POWERSTOP-A
TRUCK RESTRAINT
INSTALLATION AND
OPERATION MANUAL
Job Name
Job Number
Serial Numbers
SYSTEMS, INC.
P.O. BOX 309
Germantown, WI 53022
Phone 262-255-1510
Fax 262-255-4199
11/96-10598
Table of Contents
Safety ................................................................................................................... 1
Safety Alert Symbols ...................................................................................... 1
General Safety Precautions ............................................................................ 1
Introduction ........................................................................................................ 2-4
Installation ........................................................................................................ 5-10
Light and Sign Package ................................................................................ 10
Operating Instructions .................................................................................... 11-12
Automatic Light Control ................................................................................ 11
Manual Light Control ..................................................................................... 11
No Lights ...................................................................................................... 11
Preventative Maintenance .................................................................................... 13
Troubleshooting Guide .................................................................................... 14-17
Parts Lists ..................................................................................................... 18-23
WARNING
Safety
Safety Alert Symbols
This Safety Alert Symbol Means ATTENTION is Involved!
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.
WARNING
The use of the word Warning signifies the presence of hazards or unsafe practices
which could result in severe personal injury or death if instructions, including recommended precautions, are not followed.
Read these safety precautions before installing,
operating or servicing the
truck restraint. Failure to
follow the safety practices
could result in serious injury
or death.
CAUTION
The use of the word Caution signifies possible hazards or unsafe practices which could
result in minor injury, product or property damage if instructions, including recommended precautions, are not followed.
General Safety Precautions
1. Do not operate this equipment until you read and understand the
operating instructions and become thoroughly familiar with the
equipment and its controls.
2. Never operate a machine while a safety device or guard is removed or
disconnected.
3. Never remove Warning or Caution signs or decals on the equipment
unless they are to be replaced.
4. Do not start the equipment until all other personnel in the area have been
warned and have moved outside the operating zone.
5. Remove any tools or other foreign objects from the operating zone before
starting.
6. Keep operating zone free of obstacles that could cause a person to trip
or fall.
7. If so equipped, know EMERGENCY STOP procedures before
operating.
8. Hydraulic and electrical power must be off when servicing equipment.
Note: For maximum protection, all power sources should be locked out
using a lock for which only you have the key. This prevents anyone
from accidentally turning on the power while you are servicing the
machine.
9. Keep alert and observe indicator lights and audible alarms.
10. Do not operate faulty equipment. Make certain proper service and
maintenance procedures have been performed.
11. Avoid placing fingers, hands, or any part of your body near moving parts.
1
Introduction
The Automatic Truck Restraint is a hydraulically activated vehicle restraint
that is upwardly biased when activated. Two hooking ranges allow
engagement with ICC bars that are positioned 7" to 11" from the bumper
face and 12-1/2" to 30" off the drive approach. By rigidly mounting the
restraint to a concrete pad or drive approach, restraining forces in excess
of 22,800 pounds can be achieved. Automatic Truck Restraints may also
be equipped with light communication packages that can be operator
controlled or automatic.
Operation of the restraint is from atop the dock. With the truck positioned
squarely against the bumper, the dock attendant depresses the "Activated" pushbutton to activate the vehicle restraint. Twin extension springs,
in conjunction with a hydraulic cylinder, raise the hook vertically to meet
the ICC bar. The hook maintains positive contact with the ICC bar as the
trailer moves vertically during loading and unloading operations. To
release the vehicle (restore the restraint), the dock attendant depresses
the "Stored" pushbutton. The restraint will then lower until the storage
latch is engaged.
Visual confirmation of the restraint engagement to the ICC bar is required.
If the vehicle restraint cannot engage the trailer, the operator must chock
the trailer tires. If equipped with lights, the operator must manually select
the Bypass position on the control panel to assure proper light signals.
WARNING
Operating range of restraint
should be clear of personnel
at all times.
CAUTION
To prevent personal injury
always operate the truck
restraint from atop the
dock.
WARNING
When the loading/unloading operation is completed, the light control
switch must be switched back to the automatic position.
An integral brush shroud is utilized in the design to protect the activation
mechanism from damage and minimize the collection of debris.
Never service a trailer that
is not safely secured to
the dock.
