vac Control
Ground
GRD
Ground
Field wires:
2, 48, 51
115 Vac Control
Ground
Field wires:
2, 48, 51 - 115 Vac Control
Ground
POWERSTOP - Manual Restraint/Manual DockAlert
included with optional DockAlert Communciation Systems
MML
Field wires:
L1,L2-115VacControl
Ground
Control assembly (by Poweramp)
1 GRD
L1 L2
4722
115
Common
Vac
51
5048
Red Light
Ground
Green Light
Field wires:
2, 48, 51 - 115 Vac Control
Ground
Outside signal light assembly by Poweramp
Red
Light
2
White
48
Black
Green
Light
White
51
Black
Ground
9
4111-0014 — November 2006
Sept.2007
INSTALLATION DETAILS-MECHANICAL POWERSTOP
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)
18”
Optional
Embed
Plate
27”
Low Pit Floor (Distance from pit floor to drive under 24”)
Anchor pit floor mounting plate (minimum 3/8” x 20”W x 8” D)
(Part #9414-0056) with four (4) (3/4”x 5 1/4” min.) wedge anchors.
Weld mounting plate to curb steel and back plate of PowerStop with
a continuous 1/4” fillet weld. Anchor back plate of PowerStop to
dock face with a minimum or (4) 3/4” x 5 1/4” wedge anchors
(Kit#2103-0003).
If <24”
5 1/4” minimum
Weld three sides of PowerStop back plate to the optional
Wall Embed Method
embed mounting plate (Part #7953-0119) with ten (10)
4” long 1/4” fillet welds.
20”
3/8”
20”
Cantilevered Dock (For bumper projection >4” or cantilevered dock or Edge-of-Dock leveler)
To determine size offset required, take total effective
bumper projection (bumper size plus any cantilever) and
subtract 4”.
Offset Formula
Dim. A Dim. B
Bumper Projection Cantelever
Offset
4" + Dim B
6" + Dim B
10" + Dim B
-4" = Offset
15" + Dim B
Dim. A
Dim. B
Driveway Mount Wall Mount
Determine offset
Dim. B
then proceed with
“Driveway Mount”
instructions below.
Dim. A
Dim. B
8” Min.
48”
Offset
For filler requirements from 1 ½”to 7
½” use cantilever bracket #9414-0052
and anchor cantilever bracket to the
dock face or
mounting plate (Part #7953-0119)
For filler requirements for 8 3/4” to 13
3/4” use cantilever bracket #94140053 and anchor cantilever bracket to
the dock face (3/4” Dia. X 5 1/4” min.)
weld to embedded
(Kit #2103-0004) or weld to
embedded mounting plate
(Part #9414-0052).
Driveway Mount (Recommended when dock face is unsuitable for PowerStop Mounting)
Adhesive Anchors Method Drive Embed Method
(Kit #9414-0058)
Install two (2) 1” Dia. adhesive
anchors into 1-1/8” Dia. x 7”
deep hole at rear of PowerStop.
Install two (2) 3/4”
Dia. x 5 1/4” min.
wedge anchor at
front of PowerStop.
Weld method
Properly locate and level the drive embed weld plate (Part#7953-
0059) in the drive approach. Observe Cantilever conditions for
proper positioning. Weld restraint to embed plate with a
continuous ¼” filet weld.
Bolt on Method
Properly locate and level the
drive embed plate
(Part#9414-0057) in the drive
approach. Observe cantilever
conditions for proper positioning.
Using the bolts included, bolt
the restraint to the embed plate.
(Rear)
1” Dia. X 6”
min. bolt
48”
Driveway mount requires
attachment to a concrete
drive greater than 8”
thick. For asphalt drive,
pour 48”x48”x8” (min.)
concrete pad and include
six (6) 3/4” dowels into
foundation wall. Then
proceed with adhesive
anchors or weld plate
embed.
8” Min.
27”
(Front)
3/4” Dia. X 6”
min. bolt
14”
10
INSTALLATION
4111-0014 — November 2006
Sept 2007
1. Mount the push button control panel (B) so bottom
of control panel-to-dock floor distance (C) is 48 in.
