APS 2000® VEHICLE RESTRAINT
Contents
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3. EITHER BE PLUG ae ee WELDED OR ANCHORED i 5 8 FIGURE 6 ROLLER CARRIAGE ASSEMBLY TORQUE TO 9 FT LBS SPRING SPRING COVERS ROLLER TRACK PLATE SPRING BAR TO 3i FTLBS TORQUE TO 9 FT LBS FIGURE 7 MOUNT CONTROL BOX ON LEFT SIDE OF DOOR OPENING MOUNTING HARDWARE SUPPLIED BY OTHERS 11 Mount and wire outside signal light assembly to the FIGURE 8 control box See the Wiring Diagram for electrical connections Make sure outside light assembly is mounted with the red light on top and the green light on the bottom RED LEAD FROM RED LIGHT 12 Mount electrical junction box not supplied near the BLACK LEAD IS Vehicle Restraint See Figure 9 OUTSIDE LIGHT COMMON 13 The Vehicle Restraint includes a wiring harness Run the harness from the carriage to the outside junction box Leave about 4 of slack in the wiring harness Wire not supplied from the control box to the junction box See Wiring Diagram 14 Wire power to the control box using terminals provided in the control box See Wiring Diagram 15 Permanently mount the vehicle drivers instruction signs on the outside wall under the signal light or where clearly visible by driver when installing the Red Green Light Assembly See Figure 9 16 Operate the Vehicle Restraint following the Operation instructions Check for smooth o
4. APS Resource Your Aftermarket Solution 6219 West Eastwood Court Mequon Wisconsin 53092 TEL 262 518 1000 FAX 1 800 827 7491 APS 2000 VEHICLE RESTRAINT Installation and Owner s Manual This manual applies to Vehicle Restraints manufactured beginning AUGUST 2013 with the serial numbers 15 017 001 and higher Do not install operate or service this product unless you have read and understand the Safety Practices Warnings and Installation and Operating Instructions contained in this manual Failure to do so could result in death or serious injury 2014 4Front Engineered Solutions Inc APS Resource 5609 RN 01 14 CONTENTS CONTENTS 1 LIMITED WARRANT E 2 SAFETY PRAC TICE 3 INSTALLA TION ann mm 4 WIRING ate tg ee T 9 WIRE FHARNESS dn fee EE 10 ep cC 11 PLANNED MAINT zh e c 14 TROUBLESHOOTING wr 18 PARTS LIS PO 19 SAFETY SIGNAL WORDS You may find safety signal words such as DANGER WARNING or CAUTION throughout the Owners Manual Their use is explained below This is the safety alert symbol I
5. EDGE 25 5 8 5 8 NOTE ALL 15 HOLES MUST BE ANCHORED PAGE 5 4 Check to see if the roller track plate is plumb and flush with dock face If not use 6 shims 2 wide x 25 5 8 long If shims are over 1 2 thick use longer anchors If shims need to be 1 thick or more a bracket is required Consult APS Resource See Figure 4A The anchor bolts should be installed as the holes are drilled to prevent the Vehicle Restraint from shifting NOTICE The anchor bolt heads must be tightly secured against the roller track plate to prevent interference with the carriage assembly 9 Anchor the roller track plate to the dock face using the 15 5 8 dia x 4 long anchors provided The anchor bolts must be torqued to 60 ft lbs to achieve maximum holding strength See Figure 3 If the top portion of the roller track plate is in contact with the front pit curb angle such as installing in a deep pit weld across the top of roller track plate to the curb angle 6 Ifthe APS 2000 vehicle restraint is being installed at a loading dock with a pit style dockleveler that does not have lip storage supports otherwise known as lip keepers there is a bolt on lip deflector gusset kit P N AP5664 included with the APS 2000 This kit must be installed to prevent a pendant dock leveler lip from moving or storing behind the original lip deflector welded to the righ
