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Powerstop Owner`s/User Manual
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1. 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 SAFETY INFORMATION Unsupported dock leveler ramps can lower unexpect ffand use SN N ZAI SANS WZ 1 1 P WEL JZ q lt L v decal placed in CRUSH HAZARD 1751033009 same position on both sides A DANGER 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 1751 0728 proper maintenance procedure Do not work under dock leveler unless this maintenance prop has been secured the upright position Failure to comply will result in death or serious injury See owner s user s manual for proper 1751 0788 Rev A 1751 0789 1751 0726 Note DANGER 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
2. Dim lt gt 48 Driveway Mount Recommended when dock face is unsuitable for PowerStop Mounting Adhesive Anchors Method Drive Embed Method Driveway mount requires Kit 9414 0058 Weld method attachment to a concrete ERE Properly locate and level the drive embed weld plate Part 7953 drive greater than 8 two 2 1 Dia adhesive 0050 in the drive approach Observe Cantilever conditions for thick For asphalt drive anchors into 1 1 8 Dia x 7 proper positioning Weld restraint to embed plate with a AQIQ d hole at f P St pour 48 x48 x8 min CEP NOI ae Tear Ol continuous V4 filet weld concrete pad and include Bolt on Method six 6 3 4 dowels into Properly locate and level the Install two 2 3 4 foundation wall Then Dia x 5 1 4 min drive embed plate 14 J j proceed with adhesive wedge anchor at Part 9414 0057 in the drive front of PowerStop anchors or weld plate embed NL 1 1 approach Observe cantilever conditions for proper positioning Using the bolts included bolt e gt gt the restraint to the embed plate 27 8 Min Rear dd 1 Dia X 6 min Front 48 bolt 3 4 Dia X 6 min bolt 4111 0014 May 2014 11 INSTALLATION DETAILS MECHANICAL POWERSTOP Operating Bar Bracket ER Control Bax V Conduit From The Control
3. NS r 5062 1 7141 0042 RELAY SOCKET g ENGAGE 42 RED 16 18 AWG TB1 KB1 4 a CR2 1 7141 0062 RELAY 9 PBI 46 RED 16 18 AWG 1 50 1 14 12110100 091 031 LIGHT MODULE IF NOT FGLASS 19 6 47 RED 16 18 AWG TB1 FLI BLK KB3 1 KB3 3 T 0961 0369 LIGHT MODULE IF N4X FGLASS 421000 48 RED 16 18 AWG 50 1 5 4 111 31 MUT 115 0961 0313 LENS IF NOT N4X FGLASS 50 RED 16 18 1 50 1 9 SOCI 12 2 CRI 0961 0371 LENS IF FGLASS 51 RED 16 18 AWG 1 50 1 4 LT2 X1 5051 0059 ae RELEASE 0961 0285 PUSH BUTTON NOT FGLASS 1 3051 0059 LAMP KB2 PB2 EANG TBL FNE GRD PBI 1 Q981 0334 PUSH BUTTON F Nax 77 1751 0424 DECAL ENGLISH GREEN 14 AWG ENCL BODY ENCL DOOR h 0961 0286 PUSH BUTTON IF NOT FGLASS 1 1751 0425 DECAL FRENCH D h IF DOOR HAS GROUNDING PROVISION USE BODY GROUNDING PROVISION PB2 s 1751 0426 DECAL SPANISH USE TB1 IF BODY DOES NOT HAVE GROUNDING PROVISION 0961 0500 SELECTOR SWITCH IF 4 FGLASS OPTIONAL BILL OF MATERIAL LED LIGHTS OPTIONAL WIRING AUDIBLE amp OR VISUAL ALARM ssi 1 0961 0305 KEY SWITCH IF NOT N4X FGLASS 0961 0318 LIGHT MODULE F NOT N4X FGLASS 5002 13 0961 0346 SELECTOR SWITCH IF FGLASS 0961 0576 LIGHT MODULE IF FGLASS 2 WHITE 16 18 AWG ALMI N
4. To pole is 92 0161 34 Electrical Conduit Outside Signal Light Assembly Operating Bar u RON ForPowerSto part 5455 0005 Series Unit Only and PowerStopMAL From the Control Box amp Series Units to the PowerStop ES Al Junction Box Y Outside Signal 113 8 Light Assembly et Mount PowerStop Operating Bar 14 bracket on the P MI interior wall closest 96 to control panel if applicable 1 Wall Mounted Imbed Elec Jundi 4 Thick Laminated Plate 20 X 20 vider Bumpers in Good g lt For PowerStopMAL only By others Center In Dock Opening 4 d Condition lush With Bottom Of Curb Steel Required Leveler Length 41 Optional DockAlert Communication System POWERSTOP Manual Restraint Automatic DockAlert POWERSTOP Manual Restraint Manual DockAlert Field wires Field wires L1 L2 115 Vac Control L1 L2 115 Vac Control Ground Ground Control assembly by Poweramp Control assembly by Poweramp 1 2 2 11 11 46 47 48 50 51 55 GRD 2 47 48 51 GRD e 8 115 8 gt gt 2 9 5 o 5 Vac 8 5 5 Field wires 6 2 48 51 115 Vac Control a E Ground 5 Field wires 2 48 51 115 Vac Control Ground Conduit must be protected from