(1219.2 mm).
2. Install electrical disconnect panel (A) if not already
installed. (Provided by others)
3. Install and connect the control wiring to the face
of the building as shown in installation.
4. Connect the dock leveler power cable to the field
wires in the pit junction box. Refer to the electrical
drawings supplied with the dock leveler.
5. After all electrical connections in the truck restraint
have been made, test the truck restraint function by
following the instructions in the “Put New PowerStop
Restraint Into Service” section on next page.
Install Control Panel and Wiring
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.
Failure to follow these instructions may result in
serious personal injury or death.
DO NOT make any final electrical connections until
all welding has been completed. Failure to do this
may result in serious personal injury or death.
If dock leveler is present. Always stand clear of
platform lip when working in front of the dock
leveler. Serious personal injury or death may result.
All electrical work — including the installation of the
disconnect panel, control panel, and final
connections — must be performed by a certified
electrician and conform to all local and applicable
national codes.
POWERSTOP Overview
For comprehensive installation
instructions of the Automatic
STOP-TITE (STOP-TITE ) read and
AAL
understand the Installation
and Operation Manual.
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.
Under The Dock Leveler
When under the dock location is used, make
certain to locate the powerpack where leveler
will not interfere in below dock conditions.
The routing of hydraulic and electrical lines
from the powerpack to the restraint are
best placed through min. 3” PVC (hydraulic)
and 3/4” conduit (electricl) chase during pit
construction.
Inside Building
Locate powerpck to minimize obstruction
potential. Hydraulic and electrical lines
from the Powerpack to the restraint are best
placed through min. 3” PVC (hydraulic) and
3/4” (electrical) chase during pit construction.
11
OPERATION
4111-0014 — November 2006
Sept.2007
4. Raise the PowerStop truck restraint fully by
pushing and holding the ENGAGE/LOCK button
on Automatic/Hydraulic units or pulling latch
release with the handle provided on the
Mechanical PowerStops. .
NOTE:
The restraint weldment should raise to the
top of the track, contacting the track stop..
NOTE:
PowerStops equipped with Automatic Lights
should have a Green light inside and Red
light outside when raised unless equipped
with optional upper limit switch. A visible or
audible alarm will signal the restraint
weldment has reached the top of the track
and may not have properly engaged the ICC
bumper, if present.
5
. Lower the PowerStop truck restraint fully by
pushing and holding the RELEASE/UNLOCK
button. The restraint weldment should lower fully
until the latch release is engaged.
NOTE:
PowerStops equipped with Automatic Lights
should have a Red light inside and green
light outside when the restraint weldment is
stored.
6
. If PowerStop truck restraint cannot properly
restrain the vehicle due to missing or defective
ICC (RIG) bar advise truck driver and dock
personnel. Truck/trailer must be secured against
movement by other methods. For levelers
interlocked with the truck restraint, turn the
selector switch to Bypass to allow use of the dock
leveler and proper light changes inside and
outside the building (where equipped with lights).
1. Disconnect the external lifting device and lifting
brackets.
2. Remove latch shipping bolt from latch mechanism
on both manual and hydraulic models. This
prevents PowerStop from raising.. .
3. Turn the main electrical power ON (Hydraulic
Only).
Operating Instructions
Once the PowerStop truck restraint has been
activated, the dock attendant must visually inspect
to assure that the restraint hook has properly
engaged the ICC (RIG) bar. Serious personal
injury or death may result.
Proper engagement occurs when the hook is able
to travel vertically, contacting the bottom edge of
the horizontal member of the ICC bar (RIG),
without obstruction.
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.
Only trained personnel should operate the dock
leveler and truck restraint.
DO NOT use a broken or damaged dock leveler or
truck restraint. Make sure proper service and
maintenance procedures have been performed on
leveler before using.
Truck/trailer wheels must be chocked unless the
truck restraint is used. Never remove the wheel
chocks until loading/unloading is finished and truck
driver has been given permission to leave.
Make sure platform lip rests on the truck/trailer bed
with at least 4 in. (102 mm) of overlap.