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7. WIRE LABEL FUNCTION GROUND 2 RELEASE MOTOR 3 COMMON PLUG 4 ENGAGE 5 6 7 A BLUE BLACK 13 B WHITE BLACK 11 2 LS 1 12 1 D GREEN G A RED BLACK 15 B ORANGE BLACK 12 1 LS 2 C D MOTOR PLUG BLACK GREEN RED WHITE BLUE BLACK LS 1 CONNECTOR WHITE BLACK LIMIT SWITCH 1 ORANGE GREEN RED BLACK ORANGE BLACK BLUE LS 2 CONNECTOR LIMIT SWITCH 2 GREEN C18205 CONTROL HARNESS 2014 4Front Engineered Solutions Inc APS Resource 5609 RN 01 14 PAGE 10 OPERATION Use of the restraint is restricted to trained operators Before operating the vehicle restraining device read and follow the Safety Practices Warnings and Operation instructions contained in this manual Use by untrained people could result in death or serious injury Before chocking the wheels or engaging the vehicle restraint dump the air from the air ride suspensions and set the parking brake Do not load or unload any vehicle unless you make certain the Vehicle Restraint has securely hitched the vehicle s rear impact guard and the vehicle has set the brakes If the Vehicle Restraint does not hitch the vehicle s RIG for any reason BE CERTAIN CHOCK THE VEHICLE WHEELS BEFORE LOADING OR UNLOADING Visually inspect the Vehicle Restraint to ensure proper engagement The notch on top of the hook must wrap over the RIG See Figure 10 Enter the vehicle only when the green signal light on
8. Check wiring 6 2 Alarm horn not working Replace 6 3 Limit switch not working Replace Hook and lights work but the alarm horn continuously sounds 7 1 Not wired properly Check wiring 7 2 Limit switch LS2 not working Replace Carriage assembly does not return to the proper stored position 8 1 Springs are either weak or broken Replace 8 2 Roller track plate bent Check for proper installation and replace if necessary 8 3 Carriage not moving freely up and down in the track This may be due to an obstruction in the roller track STOP Do not work on or around the Vehicle Restraint Under this condition the springs may be under considerable tension and without properly securing the carriage assembly the Vehicle Restraint is unsafe to work on or around Call an approved and qualified technician familiar with the APS Resource line of products For a list of approved and qualified technicians call APS Resource at 262 518 1000 5609 RN 01 14 PAGE 18 PARTS LIST To ensure proper function durability and safety of the product only replacement parts that do not interfere with the safe normal operation of the product must be used Incorporation of replacement parts or modifications that weaken the structural integrity of the product or in any way alter the product from its normal working condition at the time of purchase from APS RESOURCE could result in product malfunction breakdown premature wear death or serio
9. NOTICE Use only lubricants shown Improper lubrication or adjustments may cause operational problems Legend Symbol Lubricate Oil Chain Lube p Lubricate Grease Lithium and synthetic oil based moly grease Temperature range of 2014 4Front Engineered Solutions Inc APS Resource Description 40 to 170 F or as required by service conditions Check Fasteners or Adjust Torque Torque Noted Cleaning Location Frequency 5609 RN 01 14 PLANNED MAINTENANCE FIGURE 16 4 SWITCH CARRIAGE ROLLERS MOUNTING BRACKET p x o GREASE FITTING GREASE FITTING ON BOTTOM ROLLER SHAFT NOT SHOWN DRIVE CHAIN VIEW DRIVE CHAIN 360 DAYS FIGURE 17 AROUND VEHICLE RESTRAINT DAILY CONCRETE ANCHOR BOLTS 60FT LBS PAGE 14 PLANNED MAINTENANCE PLANNED MAINTENANCE SCHEDULE 1 As required to remove debris around the Vehicle Restraint Cleaning Lubrication Not Required 1 Inspect dock bumpers Missing bumpers must be replaced 2 Inspect all operating warning and caution labels and signs to be sure they can be read Replace labels and signs as required See the PARTS LIST for
10. not hitched and not properly released Make sure trailer is parked firmly against the dock bumpers and clear any obstructions Turn the key switch from NORMAL to RESTRAINT OVERRIDE HORN SILENCE then turn key switch back to NORMAL to release the restraint vehicle may now pull out OPTIONAL OPERATIONAL FEATURES The APS 2000 control board has three optional features that can be selected by adjusting the DIP switch settings on the APS 2000 control board See Figure 12 for the DIP switch setting location For the DIP switch setting to take effect the service tech nician must disconnect power to the APS 2000 control panel prior to adjusting the DIP switch setting Then re apply power to the control panel after making the setting 2014 4Front Engineered Solutions Inc APS Resource 5609 RN 01 14 PAGE 12 OPERATION OPTIONAL OPERATIONAL FEATURES DIP Switch 1 Inside communication light illumination Reference Figure 13 for this DIP switch setting detail When DIP Switch 1 is in the OFF position the inside communication lights will illuminate solid The APS 2000 comes from the factory with this setting When DIP Switch 1 is in the ON position the inside communication lights will flash DIP Switch 2 Hook position in RESTRAINT OVERRIDE HORN SILENCE operating mode Reference Figure 14 for this DIP switch setting detail When DIP Switch 2 is in the OFF position the hook will lower when the APS 200
