PowerStop
Vehicle Restraint
Owner’s/User’s Manual
Printed in U.S.A.
Copyright © 2013
SyStemS, Inc. • W194 N11481 McCormick Drive • Germantown, WI 53022
800.643.5424 • fax: 262.255.5917 • www.docksystemsinc.com • techservices@docksystemsinc.com
Manual No. 4111-0014
July 2013
Table of Contents
Page
Safety
Recognize Safety Information ............................................................. 1
General Operational Safety Precautions ............................................ 1
Operational Safety Precautions ........................................................... 2
Maintenance Safety Precautions ......................................................... 4
Safety Decals ......................................................................................... 5
Placard installation ............................................................................... 7
Owner’s/User’s Responsibilities ......................................................... 8
Introduction
General Information .............................................................................. 9
Installation
Install Details - Automatic .................................................................. 10
Install Details - Manual ....................................................................... 12
Install Control Panel and wiring ........................................................ 14
Operation
Operating Instructions ....................................................................... 15
Troubleshooting
Troubleshooting .................................................................................. 16
Maintenance
Periodic Maintenance ......................................................................... 18
Parts
Mechanical PowerStop Components ................................................ 20
Hydraulic PowerStop Components ................................................... 22
Scissors Break down .......................................................................... 24
Hydraulic Combo valve Block ........................................................... 25
Powerpack Assembly ......................................................................... 26
Electrical .............................................................................................. 28
Outside Signs ...................................................................................... 30
Outside Light Assembly .................................................................... 31
Operations Placards .......................................................................... 32
Miscellaneous
Customer Information ........................................................................ 33
Warranty ................................................................................ Back Cover
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.
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.
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.
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.
The use of the word WARNING signifies the
presence of a serious hazard or unsafe practice
which may result in serious injury or death.
The use of the word CAUTION signifies possible
hazard or unsafe practice which could result in
personal injury.
IMPORTANT
The use of the word IMPORTANT is to draw
attention to a procedure that needs to be followed
to prevent machine damage.
e
g Zon
peratin
O
ne
Zo
ting
era
Op
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.
4111-0014 — July 2013
1
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.
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/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.
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 transport vehicle at
least 4 in. (102 mm).
Keep a safe distance from both side edges.
2
4111-0014 — July 2013
Do not use dock leveling device if transport
vehicle is too high or too low.
SAFETY
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 — July 2013
3
SAFETY
1.50"
DANGER
Hazardous Voltage
Will Cause Severe
Injury or Death
Arc Flash and
Shock Hazard
PPE (Personal Protection
Equipment) Required
De-energize equipment before
working on or inside. Do not
open cover without appropriate
PPE. Refer to NFPA 70E for
PPE requirements. This panel
may contain more than one
power source.
Maintenance Safety Precautions
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.
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.
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 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.
Access under the dock leveler may be required
to service the vehicle 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.
4
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 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.
4111-0014 — July 2013
Safety Decals
TOLERANCES
(UNLESS OTHERWISE NOTED)
FRACTIONAL: 1/32"
DECIMAL:
.00 =
.01"
MATERIAL
DRAWN BY
CHECKED BY
DRAWING NO.
DATE
BKM 10/17/2008
DL SAFETY
DOCK LEVELER
P O W E R A M P
M C G U I R E
D L M
L o a d i n g D o c k E q u i p m e n t
SAFETY LABEL LOCATIONS
5.06"
8.72"
5.05"
5.92"
9.12"
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.
1751-0727
SAFETY
DANGER
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.
1751-0727 Rev A
1751-0730 (x2)
SAFETY INFORMATION
DANGER
Unsupported dock leveler
ramps can lower unexpectedly.
Before allowing vehicle to leave
the dock always:
Ensure no equipment,
material or people are on
dock leveler.
Return dock leveler to its
Failure to follow posted instructions will result in death or serious injury.
stored position at dock level.
OPERATION 7. Stay clear of hinges and front and
1. Read and follow all instructions and sides of moving dock leveler.
warnings in owner’s/user’s manual. 8. Nev e r u s e d a m a g e d or
2. Use of dock leveler restricted to malfunctioning dock leveler. Report
trained operators problems immediately to supervisor.
3. Always chock trailer wheels or
engage truck restraint before
operating dock leveler or beginning to
load or unload.
4. Never use hands or equipment to
move ramp or lip
5. Before activating dock leveler:
Ensure trailer is backed in against
bumpers.
Remove any end loads if required.
Check trailer alignment to avoid lip
interference. If lip does not lower to
trailer bed, reposition vehicle.