Maintain a safe distance from side edges of leveler
during the loading/unloading process.
Failure to follow these instructions may result in
serious personal injury or death.
12
Troubleshooting
4111-0014 — November 2006
Sept 2007
Mechanical Troubleshooting
Restraint weldment (hook) will not raise.
Problem
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. If trucks with lift gates back into restraint
front portion of hook weldment can be bent up or
down, causing slot to close and pin to bind.
6. Joints are permanently lubricated bushings and
should not require oiling, however, rubbing surfaces of
links should be lubricated per maintenance section of
this manual.
Restraint weldment (hook) will not lower.
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. If trucks with lift gates back into restraint
front portion of hook weldment can be bent up or
down, causing slot to close and pin to bind.
6. Joints are permanently lubricated bushings and
should not require oiling, however, rubbing surfaces of
links should be lubricated per maintenance section of
this manual.
7. Check to make sur truck has not moved forward,
wedging ICC (RIG) bar against restraint hook
weldment. Back truck up tight against bumper and
repeat unlock procedure.
Troubleshooting
13
4111-0014 — November 2006
Sept.2007
Problem
Hydraulic Troubleshooting
Possible Solution(s)
Restraint will not raise.
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. Check solenoid
valve to confirm it is closed at rest and opens when
coil activated.
Restraint moves very slowly.
1. Low hydraulic fluid. Add hydraulic fluid as needed.
2. Pump by-pass set too low. Pump by-pass
adjustment is internal to pump. consult factory.
3. Debris in horizontal or vertical track. Clean tracks
and re-test.
4. Scissors pins binding. Check for rust, lubricate as
needed. Check for bent weldment. Repair or replace
as needed.
Restraint moves in one direction only regardless of
button pushed.
1. Four way valve stuck in either position. Locate
solenoid coil. Check coil for cracks or bulging.
Remove coil from solenoid valve and valve from valve
block. Check solenoid valve for contaminant's and/or
damage, including o-rings. Replace solenoid valve if
damaged.
DO NOT over tighten valve in valve block or coil on
valve when reinstalling. Valve torque is 15 foot lbs
and coil nut is 15 inch lbs.
Replace spool valve if problem persists and all other
troubleshooting procedures have been performed.
14
4111-0014 — November 2006
Sept 2007
Restraint does not raise or lower - Motor does not
run, inside and outside lights do not work.
Troubleshooting
1. No voltage at control assembly. Check voltage
input.
2. Blown fuse inside control assembly. Use voltmeter
to test.
Electrical Troubleshooting
Line side of fuse is always hot. Turn off main power
supply before removing fuses. Attach proper lockout / tag-out devices.
3. Defective contact block at power selector switch.
Test with voltmeter.
4. Defective contactor. Use voltmeter to test voltage
coming in to contactor and going out of contactor
when contactor is activated.
5. Defective overload. Use voltmeter to test voltage
coming in to contactor and going out of contactor
when contactor is activated.
Restraint does not raise or lower-motor hums but
does not run, inside and outside lights work.
1. Voltage too low. Check for low voltage. Increase
wire size from main electrical panel to PowerStop
control panel to correct voltage drop.
2. Defective capacitor. Disconnect capacitor. Test.
Discharge capacitor before attempting a capacitor
test.
Restraint does not raise-motor runs in pressure relief,
inside and outside lights work.
1. Solenoid coil not electrically energizing. Check
coil for magnetism. use voltmeter to test voltage at
coil.
2. Solenoid valve mechanically stuck OFF. Remove
valve, inspect valve and block for contaminant's.
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.
Do not over tighten valve into block: 15 foot lbs
max which is enough to compress the washer and
prevent leakage.
Restraint does not raise-motor does not run, inside
and outside lights work.
1. Defective contact block at activated pushbutton.
Use voltmeter to test.
2. No voltage at motor. Use voltmeter to test voltage
at motor.
3. Thermal protector inside motor has tripped. Wait
for protector to reset.
Problem
Possible Solution(s)
15
4111-0014 — November 2006
Sept.2007
Troubleshooting
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.