11. the control box is illuminated You must check the green signal light each time that the vehicle is entered If the illuminated green light goes off at any time during loading operations immediately cease loading operations and check the Vehicle Restraint to ensure that it is securely hitched If power to the Vehicle Restraint is interrupted immediately cease operations and check the unit Consult the troubleshooting instructions to reset the lights when power resumes Vehicles leaving or moving when loading and unloading are in process could result in death or serious injury Failure to place the hook in the stored position when not in use could result in damage to the Vehicle Restraint and incoming trucks Be certain bystanders in the driveway stand clear when the Vehicle Restraint is operated TO HITCH VEHICLE Press ENGAGE button to restrain Visually inspect the Vehicle Restraint to ensure proper engagement The notch on top of the hook must wrap over the RIG See Figure 10 If vehicle cannot be hitched red light will illuminate and the alarm will sound 2014 4Front Engineered Solutions Inc APS Resource 5609 RN 01 14 FIGURE 10 PROPER ENGAGEMENT SECURELY HITCHED FIGURE 10A SS J NN NOT SECURELY HITCHED RED SIGNAL LIGHT FIGURE 11 GREEN SIGNAL LIGHT ENGAGE RELEASE RESTRAINT OVERRIDE HORN SILENCE PAGE 11 OP
12. 0 11 31 8 9 10 11 12 ITEM DESCRIPTION Control Box Assy 24V 6013795 Programmed Control Board 6014057 6013870 6009889 6006571 6013065 6013067 6013876 AP4087 Cover Plate Control Board Audible Alarm w Locknut Label APS 2000 Instructions Push Button Green Push Button Yellow Key Switch 2 Position Spare Keys One Pair Not Shown Mounting Base For Push Buttons amp Key Switch Contact Block N O Contact Block N C Light Assy LED Red Includes 2 Red LRU s 6012562 6012563 6012564 AP2771 AP2770 SE823100 AP0027 6006375 6006377 N Light Assy LED Grn Includes 2 Grn LRU s Lens Red Lens Green LED Light Replacement Unit LRU Red LED Light Replacement Unit LRU Grn a l OPN oO ay Rio 2014 4Front Engineered Solutions Inc APS Resource 5609 RN 01 14 19 1 2 3 20 0 0 X 9 1 98 g 28 d ITEM DESCRIPTION PCB Connector 9 Position 6008824 PCB Connector 4 Position 6008822 Terminal Block Fused Disconnect 6000538 Fuse 0 5A SE6001052 Relay 24VDC 6013687 Relay Socket Base SE6000522 25 1 Fuse Block 6006849 ESENCE AP5269 6006846 6000549 Terminal Block 28 2 End Stop 1 1 EIE Not Shown 1 AP
13. 0 is switched to RE STRAINT OVERRIDE HORN SILENCE The APS 2000 comes from the factory with this setting When DIP Switch 2 is in the ON position the hook will maintain position when the operator turns the key switch from NORMAL to RESTRAINT OVERRIDE HORN SILENCE Always be certain wheels are chocked and vehicle brakes are set before switching to RESTRAINT OVERRIDE HORN SILENCE DIP Switch 3 Automatic Re Engagement 2014 4Front Engineered Solutions Inc APS Resource Reference Figure 15 for this DIP switch setting detail When DIP Switch 3 is in the OFF position the auto matic re engagement feature is active The APS 2000 comes from the factory with this setting When DIP Switch 3 is in the ON position the auto matic re engagement feature is NOT active Description of the Auto Re Engagement Feature Once the notch on the top of the hook is wrapped over the RIG as shown in Figure 10 and the inside light turns green the vehicle is safe to enter for the loading or unloading process If during the loading or unloading process the hook loses proper engagement with the RIG as shown in Figure 10A the inside light will turn red and the alarm will sound In this event after 3 second delay the restraint will automatically attempt to properly engage the RIG 2 Only one re engagement will be attempted by the APS 2000 vehicle restraint each occurrence 2 Provided a secure re engagement is achieved the APS 20