2
WARNING
Barricade the work area to
prevent unauthorized use of
the unit before installation
has been completed.
Introduction
This manual covers the Automatic Truck Restraint manufactured by Systems, Inc..
Read the entire manual before installing and/or operating the truck restraint. Auto-
matic Truck Restraints were designed to be compatible with almost all dock designs.
See Figures 1 and 2.
WARNING
Be sure power supply
circuit is opened at main
service box or circuit
breaker box prior to electrical installation. Failure to
disconnect power supply
could result in equipment
damage and/or personal
injury or death. Always
follow proper lockout tagout
procedures.
CAUTION
Have all electrical work
performed only by qualified
electricians.
Pit Style Leveler
Figure 1
Edge of Dock
Figure 2
WARNING
Do not grind or weld if
hydraulic fluid or other
flamable liquids are present.
Always keep a fire extinguisher of the proper type
nearby.
Automatic Truck Restraints can be accompanied by
a Dock Alert II light communication package and
sign kit. When installed and operated properly, the
restraint will allow the dock attendants to create a
safer work evironment in which to work.
Operation of the restraint is from atop the dock.
Figure 3
3
Introduction
Red
Light
Restraint Stored
Figure 4
Green
Light
Restraint Activated
Restraint Activated
Figure 5
Red
Light
Restraint Stored
Figure 6
Green
Light
Red
Light
CARGO
PALLET
Red
Light
When not in use, the restraint must be kept in
the stored position. If equipped with lights, the
light selector switch should be in the automatic
position. When the restraint is stored, the
outside signal light is Green and the inside light
is Red. See Figure 4.
When the restraint is activated or in use and if
equipped with lights, the outside signal light is
Red and the inside light is Green. See Figure 5.
CARGO
PALLET
When no ICC bar is present or when the restraint
is unable to successfully engage the ICC bar, the
outside light, if equipped with a Dock Alert II light
communication package can be changed to Red
by switching the light control switch to Bypass.
When in Bypass, the inside light & outside light
are both Red whether the restraint is stored or not
stored. See Figure 6.
CAUTION
Always store restraint when
not in use to prevent
damage.
WARNING
Read and understand
operating instructions
before operating.
CAUTION
Do not operate truck
restraint or dock leveler until
you read and understand
the operating instructions
and become fully familiar
with the equipment and its
controls.
WARNING
Operation of the restraint is from atop the dock. Pushbutton controls allow the dock
attendant to activate and store the restraint. To insure safety in and around the
loading dock, dock attendants must perform the following tasks:
1. The dock attendant must activate the Automatic Truck Restraint from the
control box located atop the dock. The dock attendant simply depresses the
"Activated" pushbutton to raise the restraint.
2. Once the restraint has been activated, the dock attendant must visually
inspect to assure that the hook has properly engaged the ICC bar. Proper
engagement occurs when the hook is able to travel vertically, contacting the
bottom edge of the horizontal member of the ICC bar, without obstruction.
Any missing, bent or mislocated ICC bars that do not allow for this
vertical travel and/or contact are to be considered improperly engaged.
When this condition occurs, it is imperative that the proper personnel,
especially the truck driver, be advised. The truck/trailer must also be
secured by another method to insure safety. The restraint must be stored
and, if equipped with a Dock Alert II light communication package, the
selector switch (on the control box) must be turned to the bypass position
during loading/unloading. After the loading/unloading process is complete,
the switch must be turned back to automatic. See Figure 3.
4
If truck restraint does not
engage ICC bar, turn
operation switch to Bypass
and securely chock truck/
trailer wheels. Failure to
follow these instructions
could result in serious
personal injury or death.
WARNING
Check to make sure truck
restraint hook is engaged
with ICC bar before loading
end loads. If restraint has
been disengaged by dock
leveler lip, chock truck
wheels before loading end
loads.
Installation
WARNING
Barricade the work area to
prevent unauthorized use of
the unit before installation
has been completed.
WARNING
Be sure power supply
circuit is opened at main
service box or circuit
breaker box prior to electrical installation. Failure to
disconnect power supply
could result in equipment
damage and/or personal
injury or death.
CAUTION
Have all electrical work
performed only by qualified
electricians.