Electrical Troubleshooting Continued
Restraint does not lower-motor does not run, inside
and outside lights work.
1. Obstruction activating stored limit switch.
Remove obstruction. Make sure limit switch
operates properly and light changes on limit switch.
NOTE: If equipped with outside signal lights, holding
screwdriver in front of switch and then removing
screwdriver will result in lights changing.
2. Defective limit switch. Use voltmeter to test
stored limit switch operation.
3. Defective control relay(s). Use voltmeter to test
voltage at relays(s) coil and to test relay(s) contact
operation or swap relays one at a time from known
working restraint control box to determine faulty
relay.
4. No voltage at motor. Use voltmeter to test voltage
at motor to determine if wiring is faulty.
5. Motor faulty. Test motor with with voltmeter.
Replace if necessary.
Lights do not work or lights do not work correctlyrestraint raises and lowers.
1. Defective bulb. Replace.
2. Obstruction preventing activation or deactivation
of stored limit switch. Remove obstruction. Test
switch for proper operation.
3. Defective stored limit switch. Use volt meter to
test switch.
4. Defective control relay. Use voltmeter to test
voltage at relay coil and to test relay contact
operation.
5. Defective contact block(s) at light control selector
(or key) switch. Test with voltmeter.
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.
Problem
Possible Solution(s)
MAINTENANCE
Periodic Maintenance
To ensure normal operation of the dock leveler and
truck restraint, use only aircraft hydraulic fluid
designed to meet or exceed military specification
MIL-L-5606. It is recommended that the following
hydraulic fluids be used:
• Flomite 530 ZF
• Aero Shell Fluid 4 or Fluid 41
• Mobile Aero HFA Mil-HS606A or Aero HF
• Texaco Aircraft Hydraulic Oil 15 or 5606
• Exxon Univis J13
These fluid brands can be mixed together. Mixing with
fluids that do not meet or exceed MIL-L-5606 may
damage the equipment and WILL void warranty. Use
of hydraulic fluids with equivalent specifications to
those listed here are acceptable.
A— Scissors Assembly
B— Hook Weldment
C— Rear Vertical Track
D— Rear Track Assist Spring
E— Platform Hinge Area
F— Bottom Slide Track
G — Bellows
H— Main Springs
J— Pin
K— E-Clip
L —Bearing
IMPORTANT
Use of fluids that do not have equivalent
specifications to those in the following list will result
in abnormal operation of the dock leveler and
voiding of warranty.
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.
4111-0014 — November 2006
Sept 2007
16
A
B
C
E
D
K
F
L
H
L
G
J
MAINTENANCE
Daily Maintenance
• Daily patrol truck restraint area and clear any
debris to prevent operation issues.
• Check inside and outside lights for proper
operation
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. Build-up
of foreign material in the track areas will cause
abnormal operation.
Clear all dirt and debris from the track areas to
insure proper scissor operation and hook weldment
travel.
NOTE: To thoroughly inspect and clean the scissors
and track areas raise the restraint, remove
two bolts (L), pull shroud & bellows forward to
expose scissors and frame tracks,
Make sure Rear Track Assist Spring (D) is properly
seated at the bottom of the rear track.
NOTE: Rear Track Assist Spring is different part
number for mechanical and hydraulic
PowerStop truck restraint
• Lubricate the following areas with light weight
machine oil:
(A)— Scissor pins and bearings (J&L-all)
M — Reservoir
N —1 in. (25.5 mm) (From Top of
Reservoir)
P — Breather Cap
Q — Fluid Level
• Check reservoir fluid level (Q):
1. Put the truck restraint in the stored position.
2. Turn OFF all electrical power to the truck
restraint..
3. Wipe off plastice tank as needed (P).
4. Measure fluid level. The fluid level should be
approximately 1 in. (25.5 mm) (N) from top of
reservoir (M) with truck restraint stored.
5. Add hydraulic fluid if necessary. Use only
recommended fluid. See previous page.
.6 Install cover
7.Turn ON electrical power.
IMPORTANT
Failure to clean and properly lubricate the truck
restraint will cause abnormal operation.