14. 00 vehicle restraint will return the inside light to green and the alarm will silence Enter the vehicle on a green light signal only FIGURE 13 DIP SWITCH ON DIP SWITCH 1 OFF Inside Communication Lights Solid Illumination FIGURE 14 DIP SWITCH Oo WN SWITCH 2 OFF Hook Lowers in RESTRAINT OVERRIDE HORN SILENCE mode FIGURE 15 SWITCH gt DIP SWITCH 3 OFF Auto Re Engagement is Active 5609 RN 01 14 DIP SWIT OFF 0 Oo WN SWITCH 1 Inside Communication Lights Flashing Illumination DIP SWIT 1 DIP SWITCH 2 Hook Maintains Position in RESTRAINT OVERRIDE HORN SILENCE mode DIP SWIT FF 0 1 2 3 4 5 6 7 8 DIP SWITCH 3 ON Auto Re Engagement is NOT Active PAGE 13 When lifting the carriage during service or assembly use a lifting device Lifting by hand may result in back injury Do not service this product unless you have read and followed the Safety Practices Warnings and Ope
15. 6838 6013795S 6002986 Electrical Schematic Not Shown 31 1 Label Arc Flash and Shock Hazard PAGE 21 PARTS LISTS RED GREEN LIGHT Red Lens Included 1 with Item 1 Housing Green Lens Included with Item 1 Housing 9 A CAUTION MOVE ON GREEN ONLY HONOM can ET YMO 2014 4Front Engineered Solutions Inc APS Resource 5609 RN 01 14 PAGE 22 Please direct questions to your local distributor or to 4Front Engineered Solutions Inc APS Resource Your local APS Resource distributor is 2014 4Front Engineered Solutions Inc APS Resource 5609 RN 01 14
16. ATE MOUNTING METHOD WITH EMBEDDED PLATE If the pit is either new or remodeled and has an embedded mounting plate weld the roller track plate to the embedded mounting plate See Figure 5 for proper size and type of welds required NOTICE Never weld on the APS 2000 restraint after the motor is wired to the control box and the power is on Damage to the controls or wiring may result 9 Reinstall the carriage assembly to the roller track plate Attach the four springs to the spring bar and the top of the roller track plate Slide the carriage as sembly into the roller track plate Bolt the spring bar to the bottom of the carriage assembly and install the spring and motor covers See Figure 6 When lifting the carriage during service or assembly use a lifting device Lifting by hand may result in back injury Before doing any electrical work make certain the power is disconnected and properly locked or tagged off Failure to do so may result in death or serious injury All electrical work must be done by a qualified technician and must meet all applicable codes 10 Mount control box inside the building approximately 4 feet above the floor to the left of the doorway See Figure 7 2014 4Front Engineered Solutions Inc APS Resource 5609 RN 01 14 FIGURE 5 CONTINUOUS WELD EDGE 1 4 47 PLUG WELD 15 PLACES ALL HOLES MUST
17. ERATION ENTER VEHICLE ON GREEN LIGHT ONLY FIGURE 12 certain wheels chocked and the vehicle brakes are set If the vehicle cannot be hitched and leeeeeeeee after wheels are chocked and the vehicle brakes are ane 0102 set vio Tum key switch from NORMAL to RESTRAINT OVERRIDE HORN SILENCE The inside lights 2 IRIG 0102 o 1 will change from red to red green and the alarm will swen silence New APS2000 5 103 GROUND TO EB oe PRG X2APS2K TO RELEASE VEHICLE 22 Store dockleveler Sr eae 0516 17 e Ifthe inside light is green press RELEASE push ae F button N M 15 10112 R 03 16 17 OOOOOOOOgISSSS If after pressing the RELEASE button the inside light turns RED and the alarm sounds the restraint is sensing it is not hitched and not properly released Make sure trailer is parked firmly against the dock bumpers and clear any obstructions Turn the key switch from NORMAL to RESTRAINT OVER RIDE HORN SILENCE then turn key switch back to NORMAL to release the restraint DIP SWITCH SETTING LOCATION e finside lights are red green turn key switch from RESTRAINT OVERRIDE HORN SILENCE to NORMAL If after turning the key switch to NORMAL the inside light turns RED and the alarm sounds the restraint is sensing it is