6. Ensure truck bed supports extended
lip or leveler frame supports the ramp
before driving on ramp.
Call 262.255.1510 for replacement placards, warning labels, or owner’s/user’s manuals.
(decal placed in same position on both sides)
1751-0329 (x2)
DO NOT
FORK THIS SIDE
(decal placed in same position on both sides)
1751-0330 (x2)
(decal placed in same position on both sides)
!
DANGER
CRUSH HAZARD
1751-0138
DO NOT REMOVE hydraulic cylinder until leveler is
safely supported by maintenance prop. Refer to
owner’s/user’s manual for proper maintenance
procedure. Failure to comply will result in death or
serious injury.
1751-0729
CRUSH HAZARD
Do not work under dock leveler unless this maintenance prop has been secured in the upright
position. Failure to comply will result in death or serious injury. See owner’s/user’s manual for proper
procedures.
1751-0731
DANGER
DANGER
CRUSH HAZARD
Rotate prop to maintenance
position.
Open the pin latch
and insert through the
maintenance prop housing.
Close the pin latch to secure
prop. Use every time dock
leveler is serviced. Failure to
comply will result in death
or serious injury.
MAINTENANCE/SERVICE
1. Read and follow all instructions,
warnings and maintenance
schedules in the owner’s/user ’s
manual.
2. Maintenance/Service of dock leveler
restricted to trained personnel.
3. Place barriers on the driveway and
dock floor to indicate service work is
being performed.
4. DO NOT ENTER PIT unless dock
leveler is securely supported by
maintenance prop.
5. If electrically powered turn off and use
OSHA lockout/tagout procedures.
FORK
HERE
1751-0729 Rev A
1751-0731
1751-0726
Note
This is a example of dock leveler safety decals. See manual for your specific model for correct
safety decal sheet or consulate Tech Serves
4111-0014 — July 2013
DANGER
CRUSH HAZARD
DO NOT ENTER PIT unless dock leveler is
safely supported by maintenance prop. Place
barriers on driveway and dock floor to indicate
service work being performed. Failure to comply
will result in death or serious injury. Refer to
owner’s/user’s manual for proper maintenance
procedures.
1751-0726 Rev A
5
SAFETY
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.
5.06"
DANGER
1751-0727 Rev A
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.
9.12"
Unsupported dock leveler
ramps can lower unexpectedly.
Before allowing vehicle to leave
the dock always:
Ensure no equipment,
material or people are on
dock leveler.
Return dock leveler to its
stored position at dock level.
Failure to follow posted instructions will result in death or serious injury.
SAFETY INFORMATION
Call 262.255.1510 for replacement placards, warning labels, or owner’s/user’s manuals.
DANGER
OPERATION 7. Stay clear of hinges and front and
1. Read and follow all instructions and sides of moving dock leveler.
warnings in owner’s/user’s manual. 8. Nev e r u s e d a m a g e d o r
2. Use of dock leveler restricted to malfunctioning dock leveler. Report
trained operators problems immediately to supervisor.
3. Always chock trailer wheels or
engage truck restraint before
MAINTENANCE/SERVICE
operating dock leveler or beginning to
1. Read and follow all instructions,
load or unload.
warnings and maintenance
4. Never use hands or equipment to
schedules in the owner’s/user’ s
move ramp or lip
manual.
5. Before activating dock leveler:
2. Maintenance/Service of dock leveler
Ensure trailer is backed in against
restricted to trained personnel.
3. Place barriers on the driveway and
bumpers.
dock floor to indicate service work is
Remove any end loads if required.
being performed.
Check trailer alignment to avoid lip
4. DO NOT ENTER PIT unless dock
interference. If lip does not lower to
leveler is securely supported by
trailer bed, reposition vehicle.
maintenance prop.
6. Ensure truck bed supports extended
5. If electrically powered turn off and use
lip or leveler frame supports the ramp
OSHA lockout/tagout procedures.
before driving on ramp.
DO NOT
FORK THIS SIDE
FORK
HERE
1.02"
8.72"
DANGER
1751-0788 Rev A
CRUSH HAZARD
Do not work under dock leveler unless this maintenance prop has been secured in the upright
position. Failure to comply will result in death or serious injury. See owner’s/user’s manual for proper
procedures.
5.05"
CRUSH HAZARD
Open the pin latch and insert
through the maintenance
prop housing and prop
completely. Close the pin latch
to secure prop. Use every
time dock leveler is serviced.
Failure to comply will result
in death or serious injury.