IMPORTANT
A low fluid level or the use of hydraulic fluids not
equivalent to the fluid types recommended, will
cause abnormal operation of the leveler and WILL
void warranty.
M
N
Q
P
4111-0014 — November 2006
Sept.2007
17
Quarterly Maintenance
PART S
PowerStop M (Mechanical) Parts Breakdown
4111-0014 — November 2006
Sept 2007
18
19
14
18
12
26
11
30
24
21
28
22
7
8
2
20
5
10
4
23
27
2
9
29
17
15
25
13
6
3
16
PART S
PowerStop M (Mechanical) Parts Breakdown
4111-0014 — November 2006
Sept.2007
19
Item Quantity Part Number Description
1 1 0191-0025 Bellows W/ 1 X 13=1/2 Velcro Strips
2 1 0941-0015 Spring, 1-7/8 DIA X 6.00
3 1 0615-0037 Stored Limit Switch with Bracket, NC
4 1 1751-0444 Decal-Systems, Inc./Powerstop, 3-3/4 X 14-1./2
5 1 1751-0010 Decal-Serial Number
6 1 1751-0135 Decal-Warning
7 2 2101-0009 HHCS-Grade 2-Zinc Plated, 5-16-18 UNC X 3/4
8 8 2101-0084 HHCS-Grade 5-Zinc Plated , 1/4-20 UNC X 3/4
9 1 2101-0085 Washer-Flat-Zinc Plated, 1-1/8 DIA
10 8 2101-0143 Nylon Lock Nut, 1/4-20 UNC
11 2 2101-0150 RHMS-Slotted, 10-24 UNC X 2-1/4
12 2 2101-0151 Nylon Lock Nut, #10-24 UNC
13 1 2101-0165 Shoulder Bolt,1/2 DIA X 5/8
14 8 2101-0189 E-Clip, 1/2
15 2 2101-0212 Flat Head Cap Screw, 1/2-13 UNC X 1
16* Anchor Kit
17 1 5455-0005 Level Weldment-Release
18 2 9202-0042 Pin-Pivot-Long, 1/2 DIA
19 2 9202-0043 Pin-Pivot-Short, 1/2 DIA
20 1 9411-0028 Shroud-Bellows Mounting-Pstop
21 2 9412-0161 Tube, 1-1/4 OD X 9-16 ID X 5/8
22 1 9412-0201 Bar-Bellows Mounting-Front
23 2 9412-0202 Bar-Bellows Mounting-Side
24 2 9412-0215 Bar-Bellows Mounting
25 1 9413-0049 Restraint Weldment-Pstop-Standard Profile-2 Stage
26 1 9413-0062 Scissor Lift Sub-Assembly-Pstop.
27 1 9413-0068 Spacer Assembly-Pstop Mechanical
28 1 9413-0070 Release Lever Assembly-Pstop Mechanical
29 1 9413-0087 Hook Stop-27”-Pstop
30 1 9414-0046 Final Base Weldment-27”-Pstop
* 2103-0006 Anchor Kit Drive Mount
* 2103-0003 Anchor Kit Wall Mount
PART S
PowerStop A (Hydraulic) Parts Breakdown
4111-0014 — November 2006
Sept 2007
20
PART S
Item Quantity Part Number Description
1 1 0191-0025 Bellows W/ 1 X 13=1/2 Velcro Strips
2 1 0524-0063 HYD Cylinder ASM, 1” Stroke
3 1 0524-0064 HYD Cylinder ASM, 5-3/4” Stroke
4 1 0615-0037 Stored Limit Switch with Bracket, NC
5 1 1751-0444 Decal-Systems, Inc./Powerstop, 3-3/4 X 14-1./2
6 1 1751-0010 Decal-Serial Number
7 2 2101-0009 HHCS-Grade 2-Zinc Plated, 5/16-18 UNC X 3/4
8 1 2101-0039 Nylon Lock Nut,5/16-18 UNC
9 8 2101-0084 HHCS-Grade 5-Zinc Plated, 1/4-20 UNC X 7/8
10 1 2101-0098 HHCS-Grade 5-Zinc Plated, 5/16-18 UNC X 1-3/4
11 8 2101-0143 Nylon Lock Nut, 1/4-20 UNC
12 2 2101-0150 RHMS-Slotted, 10-24 UNC X 2-1/4
13 2 2101-0151 Nylon Lock Nut, #10-24 UNC
14 1 2101-0163 Washer-Flat-Zinc Plated, 1/2 DIA X 5/8
15 1 2101-0165 Shoulder Bolt, 1/2 DIA X 5/8
16 1 2101-0187 HHCS-Grade 5, 5/16-18 UNC X 1
17 1 2101-0188 HHCS-Grade 5, 5/16-18 UNC X 1-1/4
18 8 2101-0189 E-Clip, 1/2”
19 2 2101-0202 RHMS-Phillips, 10-32 UNF X 1-3/4
20 2 2101-0212 Flat Head Cap Screw, 1/2-13 UNC X 1