18. S FOR A PARTICULAR PURPOSE ALL OF WHICH APS RESOURCE HEREBY DISCLAIMS APS RESOURCE 6219 W EASTWOOD COURT MEQUON WI 53092 2014 4Front Engineered Solutions Inc APS Resource 5609 RN 01 14 PAGE 2 SAFETY PRACTICES Read these safety practices before installing operating or servicing the APS 2000 VEHICLE RESTRAINT Failure to follow these safety practices could result in death or serious injury READ AND FOLLOW THE OPERATING INSTRUCTIONS IN THIS MANUAL BEFORE OPERATING THE APS 2000 VEHICLE RESTRAINT If you do not understand the instructions ask your supervisor to teach you how to use the Vehicle Restraint Improper installation of the Vehicle Restraint could result in death or serious injury to dock workers or other users of the Vehicle Restraint Be certain to follow the installation instructions in this manual INSTALLATION AND OPERATION Use of the restraint is restricted to trained operators Use by untrained people can cause property damage bodily injury and or death Your supervisor should teach you the safe and proper way to use the Vehicle Restraint Read and follow the complete OPERATION PROCEDURE on page 6 before use DO NOT USE THE VEHICLE RESTRAINT IF IT IS NOT WORKING PROPERLY Tell your supervisor it needs repair Be certain bystanders in the driveway stand clear when the Vehicle Restraint is operated Do not install the Vehicle Restraint anchor bolts into aged or unsound concrete For brick or bl
19. at it may be necessary to use shims or physically modify the dock face to provide a flat mounting surface If shimming is required it is necessary to shim behind the roller track as well as at the anchor bolts Consult APS Resource APS 2000 Vehicle Restraints require a minimum 4 bumper projection from the front of the bumper to the rear of the roller track plate of the restraint the mounting surface Less than 4 of projection can allow vehicle RIG to damage the restraint Some lip saddle type docklevelers may require modifications consult APS Resource 2 Astandard installation of the APS 2000 Vehicle Restraint requires a minimum dock face height of 26 Consult the factory for dock face heights under 26 2014 4Front Engineered Solutions Inc APS Resource 5609 RN 01 14 INSTALLATION 3 The standard anchors provided with this product may only be used on docks constructed of solid concrete Docks constructed with other materials require special mounting consideration which may include special brackets and a solid concrete approach Contact APS Resource for information 4 Do not install the Vehicle Restraint anchor bolts into aged or unsound concrete For brick or block wall applications contact APS Resource at 262 518 1000 5 If the driveway beneath the Vehicle Restraint is affected by frost additional clearance may be required between the Vehicle Restraint and the driveway to prevent damage 6 For insta
20. e fingers or uninsulated tools inside the control box Touching wires or other parts inside the control box could result in electrical shock serious injury or death When lifting the carriage during service or assembly use a lifting device Lifting by hand may result in back injury If you have any problems or questions contact APS Re source at 262 518 1000 PAGE 3 MOUNTING CONSIDERATIONS LAWARNING Before installation read and follow the Safety Practices Failure to follow these safety practices could result in death or serious injury READ AND FOLLOW THE OPERATION INSTRUCTIONS IN THIS MANUAL BEFORE OPERATING THE APS 2000 VEHICLE RESTRAINT If you do not understand the instructions ask your supervisor to teach you how to use the Vehicle Restraint Improper installation of the APS 2000 Vehicle Restraint could result in death or serious injury to dock workers or other users of the Vehicle Restraint Place barricades around pit on dock floor and driveway while installing maintaining or repairing vehicle restraining device Be certain bystanders in the driveway stand clear when the Vehicle Restraint is operated Be certain to follow the installation instructions in this manual Do not install the Vehicle Restraint anchor bolts into aged or unsound concrete 1 The dock face on which the APS 2000 Vehicle Restraint will be mounted must be flat to prevent binding of carriage assembly If the dock face is not fl