5. Motor overload device tripped or fuse blown Hydraulic only not run Note When replacing fuse s or breakers the new fuse or breaker must have the same specification as the old Check all wire connection for damage corrosion Prox switch failed or wired incorrectly Motor energizes but does Defective motor Replace motor not run Capacitor Capacitor shorted Capacitor wired incorrectly or bad connections Voltage Low line voltage check wire size to house power Motor energizes and runs Low Hydraulic fluid Check for leaking cylinders or hoses but restraint will not raise Or lower The suction filter my be clogged Coil Coil must be energized for restraint to raise only Coil energized to lower Motor energizes and Coil should not be energized possible bad relay ower s Rabe maybe damaged Interlock prox Leveler may have interlock see leveler specific manual 16 4111 0014 May 2014 Troubleshooting IMPORTANT IMPORTANT Do not run motor when valves are removed from Do not run motor when valves are removed from valve block valve block Do not over tighten coil on valve 15 inch lbs max Do not over tighten coil on valve 15 inch Ibs max which is just over finger tight which is just over finger tight Do not over tighten valve into block 15 foot Ibs Do not over tighten valve into block 15 foot 16 max which is enough to compress the washer and max which is enough to compress the washer and prevent
6. BASE END OF RELEASE CYL CONNECT TO CO END OK REL EASE CW HYDRAULIC SCHEMATIC CONDUIT PROM THE CONTROL BOK TO CURD LIGHT MEY POWERPACK LOCATION OPTIONS Coordinate powerpack location and hose length for proper placement Dock Face gt op Appropriate location when the likelihood of flooding snow removal and _ 122227 damage from trailer trucks S H is minimal Ss Under The Dock Leveler When under cock location is usec 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 placec through min 3 PVC hydraulic and 3 4 cx conduit electrical p hase during pit SS construction Inside Building Locate powerpack to minimize obstruction rS potential Hydraulic 113 0 and electrical lines from the Powerpack TEST to the restraint 2215 10 01 12 are best placed gt through min 3 Spee sy Pet PVC hydraulic yt and 3 4 meras Nutt ae Jf electrical CMM I chase during pit TON construction 28 07 04 2 4111 0014 2014 INSTALLATION DETAILS AUTOMATIC POWERSTOP Concrete Dock Face Standard installation Wedge Anchors Method Wall Embed Method Using back plate as a guide drill six 6 holes for Weld three sides of PowerStop back plate to the optional wedge anchors 3 4 x 5 1 4 min Kit 2103 0003 em
7. Limit Switch with Bracket NC Decal Systems Inc Powerstop 3 3 4 X 14 1 2 Decal Serial Number Decal Warning HHCS Grade 2 Zinc Plated 5 16 18 UNC X 3 4 8 2101 0084 HHCS Grade 5 Zinc Plated 1 4 20 UNC X 3 4 Washer Flat Zinc Plated 1 1 8 DIA 10 8 2101 0143 Nylon Lock Nut 1 4 20 UNC RHMS Slotted 10 24 UNC X 2 1 4 Nylon Lock Nut 10 24 UNC 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 Anchor Kit Drive Way Mount 2103 0003 0003 Anchor Kit Wall Mount Level Weldment Release Pin Pivot Long 1 2 DIA Pin Pivot Short 1 2 DIA ohroud Bellows Mounting Pstop Tube 1 1 4 OD X 9 16 ID X 5 8 Bar Bellows Mounting Front Bar Bellows Mounting Side Bar Bellows Mounting DEE Restraint Weldment Low Profile 9413 0049 0049 Restraint Weldment Two Step Profile Shown scissor Lift Sub Assembly Pstop Spacer Assembly Pstop Mechanical Release Lever Assembly Pstop Mechanical Lip Deflector Hook Stop Will NOT Work with Barrel Style Prox Final Base Weldment 27 cn Lees _ Prox Over Travel Flat Style 9415 0061 0061 Prox Over Travel Includes Hardware and Lip Deflector Flat Style 32 Barrel Prox no longer available replace with 9415 0061 Conversion Kit 4111 0014 May 2014 21 PARTS PowerStop A Hydraulic Parts Breakdown 5 eS e Lg 25 268 ON
8. PressureFromPump R RetunToTank Valve 4 Way 2 Position valve Flow Control 1 GPM Valve Flow Control 650 psi Valve Sequence Fitting Elbow 6 ORB x 8 JIC 9301 0135 Fitting Connector Straight Thread 4 ORB x 6 JIC 6 2 Fitting Connector Straight Thread 6 ORB x 8 JIC NENNEN 8 1 1 91 1 8583 0050 Valve Assemble Contains 1 8 8581 0004 Delta Coil 115 volt 4111 0014 May 2014 25 PARTS Power Pack Assembly 7 1 2 9 3 4 BC Blind End of Cylinder RC Rod End of Cylinder Amp Draw 4 8 5 2 26 4111 0014 May 2014 PARTS Power Pack Assembly HHCS Grad 2 Zinc Plated 3 8 16 UNC X 1 Lock Washer 3 8 Grommet 1 3 8 OD X 3 4 ID J Box Cover 4 4 Capacitor Motor Start 66 77mf 330V 6 1 93010221 Fitting Connector 45 Deg 4 ORB 4 Power ppac PStop 1PH 115V 1 4HP 1GPM 8 1 9391 0012 Power ppac Mounting Weldment 9 1 9391 0013 CoverPstop Hydraulic Hose ASM 1 4 100R17 X 96 4 JICF Swivel Both Ends Valve 4 Way Delta Coil 115 volt P Stop Only Decal No Step On Top of Cover ll Hose Lengths by Job Ea d Powerpac Includes Valve Body Cover complete 09 ADANGER 4111 0014 May 2014 27 1431 0328 BLOCK CLAMP EXACT LOCATION OF COMPONENTS MAY BE DIFFERENT THAN WHAT IS SHOWN 3 1431 0324 TERMINAL BLOCK 47 55 56 f 1431 0326