WARNING
These installation instructions were written to guide you during the installation
process. Please read and familiarize yourself with all sections of this manual prior to
starting the installation. If you have questions about the installation or operation of
the Automatic Truck Restraint, please consult the factory at (414) 255-1510 before
proceeding.
Open and inspect all material upon delivery. Check contents against packing slip.
Report any damage or shortages immediately to the truck line responsible.
Gather all material required for installation of restraint. Anchor kit Part #2103- 0001
supplied with the restraint consists of the following:
Item Qty. Part # Description
1 2 2101-0174 Rod 1" - 8UNC GR5 x 12
2 2 2101-0175 Nut 1" - 8UNC GR5
3 6 2101-0108 Anchor 5/8" x 5" RAWL #6944
4 2 2101-0086 Washer
Additional material required to complete the restraint installation not supplied by
Systems, Inc. consist of the following:
Item Qty. Part # Description
1 1 2101-0177 Adhesive cartridge Rawl# 8403
2 1 2101-0178 Nozzle Rawl# 7908
3 1 2101-0179 Injection tool Rawl# 8406
4 1 N/A 1" nylon bottle brush
5 2 N/A Anchor 3/8" as required by applica
tion.
Do not grind or weld if
hydraulic fluid or other
flamable liquids are present.
Always keep a fire extinguisher of the proper type
nearby.
Items listed above with System, Inc. part numbers may be purchased separately.
Each adhesive cartridge should be adequate to install two restraints. Nozzles are
not reusable.
1. Correct installation of the Automatic Truck Restraint requires attachment to a
concrete drive greater than 6" thick. If other conditions exist, such as
asphalt, a 48" wide by 48" long x 8" deep pad using a minimum of 4000 psi
concrete must be poured.
2. Because of the restraint’s unique design, its mounting location is referenced
off the bumper face. This insures its compatibility with almost all dock
designs. Properly installed bumpers, in good repair, are essential to a safe
dock. If inspection of bumpers shows them to be missing, damaged or
severely worn, contact your Poweramp representative to obtain replacements.
3. Position the Automatic Truck Restraint in the center of the dock/door
opening with the primary (1") anchor holes located 1/2" ahead of the bumper
face as shown in Figure 7. After locating and marking the primary anchor
locations (qty. 2) on the drive surface, drill 1-1/8" diameter holes 7 to 7-1/2"
deep. If drill breaks through concrete at a depth of less than 6", consult
factory. The remaining (6) 3/4" anchor holes can be drilled at this time.
5
Plumb line
1" Main Anchors
Figure 7
4. Preparation of the anchor hole is necessary to assure a
long lasting installation. Prepare the 1-1/8" diameter
holes in the following manner:
Installation
WARNING
Proper safety apparal
should be worn when
installing the truck restraint.
A. Blow the hole clean with compressed air, brush out
using 1" nylon brush, blow clean again. Holes
should be clean and sound. They may be dry or
damp, but should be free of standing water or frost.
Be sure rod fits into hole. If larger hole is required,
the diameter should be as close as possible to the
rod diameter.
B. Fill the hole approximately half way with adhesive
mortar starting from the rear of the hole. Slowly
withdraw the nozzle as the hole fills to avoid creating
air pockets within the hole.
C. Push the threaded rod into the hole while turning
slightly to insure positive distribution of the adhesive
mortar. Be sure rod is fully seated at the bottom of
the hole and that the mortar has flowed from the top
of the hole. If an insufficient amount of adhesive is
placed in the hole, indicated by a lack of filling to the
top of the hole when the rod is inserted, the rod must
be extracted, additional adhesive added and rod
reinserted. The threaded rod used must be free of
dirt, grease, oil or other foreign material. Allow the
adhesive mortar to cure for the time specified in chart
prior to applying any load. See Figure 10. Do not
distribute or load the anchor until it is fully cured.
Handling can be simplified and line up insured if restraint is
positioned over holes before rods are inserted for the final time.
After adhesive has cured, adjust restraint using a bubble level, so
the back is perpendicular. Shim under bottom as needed.