21. llation of Vehicle Restraints with EOD type docklevelers or any other special mounting considerations not covered in this manual contact APS Resource at 262 518 1000 TOOLS REQUIRED Welder Impact or rotary drill with 5 8 diameter concrete drill bit 3 4 wrench General hand tools Touch up paint Gold Torque wrench 60 ft lb min CONDUIT INSTALLATION 1 When installing conduit through building walls and floors refer to Figure 1 FIGURE 1 SEE FIGURES 7 amp 9 FOR LOCATION OF THE CONTROL BOX AND OUTSIDE SIGNAL LIGHT USE 1 2 DIAMETER CONDUIT THROUGH WALL TO OUTSIDE SIGNAL LIGHT EXIT CONDUIT INSIDE BUILDING NEAR WALL UNDER CONTROL BOX USE 1 DIAMETER CONDUIT FOR RUN TO RESTRAINT PAGE 4 INSTALLATION INSTALLATION WITH PIT TYPE DOCKLEVELERS Do not install operate or service this product unless you have read and followed the Safety Practices Warnings and Installation and Operating Instructions contained in this manual Failure to do so could result in death or serious injury ALWAYS USE DOCKLEVELER SUPPORT WHEN WORKING UNDER A DOCKLEVELER RAMP OR LIP Place barricades around the pit on the dock floor and driveway while installing maintaining or repairing dockleveler or vehicle restraint Improper installation of anchoring devices or installation into aged or unsound concrete could result in death or serious injury Inadequate lifting equipment o
22. ock wall applications call APS Resource at 262 518 1000 Do not load or unload any vehicle unless you make certain the Vehicle Restraint has securely hitched the vehicle s rear impact guard RIG and the vehicle has set the brakes If the Vehicle Restraint does not hitch the vehicle RIG for any reason BE CERTAIN TO CHOCK THE VEHICLE WHEELS BEFORE LOADING OR UNLOADING Before chocking wheels or engaging the vehicle restraint dump the air from the air ride suspensions and set the parking brakes 2014 4Front Engineered Solutions Inc APS Resource 5609 RN 01 14 MAINTENANCE AND SERVICE If the Vehicle Restraint does not operate properly using the procedures in this manual BE CERTAIN TO CHOCK THE VEHICLE WHEELS BEFORE LOADING OR UNLOADING Call APS Resource for service Place barricades around pit on dock floor and driveway while installing maintaining or repairing vehicle restraining device Do not stand in the driveway between the dock and a backing vehicle Do not use the Vehicle Restraint as a step Keep hands and feet clear of guide tracks and moving parts at all times All electrical troubleshooting and repair must be done by a qualified technician and meet all applicable codes Before doing any electrical work make certain the power is disconnected and properly tagged or locked off If it is necessary to make troubleshooting checks inside the control box with power on USE EXTREME CAUTION Do not plac
23. ove 1 1 No power in control box Check the fused disconnect and fuse block in the control box and the circuit breaker for incoming power to the control box 1 2 Not wired properly Refer to the wiring diagram inside the control box and check all wiring and connections 2 Lights are working but the hook does not move 2 1 Drive chain is either loose or broken Adjust or replace as needed 2 2 No power to motor Check all wiring connections from the control box to the motor 2 3 Drive motor not working Replace 24 ENGAGE or RELEASE push button switch not working Replace as needed 2 5 Keyswitch is in RESTRAINT OVERRIDE HORN SILENCE position Turn keyswitch to NORMAL position 3 Lights are working but the hook does not move all the way up or down 3 1 Incoming voltage is low Check voltage 3 2 Motor mounting bolts are loose Check for proper alignment between the sprockets and retighten bolts 4 Hook moves but none of the lights work 4 1 LED modules burned out Check LED modules and replace as needed 4 2 Bad wiring connections Check all wiring connections A good ground is required 5 Hook and horn work but the lights do not change from red to green or green to red 5 1 Not wired properly Check wiring 5 2 Limit switch LS2 not working Replace 2014 4Front Engineered Solutions Inc APS Resource TROUBLESHOOTING 6 Hook and lights work but the alarm horn does not work 6 1 Not wired properly