9. SOCI CRI ALARM m 0961 0312 LENS IF NOT FGLASS UNIT HAS ANY COMBINATION OF AUDIBLE ALARM amp VISUAL ALARM P 1 40 SOC2 CR2 MRI 01 Tut 0961 0370 LENS IF FGLASS g DO NOT DUPLICATE RELAY SOCKET amp RELAY ONLY ONE SOCKET amp ONE RELAY 1751 0412 DECAL PS PR ENGLISH ARE REQUIRED IF UNIT HAS ANY COMBINATION OF AUDIBLE ALARM amp VISUAL ALARM O 8 G 48 8 amp se CO 40A L LOCATE ALARM ON 1751 0413 DECAL PS FRENCH 51000 20 RIGHT HAND SIDE 1751 0414 DECAL PS SPANISH 5 OF ENCLOSURE 1 1751 0689 DECAL PS DLM ENGLISH 2 18 4140 3 2 55 00 03 2 G OPTIONAL 2 AUD ALARM 1751 0604 DECAL ST ENGLISH 11 47 Qj 542095 2 9 4 nO fih 1751 0605 DECAL ST FRENCH Lu 1 4 ALARM 1751 0606 DECAL ST SPANISH BLOCK 4 1751 0163 LABEL a 2 BLOCKS bon E FOR 1 STICKER THERMAL UNIT e a a COMPLETE LABEL AS SHOWN BELOW AFFIX TO INSIDE OF DOOR 56 2 56 9 0 800 b SEE TABLE 2 40 41 42 46 47 47 48 50 51 55 56 cRo TB1 5 VOLTS c USE ENCLOSURE MFGR S RATING 1 PHASE PLACE STICKER NEAR 60 TB1 GRD TERM BLOCK b TOTAL FLA MAXIMUM ENCL PNL 46 MOTOR FLA LARGEST MOTOR 0 25 HP LARGEST MOTOR ENCLOSURE TYPE c SHORT CIRCUIT CURRENT 5 RMS SYMMETRICAL 120 MAXIMUM d APPROPRIATE LABEL NEXT TO COMPONENT e A
10. TERM BLOCK JUMPER 40A RED 16 18 AWG MR1 B 011 4 RED 16 18 AWG 1 50 1 10 2 4 BILL OF MATERIAL BILL OF MATERIAL a WIRE_CHART LEGEND QTY PART NUMBER DESCRIPTION LEGEND QTY PART NUMBER DESCRIPTION ENCL 1 SEE TABLE 1 ENCLOSURE NO COLOR SIZE LOCATIONS PL 1 SEE TABLE 1 PANEL OPTIONAL BILL OF MATERIAL AUDIBLE ALARM 1 BLACK 14 TB1 7 15 1431 0324 TERMINAL BLOCK d 1431 0324 TERMINAL BLOCK 47 55 56 f 1 RED 14 AWG CBI B 3 BLACK 14 AWG MR1 4 OLI 1431 0327 BLOCK JUMPER 3 POLE 1451 0326 JUMPER A 1431 0326 TERM BLOCK JUMPER 2 POLE 5002 7141 0042 9 BLACK 14 AWG OLI 1431 0335 TERM BLOCK GROUNDING d CR2 7141 0062 g 2 WHITE 16 18 AWG 1 50 1 13 011 1 2 LT2 X2 1431 0336 TERM BLOCK END AM 1 3051 0112 ALARM 11 RED 14 AWG CBI 1431 0325 TERM BLOCK END 1 RED 16 18 AWG TB1 FLI RED KB1 3 KB1 3 2 3 OPTIONAL BILL OF MATERIAL VISUAL ALARM DOOR AS VIEWED FROM INSIDE WITH DOOR OPEN 40 RED 16 18 AWG 1 MRI A SOCI 6 4 8 1 1 1 1 1 2 5 3051 0032 TERM BLOCK CHANNEL TBI 1 1 1 1 1 1 1 Electrical Control Box
11. Texaco Aircraft Hydraulic 15 or 5606 e Exxon Univis J13 IMPORTANT These fluid brands can be mixed together Mixing with Use of fluids that do not have equivalent fluids that do not meet or exceed MIL H 5606 G may specifications to those in the following list will result damage the equipment and WILL void warranty Use in abnormal operation of the dock leveler and of hydraulic fluids with equivalent specifications to voiding of warranty those listed here are acceptable Failure to follow these instructions may result in 18 4111 0014 May 2014 Daily Maintenance e Daily clear any debris to prevent operation issues 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 e 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 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 an
12. damage Field wires Outside signal light assembly by Poweramp Conduit amp connections must be liquid tight P 11 46 Proximity 115 Vac Control included with optional DockAlert Communciation Systems if in area where liquid can be present 47 55 Limit Switch Option 115 Vac Control Ground Junction box at face of dock Wires 47 amp 55 if used Multiconductor cable Conduit must be protected from damage Field wires Conduit amp connections must be liquid tight 47 55 Limit Switch Option Field wires if in area where liquid can be present 115 Vac Control 2 48 51 115 Vac Control Ground Ground Truck restraint Limit switch option 47 55 BND i4 Ground Proximity switch e 12 4111 0014 May 2014 INSTALLATION DETAILS MECHANICAL POWERSTOP Concrete Dock Face Standard installation Wedge Anchors Method Wall Embed Method Using back plate as a guide drill six 6 holes for Weld three sides of PowerStop back plate to the optional wedge anchors 3 4 x 5 1 4 min Kit 2103 0003 embed mounting plate d 7953 0119 with ten 10 4 long 1 4 fillet n gt lt 5 1 4 minimum 4 2 0 0 poe 1 16 3 8 l l Anchor pit floor mounting plate minimum 3 8 x 20 W x 8 D Part 49414 0056 with four 4 3 4 x 5 1 4 min wedge anchors Weld mounting plate to curb steel and back
13. 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 Trim or cut front frame member when necessary to allow for pit floor mounting plate 27 If 24 To determine size offset required take total effective Dim A lt bumper projection bumper size plus any cantilever and subtract 4 Wall Mount For filler requirements from 1 Y2 to 7 V2 use cantilever bracket 49414 0052 and anchor cantilever bracket to the lt Dim B dock face or weld to embedded mounting plate Part 7953 0119 Driveway Mount Determine offset Dim then proceed with Driveway Mount instructions below Dim A Dim B Bumper Projection Cantelever For filler requirements for 8 3 4 to 13 3 4 use cantilever bracket 9414 0053 and anchor cantilever bracket to the dock face 3 4 Dia X 5 1 4 min Kit 2103 0004 or weld to embedded mounting plate Part 9414 0052 Dim lt gt 4 487 9 Driveway Mount Recommended when dock face is unsuitable for PowerStop Mounting Adhesive Anchors Method Drive Embed Method Driveway mount requires Kit 9414 0058 Weld method attachment to a concrete us Properly locate and level the drive embed weld plate Part 7953 drive greater than 8 Install two 2 1 Dia adhesive 050 in the drive appro