DANGER
1751-0789
DANGER
1751-0726 Rev A
5.92"
CRUSH HAZARD
DO NOT ENTER PIT unless dock leveler is
safely supported by maintenance prop. Place
barriers on driveway and dock floor to indicate
service work being performed. Failure to comply
will result in death or serious injury. Refer to
owner’s/user’s manual for proper maintenance
procedures.
1751-0727
1751-0730
(x2)
1751-0788
1751-0789
1751-0726
5.93"
DANGER
1751-0728 Rev A
CRUSH HAZARD
Do not remove main springs until leveler is securely supported by a
suitable lifting device. Main springs contain stored energy. Be sure springs
are fully unloaded and ends are loose before removal. Failure to comply
will result in death or serious injury. Refer to owner’s/user’s manual for
proper maintenance procedure.
1751-0728
(decal placed in same position on both sides)
(decal placed in same position on both sides)
(decal placed in same position on both sides)
1751-0329
(x2)
1751-0330
(x2)
Safety Decals
Note
This is a example of dock leveler safety decals. See manual for your specific model for correct
safety decal sheet or consulate Tech Serves
6
4111-0014 — July 2013
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.
Nylon Tie
Conduit
Control Box
Placard
(Placard placement
shown as reference
only.)
4111-0014 — July 2013
7
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. Maintaining, updating and re training all operators on safe working habits and
operation of the equipment, regardless of previous experience, should be done on a regular basis and
should include an understanding and familiarity with all functions of the equipment. Owner’s/user’s shall
actively maintain, update and retrain all operators on safe working habits and operations of the equipment.
2. The manufacturer shall provide to the initial purchaser all necessary information regarding Safety
Information, Operation, Installation and Safety Precautions, Recommended Initial and Periodic Inspections
Procedures, Planned Maintenance Schedule, Product Specifications, Troubleshooting Guide, Parts
Break Down, Warranty Information, and Manufacturers Contact Information, as well as tables to identify
the grade(slope) for all variations of length or configuration of the dock leveling device and information
identifying the maximum uncontrolled drop encountered when sudden removal of support while in the
working range of the equipment.
3. It is recommended that when the transportation vehicle is positioned correctly in the dock opening and
in contact with both bumpers, there shall be a minimum of 4.00 inches (100mm) overlap of the leveling
device and the transportation vehicle at all times during the loading and unloading process.
4. The Owner/User must review all name plates, placards, decals, instructions and posted warnings and
place the same in view of the operator or maintenance personnel for whom such warnings are intended
for. Contact manufacturer for any replacements.
5. Manufacturer’s recommended periodic maintenance and inspection procedures in effect at the date of
shipment shall be followed at all times. Written documentation of maintenance, replacement parts or
damage should be retained. In the event of damage notification to the manufacturer is required.
6. Loading dock equipment that has been structurally damaged or has experienced a sudden loss of main
support while under load (such as what might occur when a transport vehicle pulls out from under the
leveling device) shall be removed from service, inspected by a manufacturer’s authorized representative,
and repaired or replaced as needed before being placed back in service.
7. Any modifications or alterations of loading dock equipment shall only be done with prior written approval
from the manufacturer and the same shall be at least as safe as the original equipment was prior to the
modification and shall also satisfy all safety requirements of the manufacturer for the particular application
of the leveling device.
8. When industrial moving devices are being used in the loading or unloading of product from the
transportation vehicle, this vehicle shall have the brakes and wheel chocks applied appropriately or
all other positive restraining device shall be fully utilized. It is recommended that trailers with air-ride
suspension systems shall have its air exhausted prior to performing loading and unloading operation to
minimize trailer bed drop.
9. Loading dock safety equipment should never be used outside of its intended use, vertical working range,
or capacity. Please consult the manufacturer if you have any questions as to the use, vertical working
range or capacity of the equipment. Only properly trained and authorized personnel should operate the
equipment.
10. When selecting loading dock safety equipment, it is important to consider not only present requirements
but also future plans and any possible adverse conditions, environmental factors or usage.
8
4111-0014 — July 2013
INTRODUCTION
Manual PowerStop Vehicle Restraint
Specification Sheet and Submittal
PowerStop
MML
Panel Shown
Manual Dock Alert™ Communication System
Control Panel, Lights and Signs
are part of the optional
Dock Alert™ Communication System
8”
8”
73 ½”
3 1/2”
5 1/2”
General Information
Congratulations on your choice of a Systems, Inc.
vehicle restraint. This manual covers the PowerStop
series hydraulic vehicle restraint.
Designed by Systems, Inc. to be a marvel of
simplicity and efficiency, your vehicle 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.