24. part numbers Inspection amp Adjustments 1 Operate the Vehicle Restraint to assure that it operates smoothly and that the carriage moves freely up and down 2 Verify that the horn is working properly 3 Check the lights on the control box The RED or GREEN light must be illuminated at all times Push the buttons on the control box to be certain both lights are working Replace LED modules as required See the PARTS LIST for part numbers Operation 4 Check the outside communication light The RED or GREEN light must be illuminated at all times Push the buttons on the control box to be certain both lights are working Replace LED modules as required See the PARTS LIST for part numbers 2014 4Front Engineered Solutions Inc APS Resource 1 Perform all daily cleaning 1 Lubricate the drive chain thoroughly with chain lube 2 Lubricate the four roller bearings using the grease fittings located on the top and bottom roller shafts Use a lithium and synthetic oil based moly grease 1 Perform all daily inspection and adjustments 2 Inspect dock bumpers 4 inches of protection is required Worn torn loose or missing bumpers must be replaced 3 Inspect the Vehicle Restraint for damage which may weaken the anchoring strength Retighten the concrete anchor bolts to 60 ft lbs if necessary 4 Inspect the outside electrical connections junction box conduit power harness and outside communica
25. peration and proper light operation according to the Operation instructions 17 Instruct the dock workers how to use the Vehicle Restraint using the Operation instructions ADANGER Be certain power is off when wiring to the control GREEN LEAD FROM GREEN LIGHT FIGURE 9 INSTALLATION RED LIGHT GREEN LIGHT f MOUNT SIGNAL LIGHT ON RIGHT SIDE OF DOOR VEHICLE DRIVER S SIDE MOVE ON GREEN ONLY 7 NN m i 8 10 FT box or signal lights Failure to do so could result in electrical shock death or serious injury Do not route control wiring for any other device through this control box unless properly shielded 2014 4Front Engineered Solutions Inc APS Resource amp JUNCTION BOX BY OTHERS 3 1 2 DEEP MAXIMUM MOUNTING HARDWARE SUPPLIED BY OTHERS DIMENSIONS ARE REFERENCE ONLY USE OF A STANDOFF OR COULD AFFECT OTHER MOUNTING BRACKET THE DIMENSIONS SHOWN OR THE REQUIRED CABLE LENGTH 5609 RN 01 14 PAGE 8 WIRING DIAGRAM naviy 318l0nv 2
26. r practices can cause a load to fall unexpectedly Make sure the lifting chain or other lifting devices are in good condition and have a rated capacity of at least 500 Ibs for the lifting angle used Never allow anyone to stand on or near the restraint when it is lifted or positioned Stand clear of the vehicle restraint when it is positioned Failure to follow this warning can allow the restraint to fall tip or swing into people causing death or seri ous injury 1 carriage assembly must be removed from the roller track plate before installation First remove the motor cover and spring covers Then remove springs and nuts from spring bar Slide carriage assembly upwards out of the roller track making sure to keep the rollers on the axles See Figure 2 2 Place bottom edge of the roller track plate 5 8 above the driveway and center with the pit See Figure 3 If the driveway is susceptible to heaving from frost modify the driveway to provide additional clearance under the APS 2000 to prevent damage from the driveway movement 3 Drill 5 8 dia holes into pit wall a minimum of 4 5 8 deep using holes in roller track as a guide 2014 4Front Engineered Solutions Inc APS Resource 5609 RN 01 14 FIGURE 2 ROLLER CARRIAGE ASSEMBLY SPRING SPRING COVERS SPRING BAR ROLLER TRACK PLATE FIGURE 3 FRONT PIT CONTINUOUS CURB ANGLE WELD ON TOP
27. ration instructions contained in this manual Failure to follow these safety practices could result in death or serious injury Check the lights to be certain they are returned to the proper display If no vehicle is at the dock or the vehicle is not hitched the red inside light should be illuminated and the green outside light should be illuminated If a vehicle is at the dock and is hitched or the wheels are chocked the green inside light should be illuminated and the red outside light should be illuminated Before doing any electrical work including changing bulbs make certain the power is disconnected and properly tagged or locked off Place barricades