6
Figure 8
Installation
Install remaining six anchors using the following
procedure:
Using the proper diameter bit, drill a hole into the
drive approach to a depth of at least 1/2" or one
anchor diameter deeper than the embedment
required. The tolerances of the drill bit used
should meet ANSI Standard B94.12.
Blow the hole clean of dust and other material.
Remove the inspection tag from the anchor and
position the fixture. Do not expand the anchor
prior to installation.
Drive the anchor through the fixture into the
anchor hole until the bolt head is firmly seated
against the fixuture. Be sure the anchor is driven
to the required embedment depth.
Tighten the anchor by turning the head 3 to 4
turns.
Figure 9
Figure 10
7
Installation
INSTALLATION OF ELECTRICAL COMPONENTS
When equipped with a Dock Alert II light communication package, the Automatic
Truck Restraint includes a prewired control box, outside light box, and (2) outside
truck driver signs and a hydraulic power unit. Components such as conduit, fittings,
anchors, etc. are supplied by others. Quality workmanship using materials approved
by code is required.
A typical installation will require mounting of the outside light box as shown in Figure
11. The control box mounting is generally inside the building on the left hand side of
the overhead door.
Figure 11
CAUTION
Have all electrical work
performed only by qualified
electricians.
WARNING
Be sure power supply
circuit is open at main
service box or circuit
breaker prior to electrical
installation. Failure to
disconnect power supply
could result in equipment
damage and/or personal
injury or death. Always
follow proper lock out tag
out proceedures.
The location of the powerpack will vary from job to job. Figures 12 through 14 illustrate
several possible locations for the powerpack. when determining a suitable location for
the Powerpack, many things must be considered.
• Is the dock subject to flooding?
• Is the powerpack subject to truck/trailer damage?
• Is the powerpack subject to fork truck damage?
• Is snow removal a concern?
• Will the moving parts of a dockleveler damage the restraint?
Figure 12 illustrates a
powerpack mounting
location on the dock face.
In this location, flooding,
snow removal and damage
from trailer/trucks should
be considered.
Figure 12
8
Figure 13 illustrates a mounting
location on the inside building wall.
In this location, damage from fork
trucks must be considered. The
routing of hydraulic and electrical
lines from the powerpack to the
restraint must be determined.
Installation
Figure 13
Figure 14 illustrates a mounting
location under a dockleveler. In this
location, damage from the moving
dockleveler parts must be considered.
The routing of hydraulic and electrical
lines from the powerpack to the
restraint must be determined.
Figure 14
11-1/4"
3/8" Anchors (2)
6"
12-5/8"
10-5/8"
Figure 15
9
Installation
17”
10”
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. If the powerpack will be
mounted next to the truck restraint. Figure 15 illustrates
the approximate location of the powerpack mounting
bolts. When the powerpack is to be located inside the
building on a building wall an alternative to core drilling
into the pit would be to drill through the building wall as
shown in Figure 16. When this installation method is
selected the conduit for the Dock Alert II lights can pass
through the same wall opening. Hydraulic lines and
conduit must be fastened to the building to prevent
damage.
8”
Figure 16
INSTALLATION OF SIGN
Because of the many ways signs can be mounted, hardware is not supplied. Mount
the sign(s) on the right hand side, as viewed by truck driver, of restraint. The signs
are usually mounted near the outside signal light permitting the truck driver to read
signs from the truck.
Figure 11 provides a suggested location for mounting the signs. Good workmanship
and quality materials should be used.
NOTES:
1. Some docks may have dock/truck seals (or shelters) installed or planned. Sign
location and mounting should be studied before proceeding.
2. If required, signs may be trimmed for fit. NEVER cut or eliminate sign letters/
words.
10
Operation
WARNING
Do not operate the unit if
any personnel are on or in
front of the unit.
Do not operate the unit until
the truck/trailer is parked
squarely against the dock
bumpers.
Do not enter the truck/trailer
unless:
1. The dock leveler lip is
resting securely on the
truck/trailer bed.
2. The outside signal light
is red, and inside signal
light is green when in
Automatic or red when in
Bypass.
3. Either the truck/trailer
ICC bar is engaged by
the truck restraint or the
truck/trailer wheels have
been chocked.
Failure to follow these
instructions could result in
serious personal injury or
death.