14. 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 Troubleshooting Line side of fuse is always hot Turn off main power Discharge capacitor before attempting a capacitor test supply before removing fuses Attach proper lock out tag out devices Restraint will not raise or Debris Remove Bellows check for Debris jammed in scissor lower mechanism Restraint will not raise Lubrication Lubricate latch release leveler or lower Mechanical or Lubricate pivot points scissors mechanism Hydraulic Damaged parts 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 Restraint will not raise Lights on but Motor does
15. 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 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 14 Coordinate powerpack location and hose POWERSTOP Overview Dock Face Appropriate location when the likelinood 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 e
16. 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 4111 0014 May 2014 INTRODUCTION 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 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 INSTALLATION DETAILS AUTOMATIC POWERSTOP A Division of Systems Inc MP Premium Loading Dock MOUNTED 1 GNIEN DOOL fui wT OF Cute ru UNTON AT TOS eee IWMS JORG T A ac OR COMBINATION LAVIL ERRESTRAI
17. 1751 0880 OPERATING INSTRUCTIONS VEHICLE RESTRAINTS ENGAGE RESTRAINT 1 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 lightis GREEN 2 Depress the ENGAGE button to activate restraint 3 Once RIG has been secured inside light is GREEN outside light is RED RELEASE RESTRAINT 1 To release truck restraint depress the RELEASE button When safely stored inside lightis RED and outside light is GREEN BY PASS 1 If restraint is unable to secure transport vehicle s RIG use wheel chocks to secure transport vehicle at the dock 2 Turn switch to BY PASS Inside light is GREEN outside lightis RED 3 Loading unloading may proceed with caution BY PASS RESET RETURN To NORMAL OPERATION 1 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 Item Quantity Part Number 1751 0880 Placard Vehicle Restraint 32 4111 0014 May 2014 Customer Information NOTE Refer to illustration for left right orientation of dock leveler The LEVELER 5 number decal is located on the right platform joist near the front lip of dock leveler The RESTRAINT model Serial number decal B is located on the right side When you receive your new
18. 202 Bar Bellows Mounting Side Painted 1 8 X 1 X 23 9412 0215 Bar Bellows mounting Painted 1 8 X 1 X 13 9413 0055 Restraint Weldment Low Profile 9413 0049 Hestraint Weldment Two Step Profile Shown 9413 0062 Scissor Lift Sub Assembly Pstop 9413 0069 Spacer Assembly PStop A 9413 0071 Helease Lever Assembly 9413 0120 Lip Deflector Hook Stop Will NOT Work with Barrel Style Prox 9414 0046 Final Base Weldment 27 9904 0097 Hydraulic Hose ASM 1 4 100R1 X 24 4 JICF Swivel Both Ends 9904 0119 ydraulic Hose 1 4 100R1 X 96 4 JICF Swivel Both Ends 0522 0002 pring Helper Rear Frame CD 9413 0538 Prox Over Travel Flat Style 9415 0061 Prox Over Travel Includes Hardware and Lip Deflector Flat Style Barrel Prox no longer available replace with 9415 0061 Conversion Kit 4111 0014 May 2014 23 PARTS PowerStop Scissor Breakdown Rear of Restraint Quantity Part Number Description 3 9413 0063 Bar Assembly Tapped W Bushings Bar Assembly W Bushing Bar Assembly Notched Spring Extension socket Head Shoulder Bolt E Clip Pin Long opring Plate Weldment Flanged Bearings 1 scissor Lift Subassembly N 4111 0014 May 2014 PARTS PowerStop Valve Combined With Leveler Vai RA 60 Leveler coil De Energized leveler Energized restraint Restraint Coil De Energized Lower Energized to raise 8 P
19. A Division of Systems Inc POWERAMP PowerStop Vehicle Restraint Owner s User s Manual SYSTEMS INC W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 255 5917 www docksystemsinc com techservices docksystemsinc com Printed in U S A Manual No 4111 0014 Copyright 2014 May 2014 Table of Contents Page Safety Recognize Safety Information ee 1 General Operational Safety Precautions 1 Operational Safety 2 Maintenance Safety 1 1 4 Safety Decals ee 5 Placard installation T 7 Owner s User s Responsibilities 8 Introduction General Information anc naui tr 9 Installation Install Details Automatic 10 Install Details Manual J 12 Install Control Panel and wiring 14 Operation Operating Instructions J 15 Troubleshooting Tronbieshoet I Rguuuu u AI 16 Maintenanc