PowerStop Stock Specifications
PowerStop vehicle 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)
The Automatic (hydraulic) PowerStop series vehicle
restraint comes equipped with an electrical control
panel, which allows push button operation of the
vehicle restraint functions. Each PowerStop dock
vehicle 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. vehicle restraint.
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.
29 ½”
12”
4111-0014 — July 2013
9
INSTALLATION DETAILS-AUTOMATIC POWERSTOP
POWERSTOP Overview
STOP-TITE Overview
Poweramp
McGuire
LEVEL
11”
McGuire.
POWERSTOP Overview
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
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.
QTYITEM DESCRIPTIONPART NO. SIZE
1431-0011
1 1
2 3
3 2
4 2
5 1
6 1
7 2
8 2
9 1
10 1
11 1
12 2
13 1
14 2
Connector - 2-Screw 3/8
1431-0086
Insulated Terminial 16-14 AWG
2101-0017
Hex Head Capscrew 3/8-16 UNC X 1
2101-0140
Lock Washer 3/8
2751-0016
Cover - J-Box 4X 4
3051-0058
Capacitor - Motor Start 64-77mF- 330V
6431-0001
Grommet 1-3/8 OD X 3/4 ID
9301-0164
Fitting Conn Str Thrd #4 ORB X #4 JIC
9391-0009
Powerpac - PowerStop 1PH- 115V - 1/4 HP - 1 GPM
9392-0045
Cover - PowerStop B CAD
9393-0025
Powerpac Mounting Weldment B CAD
9904-0097
Hyd Hose Assy - 1/4"100R1 X 24.00 #4JICF SWIVEL BOTH ENDS
R513-0050
Wire 16 GA RED X 5.00"
R598-0090
Split Flex Conduit 1/4" X 9.00"
10
BILL OF MATERIAL
STOP-TITE
STOP-TITE
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.
A
Motor Blue
Motor Red
Capacitor Wiring Detail
RC BC
13
2
6
R.V.SET @
650PSI
M
105
HYDRAULIC SCHEMATIC
SECTION "A-A"
DESCRIPTIONNOTE
CONNECT TO BASE END OF RELEASE CYL.BC
RC CONNECTTO ROD END OF RELEASE CYL.
4111-0014 — July 2013
INSTALLATION DETAILS-AUTOMATIC POWERSTOP
Concrete Dock Face (Standard installation)
For comprehensive installation
instructions read and understand the
Installation and Operation Manual.
Automatic PowerStop Installation
Overview
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).
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
Driveway Mount (Recommended when dock face is unsuitable for PowerStop Mounting)
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.
48”
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
If <24”
Dim. A
Dim. B
8” Min.
Driveway Mount Wall Mount
Determine offset
Dim. B
then proceed with
“Driveway Mount”
instructions below.
8” Min.
48”
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 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”
Dim. A
For filler requirements from 1 ½”to 7
½” use cantilever bracket #9414-0052
and anchor cantilever bracket to the
dock face or
Dim. B
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.)
Offset
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
20”
weld to embedded
(Kit #2103-0004) or weld to
embedded mounting plate
(Part #9414-0052).
14”
27”
(Front)
3/4” Dia. X 6” min.
4111-0014 — July 2013
11
INSTALLATION DETAILS-MECHANICAL POWERSTOP
IO PSM PR 06/04
For comprehensive installation instructions of the Manual PowerStop
M
(PowerStop ) read and understand the Installation and Operation Manual.
Manual PowerStop Installation
Overview
Optional DockAlert Communication System
POWERSTOP - Manual Restraint/Automatic DockAlert
MAL
Field wires:
L1, L2 - 115 Vac Control
Ground
Control assembly (by Poweramp)
1
L1 L2
11 46
115
Common
Vac
Proximity Switch
51
55
4722
11
Proximity Switch
5048
Red Light
Limit Switch (option)
GRD
Ground
Green Light
Field wires:
Limit Switch (option)
2, 48, 51
115 Vac Control
Ground
POWERSTOP - Manual Restraint/Manual DockAlert
MML
Field wires:
L1, L2 - 115 Vac Control
Ground
Control assembly (by Poweramp)
1 GRD
L1 L2
4722
5048
115
Common
Vac
Red Light
51
Green Light
Ground
Field wires:
2, 48, 51 - 115 Vac Control
Ground
Conduit must be protected from damage.
Conduit & connections must be liquid tight
if in area where liquid can be present
Junction box at face of dock
Conduit must be protected from damage.