21@ 1 Anchor Kit
22 2 9202-0042 Pin Pivot Long, 1/2 DIA
23 2 9202-0043 Pin Pivot Short, 1/2 DIA
24 1 9411-0024 Shroud-Cylinder, 1/16 X 2-1/16 X 4-1/2 X 6
25 1 9411-0028 Shroud-Bellows Mounting-Pstop
26 2 9412-0161 Tube, 1-1/4 OD X 9/16 ID X 5/8
27 1 9412-0201 Bar-Bellows Mounting-Front, Painted-1/8 X 1 X 7
28 2 9412-0202 Bar-Bellows Mounting-Side, Painted-1/8 X 1 X 23
29 1 9412-0215 Bar Bellows mounting, Painted-1/8 X 1 X 13
30 1 9413-0055 Restraint Weldment-Pstop-Low Profile
31 1 9413-0062 Scissor Lift Sub-Assembly-Pstop
32 2 9413-0069 Spacer Assembly-PStop-A
33 1 9413-0071 Release Lever Assembly
34 1 9413-0087 Hook Stop-27” Powerstop
35 1 9414-0046 Final Base Weldment-27”-Pstop
36 1 9904-0097 Hydraulic Hose ASM-1/4” 100R1 X 24”, #4 JICF Swivel Both Ends
37 1 9904-0119 Hydraulic Hose, 1/4” 100R1 X 96”, #4 JICF Swivel Both Ends
* 1 0522-0002 Spring, Helper, Rear Frame (Not Shown)
@ 2103-0006 Anchor Kit Drive Mount
@ 2103-0003 Anchor Kit Wall Mount
PowerStop A (Hydraulic) Parts Breakdown
4111-0014 — November 2006
Sept.2007
21
PART S
Power Pack Assembly
4111-0014 — November 2006
Sept 2007
22
Amp Draw 4.8- 5.2
PART S
Power Pack Assembly
Item Quantity Part Number Description
1 1 1431-0011 Connector-2 Screw, 3/8
2 3 1431-0086 Insulated Terminals, 16-14 AWG
3 2 2101-0017 HHCS-Grad 2-Zinc Plated, 3/8-16 UNC X 1
4 2 2101-0140 Lock Washer, 3/8
5 2 2401-0001 Grommet, 1-3/8 OD X 3/4 ID
6 1 2751-0016 J-Box Cover, 4 X 4
7 1 3051-0058 Capacitor-Motor Start, 66-77mf-330V
8 1 9301-0164 Fitting Connector Straight Thread, #4 ORB #4 JIC
9 1 9391-0009 Powerpack-PStop, 1PH-115V-1/4HP-1GPM
10 1 9391-0012 Powerpack Mounting Weldment
11 1 9391-0013 Cover-Pstop
12 REF 9904-0119 Hydraulic Hose ASM-1/4” 100R17 X 96, #4 JICF Swivel Both Ends
13 1 R513-0050 Wire, 16 GA Red X 5.00
14 2 R598-0090 Split Flex Conduit, 1-4 X 9.00
* Hose Lengths Vary by Job
BC = Blind End of Cylinder
4111-0014 — November 2006
Sept.2007
23
RC = Rod End of Cylinder
24
4111-0014 — November 2006
Sept 2007
PART S
Power Stop Valve Combined With Leveler
25
4111-0014 — November 2006
Sept.2007
NOTES
PART S
4111-0014 — November 2006
Sept 2007
26
Outside Signs
Item Quantity Part Number Description
A 1 1751-0133
SIGN,PULL IN/OUT ON GREEN ONLY
RIGHT READING,16-7/8x8x3/32
B 1 1751-0134
SIGN,PULL IN/OUT ON GREEN ONLY
MIRROR IMAGE,16-7/8x8x3/32
B
A
PART S
OSLA (Outside Light Assembly)
Item Quantity Part Number Description
1-7 1 3055-0008 Complete Light Housing, Yellow Plastic, LED Lights
1-7 1 3055-0002 Complete Light Housing, Yellow Plastic, Incandescent Lights
1 1 3051-0002 Light Housing Only, Yellow Plastic
2 1 3051-0064 Lens Red, for use with incandescent bulbs
3 1 3051-0065 Lens Green, for use with incandescent bulbs
* 2 3051-0085 Lamp, 25W,120V,Incandescent, BAY (Rated 1000 Hours)
* 2 3051-0066 Socket Harness for Incandescent Lamp
2 1 3051-0102 Lens/Housing/Circuit Assembly Red-LED
3 1 3051-0103 Lens/Housing/Circuit Assembly Green-LED
4 1 3051-0068 Mounting Gasket
5 4 3051-0105 Clips, Lens Holding