20. FFIX TO SIDE OF ENCLOSURE WALL NEAR OVERLOAD RELAY TABLE 2 VS ALM AUD ALM TOTAL FLA TABLE 1 5 1 A OPTIONAL OPTIONAL OPTIONAL 12 4 NEMA 4X STAINLESS NEMA 4X FIBERGLASS 51 A ENL PN PN PN 52 A 2751 0084 2751 0085 2751 0070 2751 0085 2751 0142 2751 0085 2751 0144 2751 0032 4111 0014 May 2014 Provide serial number for specific drawings Generic Drawings shown 28 Electrical Ladder Diagram SEE LABEL INSIDE THE CONTROL ASSY FOR OPTIONS INCLUDED ON UNIT OMER SUPPLIED T V 1 PHASE 60 HZ FROM BRANCH CIRCUIT DISCONNECT SWITCH L1 amp OVERCURRENT DEVICE BY OTHERS SELECT DISCONNECT SWITCH amp OVERCURRENT DEVICE PER THE NEC DISCONNECT pty THE CONTROL A ua TIME DELAY nes MUST BE USED FOR BRANCH CIRCUIT PROTECTION MTR1 MOTOR NAMEPLATE DATA 1 4 4 6 SOL A prx FLUID M RESTRAINT WHEN DE ENER RAISE RESTRAINT WHEN ENERGIZED 103 109 110 ED CEs DE Wes RESTRAINT FULLY LOWERED RESTRAINT FULLY LOWERED 112 CR2 OPTIONAL DE ENERGIZED WHEN RESTRAINT NOT FULLY RAISED ENERGIZED WHEN RESTRAINT FULLY RAISED amp LTS OPTIONAL DE ENERGIZED WHEN RESTRAINT NOT FULLY RAISED ENERGIZED WHEN RESTRAINT FULLY RAISED Generic Drawings shown Provide serial number for specific drawings 4111 0014 May 2014 29 PARTS Outside Signs CAUTION PULL IN OR OU
21. Failure to comply will result in death or serious injury 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 This 1s a example of dock leveler safety decals See manual for your specific model for correct safety decal sheet or consulate Tech Services 4111 0014 May 2014 Placard Installation Instructions PLACARDS Make sure placard is in plain view of dock leveler operations Owner is responsible for the installation and placement of product placards 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 SS NSESEES SS 4111 0014 2014 SEE Teta Sete 0 OWNER S USER S RESPONSIBILITIES 10 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 fo
22. IF AUD ALM 0961 0351 KEY SWITCH 4 FGLASS LTI 0961 0322 LENS IF NOT FGLASS OPTIONAL LT5 X2 IF MS ALM i 0961 0295 MTG BASE W CONTACT BLOCK NOT FGLASS 0961 0380 LENS IF FGLASS MM 47 RED 16 18 AWG S0C2 9 0961 0343 BASE z CONTACT BLOCK t FGLASS 7 0961 0316 LIGHT MODULE F NOT MEI FGLASS 55 RED 16 18 AWG 1 1 50 2 14 0961 0293 MTG BASE W CONTACT BLOCK IF NOT N4X FGLASS 0961 0374 LIGHT MODULE IF 55 S0C2 5 0961 0341 BASE W CONTACT BLOCK IF 4 FGLASS LT2 0961 0320 LENS IF FGLASS ud D 56 RED 16 18 AWG AUD ALM 0961 0297 MTG BASE W CONTACT BLOCKS IF NOT FGLASS ET 0961 0378 LENS IF FGLASS 48100100 0961 0345 MTG W CONTACT BLOCKS IF N4X FGLASS 0961 0317 LIGHT MODULE IF FGLASS 2 0901031 LIGHT MODULE IF NOT N4X FGLASS E ET 0961 0375 LIGHT MODULE IF FGLASS LTI 2 0961 0569 LIGHT MODULE IF FGLASS 0961 0321 LENS IF NOT FGLASS PANEL EXACT LOCATION OF COMPONENTS MAY BE DIFFERENT THAN WHAT IS SHOWN 2 3051 0059 LAMP 0961 0379 LENS IF N4X FGLASS BOLD LINES INDICATE FIELD WIRING LTI 0961 0314 LENS IF NOT ND FGLASS f DO NOT DUPLICATE TERMINAL BLOCKS 47 55 amp 56 ONLY ONE TERMINAL BLOCK OPTIONAL 0961 0372 LENS IF FGLASS 47 ONE TERMINAL BLOCK 55 amp ONE TERMINAL BLOCK 56 ARE REQUIRED IF
23. NT MOSTA OR W ui MOTOR N PW m POWERSTOP 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 Va ELECTR AL CONDUI FROM THE 00 ome 8 POWETED LEVELES 5 gum Automatic PowerStop Installation Overview For comprehensive installation instructions of the Automatic PowerStop PowerStop read and understand the Installation and Operation Manual CONTRO BOX 4 EECTIICAL CONDUIT THE CONTROL 90 THE POSER GOP IUNCTION BOX EY OTHERS CONTROL 103 TO THE PTT OMS BOR POWER UT I I I BASF PYELER LENGTH Conduit and associatec hardware to complete wiring and mounting of powerpack are to be supplied by others Fr Tr Fr T use ama rcd apices 2 mese 511 171205 oe mam Ls ema Se tee 109 101 992206 CM 11 998005 Powermac Mounting men BCA Vive Ay IIASA MADO WATU ROTH PAC N u 4 884 soit len Cond 10 Capacitor Wiring Detail MOTE CONNECTTO