Conduit & connections must be liquid tight
if in area where liquid can be present
Truck restraint
Limit switch (option)
47
Proximity switch
12
Multiconductor cable
13
Ground
Field wires:
11, 46 - Proximity - 115 Vac Control
47, 55 - Limit Switch Option - 115 Vac Control
Ground
46
11
Brown
55
14
Wires 47 & 55
(if used)
Blue
Field wires:
47, 55 - Limit Switch Option
- 115 Vac Control
Ground
Ground
included with optional DockAlert Communciation Systems
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
4111-0014 — July 2013
INSTALLATION DETAILS-MECHANICAL POWERSTOP
For comprehensive installation instructions read and understand the
Installation and Operation Manual.
Manual 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)
18”
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”
Optional
Embed
Plate
27”
20”
3/8”
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”
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
then proceed with
Dim. B
“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”
4111-0014 — July 2013
13
Powerpack
Location Options
For comprehensive installation
instructions of the Automatic
STOP-TITE (STOP-TITE ) read and
understand the Installation
and Operation Manual.
AAL
INSTALLATION
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.
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.
Coordinate powerpack location and hose
length for proper placement.
POWERSTOP Overview
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.
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.
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 vehicle
restraint have been made, test the vehicle restraint
function by following the instructions in the “Put New
PowerStop Restraint Into Service” section on next
page.
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.
14
4111-0014 — July 2013
Operating Instructions
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.
OPERATION
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).
4. Raise the PowerStop restraint fully by pushing
and holding the ENGAGE 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.
Only trained personnel should operate the dock
leveler and vehicle restraint.
DO NOT use a broken or damaged dock leveler
or vehicle restraint. Make sure proper service and
maintenance procedures have been performed on
leveler before using.
Transport vehicle wheels must be chocked unless
the vehicle restraint is used. Never remove the
wheel chocks until loading/unloading is finished
and transport driver has been given permission to
leave.
Make sure platform lip rests on the transport
vehicale’s 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.
Once the PowerStop vehicle 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.
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 restraint fully by pushing
and holding the RELEASE 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 restraint cannot properly restraint
the vehicle due to missing or defective ICC (RIG)
bar advise driver of the transport vehicle and dock
personnel. The transport vehicle must be secured
against movement by other methods. For levelers
interlocked with the 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).
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.
4111-0014 — July 2013
15
Troubleshooting
Discharge capacitor before attempting a capacitor
test.
Symptom Possible Cause Solution
Restraint will not raise or
lower.
Restraint will not raise
or lower Mechanical or
Hydraulic
Restraint will not raise
(Hydraulic only)
Debris Remove Bellows check for Debris jammed in scissor
Lubrication
Damaged parts
Lights on but Motor does
not run
Wire Connections Check all wire connection for damage corrosion.
Line side of fuse is always hot. Turn off main power
supply before removing fuses. Attach proper lockout / tag-out devices.
mechanism.
- Lubricate latch release leveler.
- Lubricate pivot points scissors mechanism.
- Damaged or missing store spring.
- Damaged of missing scissors springs.
- Worn out or damaged flanged bearings in
Scissors assemble.
- Front slot on hook weldment bent up or down.
- Motor overload device tripped or fuse blown.
Note:
When replacing fuse(s) or breakers , the new fuse or
breaker must have the same specification as the old.
Motor energizes but does
not run.
Motor energizes and runs
but restraint will not raise
or lower.
Motor energizes and
runs but restraint will not
lower
Prox switch Prox switch failed or wired incorrectly.
Defective motor Replace motor.
Capacitor -Capacitor shorted.
-Capacitor wired incorrectly or bad connections.
Voltage Low line voltage check wire size to house power.
Low Hydraulic fluid Check for leaking cylinders or hoses.
Filter The suction filter my be clogged.
Coil Coil must be energized for restraint to raise only.
Coil energized to lower.
valve Valve may be damaged.
Coil. Coil should not be energized possible bad relay.
Valve Valve may be damaged.
Interlock prox Leveler may have interlock, see leveler specific
manual.
16
4111-0014 — July 2013
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 Possible Cause Solution
Restraint move in one
direction only.
Lights don’t change
Lights not flashing or
not on
Valve The four way valve may be damaged or has trash in
Coil Check nut on coil may be over tightened and
Prox switch Prox switch has two lights on switch. Green when
Flasher
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.
the valve.
causing valve to bind up.
metal is present on red when no metal is present.
- Flasher can fail closed (lights on steady no flash).
- Flasher can fail open (lights will not be on).
Alarm on or caution
light on.
Bulbs
Damaged over travel prox
Check to make sure bulbs are not burned out.