The Poweramp Automatic Truck Restraint was designed to work in conjunction with other dock equipment allowing the dock attendant to create a safer
working environment.
Before operating the equipment, be sure the rear of the trailer has been
parked tight against the face of both dock bumpers. If your loading dock is
equipped with a dock leveler, the hinged lip must be in the pendant, stored
position prior to operating the restraint.
Operation of the restraint will vary slightly depending on whether your restraint
is equipped with a light communication package. Always operate the truck
restraint from atop the dock using the operator control panel provided to
prevent personal injury.
Prior to operating the equipment for the first time, check to see if the installers moved the release lever shipping bolt to the operating position. The
release lever shipping bolt is located directly above the release lever (see item
. Failure to move this bolt will result in a non-operational restraint.
OPERATION WITH AUTOMATIC LIGHTS
The following procedure can be used for operating Automatic Truck Restraints
equipped with automatic lights.
1. Verify that the light control switch is in the "Automatic" position, and that
a red light is illuminated inside with a green light illuminated outside.
2. Verify that the trailer is parked tight against both bumpers.
WARNING
If truck restraint does not
engage ICC bar, turn
selector switch to Bypass
and securely chock truck/
trailer wheels. Failure to
follow these instructions
could result in serious
personal injury or death.
WARNING
Check to make sure truck
restraint hook is engaged
with ICC bar. Securely
chock truck/trailer wheels
before loading or unloading
end loads.
WARNING
In Bypass operation, failure
to securely chock truck/
trailer wheels while loading
or unloading could result in
serious personal injury or
death.
3. Depress the "Activate" pushbutton on the control panel.
4. Visually inspect and confirm that the truck restraint arm has travelled vertically
and has engaged the horizontal member of the ICC bar. Visually verify that the
outside light has switched to red and that the activated light inside is illuminated.
If the restraint has not engaged the ICC bar, turn selector switch to Bypass and
secure the trailer by other safety means prior to activating dockleveler.
5. Activate dock leveler so that the lip is positioned in the rear of the trailer and
proceed to load/unload.
6. When loading/unloading of truck is completed, return the dock leveler to the
stored position.
7. Depress the "Store" pushbutton on the control panel.
8. Verify that the inside light has changed and that the stored red light is now
illuminated.
OPERATION WITHOUT LIGHTS
1. Verify that the trailer is parked tight against both bumpers.
2. Depress the "Activate" pushbutton on the control panel.
3. Visually inspect and confirm that the truck restraint arm has traveled vertically
and has engaged the horizontal member of the ICC bar. If the restraint has not
engaged the ICC bar, secure the trailer by other safety means, such as wheel
chocks, prior to activating the dock leveler.
11
Operation
4. Activate the dock leveler and proceed to load/unload.
5. When loading/unloading of the truck is complete, return the dock leveler to the
stored position.
6. Depress the "Store" pushbutton on the control panel and verify that the unit has
stored.
12
WARNING
Always barricade the work
area to prevent unauthorized use of the unit before
maintenance is complete.
If powerpack is stored under
dock leveler in pit, always
lock off all electrical
disconnects after raising
platform and setting
maintenance prop when
service under the unit is
required. More than one
electrical disconnect switch
may be required to deenergize the equipment.
Always stand clear of the
dockleveler lip when
working in front of the unit.
Maintenance
MAINTENANCE
1. Good housekeeping practice is the most commonly needed truck restraint requirement. Shipping and receiving docks are notorious for having
wood scraps, steel banding and other debris laying at the front of the
dock. Daily patrol truck restraint area and clean up dock.
2. Depending on the type of application, the Automatic Truck
Restraints usually require lubrication every three months. Lubricate back
track with an anti-seize lubricant. Lubricate linkage with 30 wt. oil.
3. IMPORTANT: Inspect daily and test the inside and outside signal lights.
THEY MUST WORK. Replace broken light bulb as required.
4. Repair or replace signs if required.
5. IMPORTANT: Truck restraint must be protected by dock bumpers.
Worn, torn, loose or missing bumpers must be replaced. Contact your
local Poweramp representative for replacement bumpers.