24. T ON GREEN ONLY Dm Germantown 51022 Item Quantity Part Number MOITUAJ 109 AO TUO nadig 1 0 Germantown WT E1022 Description SIGN PULL IN OUT ON GREEN ONLY es RIGHT READING 16 7 8x8x3 32 B 3251 0034 SIGN PULL IN OUT ON GREEN ONLY MIRROR IMAGE 16 7 8x8x3 32 30 4111 0014 May 2014 PARTS OSLA Outside Light Assembly Quantity Part Number Description Complete Light Housing Yellow Plastic LED Lights Complete Light Housing Yellow Plastic Incandescent Lights Light Housing Only Yellow Plastic Lens Red for use with incandescent bulbs Lens Green for use with incandescent bulbs Lamp 25W 120V Incandescent BAY Rated 1000 Hours Socket Harness for Incandescent Lamp Lens Housing Circuit Assembly Red LED Lens Housing Circuit Assembly Green LED Mounting Gasket Clips Lens Holding 6 4 3051 0104 Screw Lens Holding Clip Conduit Fastener 3 4 x 3 8 4111 0014 May 2014 31 PLACARD A DANGER Read and follow all instructions warnings and maintenance schedules the manual and on placards Vehicle restraint operation and servicing 1 restricted to trained personnel 1 Before using the vehicle restraint e Remove any debris snow 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 r
25. Z U 7 DAN PA lt SS Oe lt A 2102229 220 4111 0014 2014 PARTS PowerStop A Hydraulic Parts Breakdown Item Quantity Part Number Description 0191 0025 Bellows W 1 X 13 1 2 Velcro Strips 0524 0063 HYD Cylinder ASM 1 Stroke 0524 0064 HYD Cylinder ASM 5 3 4 Stroke 0615 0037 Stored Limit Switch with Bracket NC 1751 0444 Decal Systems Inc Powerstop 3 3 4 X 14 1 2 1751 0010 Decal Serial Number 2101 0009 HCS Grade 2 Zinc Plated 5 16 18 UNC X 3 4 2101 0039 Nylon Lock Nut 5 16 18 UNC 2101 0084 HCS Grade 5 Zinc Plated 1 4 20 UNC X 7 8 2101 0098 HCS Grade 5 Zinc Plated 5 16 18 UNC X 1 3 4 2101 0143 Nylon Lock Nut 1 4 20 UNC 2101 0150 HMS Slotted 10 24 UNC X 2 1 4 2101 0151 Nylon Lock Nut 10 24 UNC 2101 0163 Washer Flat Zinc Plated 1 2 DIA X 5 8 2101 0165 Shoulder Bolt 1 2 DIA X 5 8 2101 0187 HCS Grade 5 5 16 18 UNC X 1 2101 0188 HCS Grade 5 5 16 18 UNC X 1 1 4 2101 0189 E Clip 1 2 2101 0202 Phillips 10 32 UNF X 1 3 4 2101 0212 Flat Head Cap Screw 1 2 13 UNC X 1 2103 0006 Anchor Kit Drive Way Mount 2101 0003 Anchor Kit Wall Mount 9202 0042 Pin Pivot Long 1 2 DIA OO 02 Co C2 Co 100 CO GO N 1 JO JO 410 11 1 1 4 2 Co OI OO LIL JJ 9202 0043 9411 0024 9411 0028 9412 0161 9412 0201 9412 0
26. ach Observe Cantilever conditions for thick For asphalt drive anchors into 1 1 8 Dia x 7 proper positioning Weld restraint to embed plate with a pour 48 x48 x8 min deep hole at rear of PowerStop continuous 347 filet weld concrete pad and include Bolt on Method six 6 3 4 dowels into Properly locate and level the Install two 2 3 4 foundation wall Then Dia x 5 1 4 min drive embed plate 14 J j proceed with adhesive wedge anchor at Part 9414 0057 in the drive front of PowerStop approach Observe cantilever conditions for proper positioning Using the bolts included bolt lt the restraint to the embed plate 27 Rear E d Front 1 Dia X 6 3 4 Dia X 6 48 A min bolt min bolt D anchors or weld plate embed LY 4111 0014 2014 13 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
27. ailers with air ride suspension systems shall have its air exhausted prior to performing loading and unloading operation to minimize trailer bed drop 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 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 4111 0014 May 2014 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 trouble free performance with an absolute minimum of maintenance To obtain maximum performance and longest possible use a simple program of preventive maintenance is recommended 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
28. ath The use of the word CAUTION signifies possible hazard or unsafe practice which could result in personal injury IMPORTANT The use of the word IMPORTANI 1 draw attention to a procedure that needs to be followed to prevent machine damage 4111 0014 May 2014 SAFETY 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 EE Whey 58 AAA 4 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 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 ee 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 K
29. bed mounting plate 7953 0119 with ten 10 4 long 1 4 fillet mu gt 1 1 gt lt 5 1 4 minimum pn u Plate 1 1 lt 3 8 Anchor pit floor mounting plate minimum 3 8 x 20 W x 8 D Part 49414 0056 with four 4 3 4 x 5 1 4 min wedge anchors Ti rim or cut front frame member Weld mounting plate to curb steel and back plate of PowerStop with when necessary to allow for pit a continuous 1 4 fillet weld Anchor back plate of PowerStop to floor mounting plate dock face with a minimum or 4 3 4 x 5 1 4 wedge anchors Kit 2103 0003 mm If 24 4 To determine size offset required take total effective Dim A lt bumper projection bumper size plus cantilever subtract 4 Driveway Mount Dim gt lt Wall Mount For filler requirements from 1 to 7 V2 use cantilever bracket 49414 0052 and anchor cantilever bracket to the lt Dim B dock face or weld to embedded mounting plate Part 7953 0119 Determine offset Dim B then proceed with Driveway Mount gt instructions below Dim A Dim B Bumper Projection Cantelever For filler requirements for 8 3 4 to 13 3 4 use cantilever bracket 9414 0053 and anchor cantilever bracket to the dock face 3 4 Dia X 5 1 4 min Kit 2103 0004 or weld to embedded mounting plate Part 9414 0052