Damaged or malfunctioning prox switch.
4111-0014 — July 2013
17
MAINTENANCE
Periodic Maintenance
K
A
L
J
H
G
L
B
C
F
E
D
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.
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.
18
G — Bellows
H— Main Springs
J— Pin
K— E-Clip
L —Bearing
To ensure normal operation of the dock leveler and
vehicle restraint, use only aircraft hydraulic fluid
designed to meet or exceed military specification
MIL-H-5606 G. It is recommended that the following
hydraulic fluids be used:
• ULTRA-VIS-HVI-15
• 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.
4111-0014 — July 2013
Daily Maintenance
• Daily clear any debris to prevent operation issues.
MAINTENANCE
• Check inside and outside lights for proper
operation
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.
IMPORTANT
Failure to clean and properly lubricate the vehicle
restraint will cause abnormal operation.
Quarterly Maintenance
• Clear any debris to prevent operation issues.
• Check inside and outside lights for proper
operation
Q
N
M
M — Reservoir
N —1 in. (25.5 mm) (From Top of
Reservoir)
P
P — Breather Cap
Q — Fluid Level
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.
• 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.
• Clean and lubricate scissors assembly (A) and all
pivot points.
• Make sure Rear Track Assist Spring (D) is properly
seated at the bottom of the rear track.
Yearly Maintenance
• Repeat of Quarterly Maintenance.
• Change Hydraulic Oil (May be required earlier
depending on conditions).
• Check reservoir fluid level (Q):
1. Put the vehicle restraint in the stored position.
2. Turn OFF all electrical power to the vehicle
restraint.
3. Wipe off plastic 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 vehicle restraint stored.
5. Add hydraulic fluid if necessary. Use only
recommended fluid. See previous page.
6. Install cover
7. Turn ON electrical power.
*Refer to OSHA regulation 1910.147.
4111-0014 — July 2013
19
PARTS
PowerStop (Mechanical) Parts Breakdown
19
18
14
26
12
11
24216
30
17
29
15
25
13
28
1
20
8
3
16
27
7
22
10
4
23
5
2
9
20
4111-0014 — July 2013
PowerStop M (Mechanical) Parts Breakdown
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 1
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
*
1
2103-0006 Anchor Kit Drive Way Mount
2103-0003 Anchor Kit Wall Mount
9413-0098
Prox Over Travel (Not Shown)
PARTS
4111-0014 — July 2013
21
PARTS
PowerStop A (Hydraulic) Parts Breakdown
18
31
29
30
1213
35
22
23
9
1
34
20
26
16
2
14
10
33 15
37
28
27
25
22
36
4
24
21
7
11
5 6
32
3 8
19
17
4111-0014 — July 2013
PARTS
PowerStop A (Hydraulic) Parts Breakdown
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
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 9413-0098
1 0522-0002 Spring, Helper, Rear Frame (Not Shown)
2103-0006 Anchor Kit Drive Way Mount
2101-0003 Anchor Kit Wall Mount
Prox Over Travel (Not Shown)
4111-0014 — July 2013
23
PARTS
PowerStop Scissor Breakdown
1
4
8
6
7
5
2
9
Rear of Restraint
3
Item Quantity Part Number Description
1 3 9413-0063 Bar Assembly - Tapped W/Bushings
2 4 9413-0064 Bar Assembly - W/Bushing
3 1 9413-0065 Bar Assembly - Notched
4 2 0941-0011 Spring Extension
5 4 2101-0165 Socket Head Shoulder Bolt
6 4 2101-0189 E-Clip
7 2 9202-0042 Pin - Long
8 2 9413-0044 Spring Plate Weldment
9 16 9461-0006 Flanged Bearings
1 9413-0062 Scissor Lift Subassembly
24
4111-0014 — July 2013
PowerStop Valve Combined With Leveler
TOLERANCES
(UNLESS OTHERWISE NOTED)
FRACTIONAL: 1/32"
MATERIAL
DRAWN BY CHECKED BY
DRAWING NO.
DATE
BKM 3/24/2010
VALVE ASSEMBLY
P O W E R A M P
M C G U I R E
D L M
S Y S T E M S, I N C.