6 4 3051-0104 Screw, Lens Holding Clip
7 1 x Conduit Fastener, 3/4” x 3/8”
4111-0014 — November 2006
Sept.2007
27
NOTES
4111-0014 — November 2006
Sept 2007
28
This Page Intentionally Left Blank
MISCELLANEOUS
Customer Information
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. This
will help ensure safe keeping of the numbers in the
event the model/serial number decal (A) becomes
lost or damaged.
Also, write down Systems, Inc.’s job number (found
inside the control box door on a white sticker), the
company that installed the dock leveler, and the
original owner’s name. This will all help to identify the
specific dock leveler if more information is required.
When ordering, use part numbers and description to
help identify the item ordered. Do not use “item”
numbers. These are only for locating the position of
the parts. Always give dock leveler MODEL NUMBER
and/or SERIAL NUMBER.
For service, call or contact:
Systems, Inc.
P.O. Box 309
Germantown, WI 53022
Phone: (800) 643-5424
Fax: (262) 257-7399
Truck Restraint Information
Model ___________________________________
Serial No. ________________________________
Systems, Inc., Job No. ______________________
Dock Leveler Information
Model ___________________________________
Serial No. ________________________________
Systems, Inc., Job No. ______________________
Original Owner Information
Name ___________________________________
Address _________________________________
________________________________
Installer Information
Name ___________________________________
Address _________________________________
_________________________________
Date of Installation ________________________
A
4111-0014 — November 2006
Sept.2007
29
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. truck restraints for a period of One (1) Year from date of shipment.
Specifically this guarantee applies to:
• Fluid valves and valve body control assembly
• All hydraulic cylinders
• Hydraulic pressure lines
• Hydraulic pump and motor.
The electrical components carry a One (1) year warranty.
In the event of any defect covered by this guarantee, Systems, Inc., will remedy
said defect by repairing or replacing all defective parts, bearing all of the costs for
parts, labor, and transportation.
All guarantee claims will be settled on a timely basis when defects are found to be
from other than improper installation, operating contrary to instructions or beyond
rated load capacities, abuse, careless or negligent use, or failure to maintain the
unit as recommended by the owner's manual.
There are no guarantees, either expressed or implied, including any implied
guarantees of merchantability or fitness for a particular purpose which shall extend
beyond the guarantee periods indicated above. This guarantee is valid only if the
unit(s) is unaltered from original condition as delivered from the factory and a
survey is completed by a Systems, Inc. representative.
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