6. Perform operational tests after all repairs and adjustments.
7. Check hydraulic fluid level with restraint raised. Put selector/power
switch in "off" position. Remove breather from tank. Oil should be
approximately one (1) inch from top of tank.
WARNING
Failure to check and repair
or replace if required, lights
and/or alarm will jeopardize
dock attendant safetly.
Hydraulic Fluid - to assure normal operating in an ambient temperature
range of -30 degrees to +125 degrees Fahrenheit these fluids are recommended:
Aero Shell Fluid #4 Code #60421 by Shell Oil Co.
Mobil Aero HFA Mil-H5606A by Mobil Oil Co.
Texaco Type BB
Filmite No. 530
Exxon "Univis J13"
Note: Hydraulic fluids with equivalent specifications
may be used.
13
Troubleshooting
Always barricade the work area to prevent unauthorized use of the unit during
repair or maintenance procedures.
Always lock OFF all electrical disconnects when servicing the unit. Always
stand clear of the dockleveler lip when working in front of the unit. Never work in
the operating range of the restraint with power ON.
Always check and either repair or replace burned out lights. Failure to do so
could jeopardize dock attendant's safety.
Perform the following proceedures prior to beginning detailed troubleshooting:
A. Check all fuses inside the control assembly. Replace any bad fuse with
one of equivalent specification.
B. Confirm presence of necessary voltages inside the control assembly.
C . Make sure the thermal overload on the motor has not tripped. (Motor has
an integral thermal protector that automatically resets).
Mechanical Troubleshooting
WARNING
Problem Possible Solution(s)
Carriage will not raise. 1. Check side release lever--it may be bound and not releasing.
2. Check restraint body for debris which may bind operation.
3. Check for broken extension springs.
4. Check link joints for missing or bent shoulder bolts, pins or
excessive wear.
5. Joints are permanently lubricated bushings and should not
require oiling, however, rubbing surfaces of links should be
lubricated per maintenance section of this manual.
Carriage will not lower or lock
down.
1. Check side release lever--it may be bound and not engaging.
2. Check restraint body for debris which may bind operation.
3. Check link joints for missing or bent shoulder bolts, pins or
excessive wear.
4. Joints are permanently lubricated bushings and should not
require oiling, however, the rubbing surfaces of links should
be lubricated per maintenance section of this manual.
5. On occasion, a truck may move forward, trapping the ICC
bumper maintaining a positive engagement. To unlock the
restraint carriage, it may be necessary for the truck to back up.
14
Troubleshooting
Hydraulic Troubleshooting
Problem 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.
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.
Restraint moves in one direction only
reguardless of button pushed.
1. 4 way valve stuck in either position. Locate
solenoid. Remove coil from spool and spool from
valve block. check spool for contaminants and/or
damage. Replace spool if damaged. Carefully wipe off
spool with clean rag (do not damage "O" rings on
spool) Check valve block for contaminants. Replace
spool in block and coil on spool. DO NOT overtighten
spool into block. Maximum tightening torque for
spool is 35-40 lb./ft. DO NOT overtighten coil on spool.
Operate the unit. Replace spool if problem persists
and all other troubleshooting procedures performed.
15
Electrical Troubleshooting
PROBLEM POSSIBLE SOLUTION(S)
Restraint does not raise or lower - Motor
does not run, inside & outside lights do
not work.
Restraint does not raise or lower - motor
hums but does not run, inside & outside
lights work.
Restraint does not raise - motor runs in
pressure relief, inside & outside lights
work.
1. No voltage at control assembly. Check voltage
input.
2. Blown fuse inside control assembly. Use voltmeter
to test.
WARNING: LINE SIDE OF FUSE IS ALWAYS HOT. LOCK
OFF POWER TO CONTROL ASSEMBLY BEFORE
REMOVING FUSE.
3. Defective contact block at power selector switch.
Use voltmeter to test.
1. Voltage too low. Check for low voltage. Increase
wire size to correct voltage drop.
2. Defective capacitor. Disconnect capacitor. Test.
CAUTION: DISCHARGE CAPACITOR BEFORE
ATTEMPTING A CAPACITOR TEST.
1. Solenoid coil not electrically energizing. Check coil
for magnetism. Use voltmeter to test voltage at coil.