30. cus 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 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 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 The Owner User must review all name plates placards decals instruct
31. d lubricate scissors assembly A and all pivot points e Make sure Rear Track Assist Spring D is properly seated at the bottom of the rear track Yearly Maintenance Repeat of Quarterly Maintenance e Change Hydraulic Oil May be required earlier depending on conditions 4111 0014 May 2014 MAINTENANCE M Reservoir P Breather Cap N 1 in 25 5 mm From Top of Q Fluid Level Reservoir 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 Check reservoir fluid level 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 ON electrical power Hefer to OSHA regulation 1910 146 Hefer to OSHA regulation 1910 147 PowerStop Mechanical Parts Breakdown PARTS 12 1 64 6 ED 06 ON oD b IA DETAIL A 4111 0014 May 2014 PARTS PowerStop M Mechanical Parts Breakdown Bellows W 1 X 13 1 2 Velcro Strips Spring 1 7 8 DIA X 6 00 Stored
32. e Periodic Maintenances 18 Parts Mechanical PowerStop Components 20 Hydraulic PowerStop Components 22 Scissors Break down 24 Hydraulic Combo valve Block 17 25 Powerpack Assembly 26 zeigt P 28 Outside sme 30 Outside Light Assembly 31 Operations Placards ee 32 Miscellaneous Customer Information J J J J J J J U 33 ua Back Cover 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 The use of the word WARNING signifies the presence of a serious hazard or unsafe practice which may result in serious injury or de
33. eep hands and feet clear of pinch points Avoid putting any part of your body near moving parts EEZE 7 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 AND Do not use a broken or damage dock leveling device Make sure proper service and maintenance procedures have been performed before using CP _ or Make sure lip overlaps onto transport vehicle at least 4 in 102 mm Keep a safe distance from both side edges 4111 0014 May 2014 Do not use dock leveling device if transport vehicle is too high or too low Do not overload the dock leveling device Do not operate any equipment while under the influence of alcohol or drugs Do not leave equipment or material unattended on dock leveling device 4111 0014 May 2014 SAFETY 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 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 res
34. equipment write down the model and serial number 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 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 SEHIAL NUMBER For service call or contact Systems Inc P O Box 309 Germantown WI 53022 Phone 800 643 5424 Fax 262 255 5917 4111 0014 May 2014 MISCELLANEOUS MALI i Truck Restraint Information Serial No eae Systems Inc Job No Dock Leveler Information Serial No O Systems Inc Job No Original Owner Information Address Address 33 STANDARD PRODUCT WARRANTY 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 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 e
35. estraint 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 2 Before attempting to restrain a transport vehicle Verify that transport vehicle is positioned squarely against dock bumpers nspect 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 f equipped with a light communication package load and unload on GREEN light only 4 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 AE uu 1 262 255 1510 or 1 800 643 5424 MCGUIRE DLM Call for additional placards or manuals or with questions regarding proper use maintenance and repair of dock leveler Loading Dock Equipment Www DockSystemsinc com
36. fore 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 Hazardous Voltage Will Cause Severe Injury or Death 4111 0014 May 2014 Safety Decals 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 A DANGER CRUSH HAZARD for replacements 1751 0727 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 0730 x2 ADANGER SAFETY INFO ler problems immediately to supervisor MAINTENANCE SERVICE j ingto 1 Read and follow ions Before allowing vehicle to leave 9 ihe dock always e Ensure no equipment material or people are on dock leveler e Return dock leveler to its stored position at dock level i Failure to follow posted instructions will result in death or serious injury decal placed in same position on both sides 1751 0329 x2 decal placed in same position on both sides 1751 0330 x2 decal placed in same position on both sides ADANGER CRUSH HAZARD 1 7 5 1 01 3 8 DO NOT REMOVE hydraulic cylinder until leveler is safely supported by maintenance p