L o a d i n g D o c k E q u i p m e n t
POWERSTOP ON PR/E/CH LEVELER
LP
BC
RC
PARTS
Leveler coil
De-Energized leveler
Energized restraint
2
5
LP
1
3
LR
5
4
RC
6
BC
6
Restraint Coil
R
9
5
P
De-Energized Lower
7
Energized to raise
LP
P
Item Description
P Pressure From Pump
R Return To Tank
LP Presure To Logic Block
LR Return From Logic Block
BC Blind End of Powerstop Cylinders
RC Rod End Of Powerstop Cylinder
Item Quantity Part Number Description
1 2 8581-0011 Valve 4 Way 2 Position
2 1 8581-0112 valve, Flow Control 1 GPM
3 1 8581-0113 Valve, Flow Control 650 psi
4 1 8581-0014 Valve, Sequence
5 3 9301-0115 Fitting Elbow #6 ORB x #8 JIC
6 2 9301-0135 Fitting Connector Straight Thread #4 ORB x #6 JIC
7 1 9301-0111 Fitting Connector Straight Thread #6 ORB x #8 JIC
8 1 8583-0050 Valve Assemble (Contains 1-8)
9 1 8581-0004 Delta Coil 115 volt
4111-0014 — July 2013
R
LR
BC
RC
25
PARTS
Power Pack Assembly
10
BC
RC
10
11
4
12
3
8
7
Amp Draw 4.8- 5.2
BC = Blind End of Cylinder
RC = Rod End of Cylinder
6
5
1 2
26
4111-0014 — July 2013
PARTS
Power Pack Assembly
Item Quantity Part Number Description
1 2 2101-0017 HHCS-Grad 2-Zinc Plated, 3/8-16 UNC X 1
2 2 2101-0140 Lock Washer, 3/8
3 2 2401-0001 Grommet, 1-3/8 OD X 3/4 ID
4 1 2751-0016 J-Box Cover, 4 X 4
5 1 3051-0058 Capacitor-Motor Start, 66-77mf-330V
6 1 9301-0221 Fitting Connector 45 Deg, #4 ORB #4 JIC
7 1 9391-0040 Powerppac-PStop, 1PH-115V-1/4HP-1GPM
8 1 9391-0012 Powerppac Mounting Weldment
9 1 9391-0013 Cover-Pstop
10 REF 9904-0119 Hydraulic Hose ASM-1/4” 100R17 X 96, #4 JICF Swivel Both Ends
11 1 8581-0117 Valve, 4 Way
12 1 8581-0118 Delta Coil 115 volt (P Stop Only)
13 1 1751-0149 Decal “ No Step” (On Top of Cover)
* Hose Lengths Vary by Job
14 1 9395-0092 Powerpac (Includes Valve Body, Cover) complete
139
4111-0014 — July 2013
27
Electrical Control Box
28
Generic Drawings shown
Provide serial number for specic drawings
4111-0014 — July 2013
Electrical Ladder Diagram
4111-0014 — July 2013
Generic Drawings shown
Provide serial number for specic drawings
29
PARTS
Outside Signs
B
A
Item Quantity Part Number Description
A 1 1751-0033
B 1 1751-0034
30
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
OSLA (Outside Light Assembly)
PARTS
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 — July 2013
31
NOTES
!
O P E R A T I N G
1751-0880
Use with PowerHook, Powerhold, Holdtite and TPR series
A
DANGER
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.
Operate the vehicle restraint thru one complete cycle, inspecting it for
proper operation and light sequence. Advise maintenance personnel of
any damage or improper operation immediately. Remove all
malfunctioning or damaged vehicle restraints from service using
approved lockout/tagout procedures.
Before attempting to restrain a transport vehicle:
Verify that transport vehicle is positioned squarely against dock
bumpers
Inspect the transport vehicle’s rear impact guard (RIG). Damaged or
missing RIGs may not allow the vehicle restraint to securely capture the
RIG. Wheel chocks must be used whenever the ability for the vehicle
restraint to capture the RIG is in question. (NOTE: The transport
vehicle’s suspension and load condition will effect trailer height.)
After activating vehicle restraint:
Verify that the transport vehicle’s RIG has been restrained successfully.
In the event this cannot be determined use wheel chocks in addition to
restraint.
If equipped with a light communication package load and unload on
GREEN light only.
Maintenance or service must be performed by authorized personnel only.
Follow approved lockout/tagout procedures.
FAILURE TO FOLLOW THESE INSTRUCTIONS
COULD RESULT IN DEATH OR OTHER SERIOUS
INJURY.
1.262.255.1510 or 1.800.643.5424
Call for additional placards, or manuals, or with questions
regarding proper use, maintenance, and repair of dock leveler.
www.DockSystemsInc.com
INSTR UCTIONS
VEHICLE RESTRAINTS
ENGAGE RESTRAINT
Open overhead door and visually check that
truck is positioned squarely against dock
bumpers and has a RIG bar. Inside light is
RED and outside light is GREEN.