Restraint does not raise - motor does not
run, inside & outside lights work.
2. Solenoid spool mechanically stuck OFF. Remove
spool from hydraulic block. Inspect spool & block for
contaminants. Test. Restraint if necessary.
NOTES:
DO NOT RUN MOTOR WHEN SPOOL IS REMOVED FROM
BLOCK.
DO NOT OVERTIGHTEN COIL ON SPOOL. NUT IS TO ONLY
BE TIGHTENED TO PREVENT COIL FROM FALLING OFF
SPOOL.
DO NOT OVERTIGHTEN SPOOL INTO BLOCK. SPOOL IS
ONLY TO BE TIGHTENED TO PREVENT FLUID EXIT FROM
BLOCK VIA SPOOL WHEN UNIT OPERATING.
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.
16
Electrical Troubleshooting - Continued
PROBLEM POSSIBLE SOLUTION(S)
Restraint does not lower - motor runs in
pressure relief, inside & outside lights
work.
Restraint does not lower - motor does
not run, inside & outside lights work.
1. Solenoid spool mechanically stuck ON. Remove
spool from hydraulic block. Inspect block for
contaminants. Test. Replace if necessary.
NOTES:
DO NOT RUN MOTOR WHEN SPOOL IS REMOVED FROM
BLOCK.
DO NOT OVERTIGHTEN COIL ON SPOOL. N UT IS TO
ONLY BE TIGHTENED TO PREVENT COIL FROM FALLING
OFF SPOOL.
DO NOT OVERTIGHTEN SPOOL INTO BLOCK. SPOLL IS
ONLY TO BE TIGHTENED TO PREVENT FLUID EXIT FROM
BLOCK VIA SPOOL WHEN UNIT OPERATING.
1. Obstruction activating limit switch lever. Remove
obstruction. Make sure lever operates freely.
2. Defective limit switch. Use voltmeter to test switch
contact operation.
3. Defective control relay(s). Use voltmeter to test
voltage at relay(s) coil & to test relay(s) contact
operation.
Light(s) does not work or light(s) does
not work correctly - restraint raises &
lowers.
4. No voltage at motor. Use voltmeter to test voltage
at motor.
5. Thermal protector inside motor has tripped. Wait
for protector to reset.
1. Defective bulb. Replace.
2. Obstruction preventing activation or deactivation of
limit switch lever. Remove obstruction. Make sure
lever operates freely.
3. Defective limit switch. Use voltmeter to test switch
contact operation.
4. Defective control relay. Use voltmeter to test
voltage at relay coil & to test relay contact operation.
5. Defective contact block(s) at light control selector
(or key) switch. Use voltmeter to test.
17
ITEM #14 IS COMMON
TO ALL PIVOT POINTS
14
15
13
10
36
3
14
9
5
9
11
39
9
15
17
17
15
30
14
7
35
31
TO “B”
RELEASE
CYLINDER
TO “A”
RELEASE
CYLINDER
19
33
32
12
25
34
26
SPRING IS SHOWN
REMOVED FROM ITEM
#26 FOR CLARITY
TO “B”
TO “A”
16
18
14
21
22
6
39
9
8
12
40
2
20
28
24
4
1
23
OPTIONAL
38
37
21
29
Figure 18
18
BILL OF MATERIALS
ITEM QTY PART NUMBER DESCRIPTION
1 1 9414-0035 BASE WELDMENT
2 1 0961-0148 LIMIT SWITCH
3 1 9413-0049 RESTRAINT WELDMENT
4 1 9411-0023 SHROUD