37. ions 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 Manufacturers 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 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 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 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 tr
38. leakage prevent leakage Restraint move in one The four way valve may be damaged or has trash in direction only the valve Coil Check nut on coil may be over tightened and causing valve to bind up Lights don t change Prox switch Prox switch has two lights on switch Green when metal is present on red when no metal is present Lights not flashing or Flasher Flasher can fail closed lights on steady no flash not on Flasher can fail open lights will not be on Check to make sure bulbs are not burned out Alarm on or caution Damaged over travel prox Damaged or malfunctioning prox switch light on 4111 0014 May 2014 17 MAINTENANCE Periodic Maintenance T ELE DUX v Fo 4 A Scissors Assembly D Rear Track Assist Spring G Bellows K E Clip B Hook Weldment E Platform Hinge Area H Main Springs L Bearing C Rear Vertical Track F Bottom Slide Track J Pin 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 Before performing any maintenance under the dock leveler or vehicle restraint lock the electrical power source in OFF position using an approved locking ULTRA VIS HVI 15 Aero Shell Fluid 4 or Fluid 41 Mobile Aero HFA Mil HS606A or Aero HF serious personal Injury or death e
39. lectrical lines from the powerpack to the restraint are best placed through min 3 PVC hydraulic and 3 4 conduit electricl chase during pit construction z x Inside Building Locate powerock 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 4111 0014 May 2014 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 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 fro
40. m 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 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 May 2014 OPERATION Disconnect the external lifting device and lifting brackets Remove latch shipping bolt from latch mechanism on both manual and hydraulic models This prevents PowerStop from raising 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 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 Lower
41. ntitled to the benefits of this warranty the product must have been properly installed maintained and operated in accordance with all manufacturers recommendations and or specified design parameters and not otherwise 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 adjustment and inspection in accordance with all manufacturers recommendations are the sole responsibility of the Owner User 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 for the parts labor and transportation This shall be exclusive remedy for all claims whether based on contract negligence or strict liability WARRANTY LIMITATIONS 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 FITNESS FOR A PARTICULAR PURPOSE SYSTEMS INC AND ITS SUBSIDARIES SHALL 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 BREACH OF WARRANTY LOSS OF USE LOSS OF PROFIT INTERUPTION OF BUSINESS OR LOSS OF GOODWILL
42. rop Refer to owner s user s manual for proper maintenance procedure Failure to comply will result in death or serious injury 1751 0729 A DANGER 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 0729 Rev A DANGER CRUSH HAZARD Rotate prop to maintenance position Open the pin latch 1 7 5 1 07 3 1 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 DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is 75 Em 7 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 Note This 1s a example of dock leveler safety decals See manual for your specific model for correct safety decal sheet or consulate Tech Services 4111 0014 May 2014 SAFETY Safety Decals 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 1751 0730 x2
43. traint 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 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 grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present Stray sparks can ignite spills or leaks near the work area Always clean up the oil leaks and spills before proceeding with grinding or welding Always keep a fire extinguisher of the proper type nearby when grinding or welding Failure to follow these instructions may result in serious personal injury or death ALWAYS 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 DANGER Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De energize equipment be
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