Depress the ENGAGE button to activate
restraint.
Once RIG has been secured inside light is
GREEN outside light is RED
RELEASE RESTRAINT
To release truck restraint depress the
RELEASE button. When safely stored inside
light is RED and outside light is GREEN.
BY-PASS
If restraint is unable to secure transport
vehicle’s RIG, use wheel chocks to secure
transport vehicle at the dock.
Turn switch to BY-PASS. Inside light is
GREEN outside light is RED.
Loading/unloading may proceed with
caution.
BY-PASS RESET
When loading or unloading is completed,
and wheel chocks are removed, manual
reset of BY-PASS is accomplished by
depressing the RELEASE button or turning
switch to NORMAL. Lights change to RED
inside GREEN outside.
(RETURN TO NORMAL OPERATION)
Item Quantity Part Number Description
A 1 1751-0880 Placard Vehicle Restraint
32
4111-0014 — July 2013
Customer Information
MISCELLANEOUS
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.
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.
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
For service, call or contact:
Systems, Inc.
P.O. Box 309
Germantown, WI 53022
Phone: (800) 643-5424
Fax: (262) 255-5917
4111-0014 — July 2013
Name ___________________________________
Address _________________________________
_________________________________
Date of Installation ________________________
33
STANDARD PRODUCT WARRANTY
STANDARD PRODUCT WARRANTY
SYSTEMS, INC. warrants that its products will be free from defects in design, materials and workmanship
SYSTEMS, INC. warrants that its products will be free from defects in design, materials and workmanship
for a period of one (1) year from the date of shipment. All claims for breach of this warranty must be
for a period of one (1) year from the date of shipment. All claims for breach of this warranty must be
made within 30 days after the defect is or can with reasonable care, be detected. In no event shall any
made within 30 days after the defect is or can with reasonable care, be detected. In no event shall any
claim be made more than 30 days after this warranty has expired. In order to be entitled to the benefits
claim be made more than 30 days after this warranty has expired. In order to be entitled to the benefits
of this warranty, the product must have been properly installed, maintained and operated in accordance
of this warranty, the product must have been properly installed, maintained and operated in accordance
with all manufacturer’s recommendations and/or specified design parameters and not otherwise
with all manufacturer’s recommendations and/or specified design parameters and not otherwise
have been subject to abuse, misuse, misapplication, acts of nature, overloading, unauthorized repair
have been subject to abuse, misuse, misapplication, acts of nature, overloading, unauthorized repair
or modification, application in a corrosive environment or lack of maintenance. Periodic lubrication,
or modification, application in a corrosive environment or lack of maintenance. Periodic lubrication,
adjustment and inspection in accordance with all manufacturers’ recommendations are the sole
adjustment and inspection in accordance with all manufacturers’ recommendations are the sole
responsibility of the Owner/User.
responsibility of the Owner/User.
In the event of a defect, as determined by SYSTEMS INC., covered by this warranty, SYSTEMS INC.
In the event of a defect, as determined by SYSTEMS INC., covered by this warranty, SYSTEMS INC.
shall remedy such defect by repairing or replacing any defective equipment or parts, bearing the cost
shall remedy such defect by repairing or replacing any defective equipment or parts, bearing the cost
for the parts, labor and transportation. This shall be exclusive remedy for all claims whether based on
for the parts, labor and transportation. This shall be exclusive remedy for all claims whether based on
contract, negligence or strict liability.
contract, negligence or strict liability.
WARRANTY LIMITATIONS
WARRANTY LIMITATIONS
THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES, WHETHER EXPRESSED
THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES, WHETHER EXPRESSED
OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY
OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE. SYSTEMS INC. AND ITS SUBSIDARIES SHALL
OR FITNESS FOR A PARTICULAR PURPOSE. SYSTEMS INC. AND ITS SUBSIDARIES SHALL
NOT IN ANY EVENT BE LIABLE TO ANYONE, INCLUDING THIRD PARTIES, FOR INCIDENTAL,
NOT IN ANY EVENT BE LIABLE TO ANYONE, INCLUDING THIRD PARTIES, FOR INCIDENTAL,
CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO,
CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO,
BREACH OF WARRANTY, LOSS OF USE, LOSS OF PROFIT, INTERUPTION OF BUSINESS OR
BREACH OF WARRANTY, LOSS OF USE, LOSS OF PROFIT, INTERUPTION OF BUSINESS OR
LOSS OF GOODWILL.
LOSS OF GOODWILL.
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