5 3 9412-0148 BAR LINK - TAPPED CENTER
6 4 9412-0149 BAR LINK
7 1 9412-0187 BAR LINK W/TAPPED CENTER & NOTCH
8 2 0192-0053 BRUSH - WEATHERSEAL
9 4 9202-0042 PIN - LONG
10 2 9413-0044 SPRING PLATE WELDMENT
11 2 0941-0011 SPRING EXTENSION
12 2 9904-0097 HOSE ASSY 1/4” 100 R1 X 24”
13 2 9412-0185 ROLLER
14 23 9461-0006 FLANGED SHOULDER BEARING - BRONZE
15 5 2101-0165 SOCKET HEAD SHOULDER SCREW
16 1 2101-0098 HEX HEAD CAP SCREW GRADE 5
17 2 9202-0043 PIN - SHORT
18 1 2101-0163 FLAT WASHER
19 3 2101-0039 HEX HEAD NUT
20 2 2101-0057 HEX HEAD CAPSCREW
21 2 0192-0052 TRACK - WEATHERSEAL
22 6 2101-0180 SCREW - PHILIPS
23 1 2103-0001 ANCHOR KIT
24 2 2101-0182 SCREW-PHILLIPS
25 1 2101-0018 HEX HEAD CAP SCREW GRADE 2
26 1 0524-0063 HYDRAULIC CYLINDER - RELEASE
27 1 2101-0181 SOCKET HEAD SHOULDER SCREW
28 2 2101-0156 LOCK WASHER
* 29 1 9411-0025 SHROUD - TAPERED
30 1 9413-0051 RELEASE LEVER WELDMENT
31 1 0524-0064 HYDRAULIC CYLINDER - STORE
32 1 9411-0024 SHROUD - RELEASE CYLINDER
33 2 2101-0133 MACHINE SCREW - ROUND HEAD
34 1 2101-0187 HEX HEAD CAPSCREW GRADE 5
35 1 2101-0188 HEX HEAD CAPSCREW GRADE 5
36 2 9412-0161 BOSS
* 37 2 0192-0056 BRUSH WEATHERSEAL
* 38 2 0192-0057 BRUSH WEATHERSEAL
39 12 2101-0189 E CLIP
40 1 0941-0012 SPRING
* OPTIONAL: ITEM# 29, 37 & 38 REPLACES ITEM #4 & 8.
ITEM #22 QUANTITY CHANGES FROM 6 TO 8.
19
8
2
3
6
4
7
12
5
P
O
W
E
R
A
M
P
S
T
O
R
E
D
A
A
C
U
T
I
T
V
O
A
M
T
E
A
D
T
I
C
B
Y
P
A
S
S
O
F
F
A
C
T
I
V
O
A
N
T
E
D
P
O
W
E
R
20
Figure 18
BILL OF MATERIALS
ITEM QTY. PART NUMBER DESCRIPTION
1 1 7154-0002 SIGNAL LIGHT HOUSING ASSY.
2 2 7153-0006 LIGHT ASSEMBLY
3 2 3051-0046 10 WATT LAMP (GE 10C7DC)
4 1 7151-0002 RED LENS
5 1 7151-0003 GREEN LENS
6 2 7151-0026 LENS GASKET
7 2 7151-0011 SNAP RING
8 2 7151-0006 LIGHT ASSEMBLY GASKET
9 1 7152-0006 BACK PLATE
10 1 1751-0034 CAUTION SIGN - MIRRORED
11 1 1751-0033 CAUTION SIGN
12 1 9-K0-000-0-B CONTROL BOX W/AUTO/MANUAL DOCK ALERT
21
RELEASE CYL (BLIND END)
RELEASE CYL (ROD END)
10
14
13
5
Figure 19
9
24
8
7
1
36
12
11
3
CAPACITOR WIRING DETAIL
NOTE: BASE WELDMENT (ITEM #1)
& JUNCTION BOX (ITEM #6) SHOWN
REMOVED FOR CLARITY.
22
BILL OF MATERIALS
ITEM QTY. PART NUMBER DESCRIPTION
1 1 9393-0025 BASE WELDMENT
2 1 9391-0009 POWERPACK
3 1 3051-0058 CAPACATOR
4 1 1431-0011 CONNECTOR - 2 SCREW
5 2 9904-0097 HOSE ASSEMBLY X 24"
6 1 2751-0016 COVER - J-BOX
7 2 2101-0140 LOCK WASHER
8 2 2101-0017 HEX HEAD CAPSCREW
9 2 R598-0090 SPLIT FLEXIBLE CONDUIT
10 2 6431-0001 GROMMET
11 3 1431-0035 INSULATED TERMINAL
12 1 R513-0050 WIRE
13 2 9301-0164 CONNECTOR
14 1 9391-0013 COVER (SHOWN PARTIALLY IN TOP)
23
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