around the pit on the dock floor and driveway while installing maintaining or repairing the dockleveler or the vehicle restraint Before working on or around the Vehicle Restraint visually confirm that the carriage assembly is at the top of its travel range If not STOP do not work on or around the Vehicle Restraint If the Vehicle Restraint is not at the top of its travel range it may be due to an obstruction in the roller track Under this condition the springs may be under considerable tension Without properly securing the carriage assembly the Vehicle Restraint is unsafe to work on or around Call an approved and qualified technician familiar with the APS Resource line of products For a list of approved and qualified technicians call APS Resource at 1 262 518 1000
28. t hand spring cover See Figure 4B for installation 7 Install additional lip deflector plates as required by the application Materials supplied by the installer See Figure 4A Improper installation that allows a pendant dock leveler lip to be supported by the restraint could result in death or serious injury It is sometimes necessary to install lip deflector plates as indicated in Figure 4A to avoid any chance of the pendant lip storing on top of or behind the roller track plate Materials supplied by installer 2014 4Front Engineered Solutions Inc APS Resource 5609 RN 01 14 INSTALLATION FIGURE 4A ADD LIP DEFLECTOR PLATES IF REQUIRED INSTALL S ANCHORS IN 15 LL a MOUNTING HOLES NY Jj ROLLER TRACK PLATE SHIM BETWEEN ROLLER TRACK PLATE AND FACE OF DOCK IF ROLLER TRACK PLATE IS NOT PLUMB AND FLUSH WITH DOCK FACE WELD SHIMS IN PLACE 16 1 8 REF 2 2 5 8 2 1 1 4 1 6 TYPICAL ALONG SIDES 1 4 1 6 amp BETWEEN HOLES TOP VIEW FIGURE 4B NUT WASHER BOLT ON LIP P DEFLECTOR SLOTTED FOR ADJUSTABILITY HEX BOLT TORQUE TO 70 FT LBS WASHER ums oe PAGE 6 INSTALLATION 8 ALTERN
29. t is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER ACAUTION Indicates an imminently hazardous situation which Indicates a potentially hazardous situation which if if not avoided will result in death or serious injury not avoided may result in minor or moderate injury A WARNING NOTICE Indicates a potentially hazardous situation which if Notice is used to address practices not related to not avoided could result in death or serious injury personal injury 2014 4Front Engineered Solutions Inc APS Resource 5609 RN 01 14 PAGE 1 LIMITED WARRANTY THIS LIMITED WARRANTY IS APS RESOURCE S SOLE AND EXCLUSIVE WARRANTY WITH RESPECT TO THE VEHICLE RESTRAINT AND IS IN LIEU OF ANY OTHER GUARANTEES OR WARRANTIES EXPRESS OR IMPLIED APS Resource warrants that this APS 2000 will be free from flaws in material and workmanship under normal use for a period of two 2 years from the earlier of 1 60 days after the date of initial shipment by APS Resource or 2 the date of installation of the APS 2000 by the original purchaser provided that the owner maintains and operates the APS 2000 in accordance with this User s Manual In the event that this APS 2000 proves deficient in material or workmanship within the applicable Limited Warranty period owner shall so notify APS Resource and APS Resource will at its option 1 Replace
30. the APS 2000 or the deficient portion s thereof without charge to the owner or 2 Alter or repair the APS 2000 on site or elsewhere without charge to the owner This Limited Warranty does not cover any failure caused by improper installation abuse improper operation negligence or failure to maintain and adjust the APS 2000 properly Parts requiring replacement due to damage resulting from vehicle impact abuse or improper operation are not covered by this warranty APS RESOURCE DISCLAIMS ANY RESPONSIBILITY OR LIABILITY FOR ANY LOSS OR DAMAGE OF ANY KIND INCLUDING WITHOUT LIMITATION DIRECT INDIRECT CONSEQUENTIAL OR PUNITIVE DAMAGES OR LOST PROFITS OR LOST PRODUCTION arising out of or related to the use installation or maintenance of the APS 2000 including premature product wear product failure property damage or bodily injury resulting from use of unauthorized replacement parts or modification of the APS 200095 APS Resource s sole obligation with regard to a APS 2000 that is claimed to be deficient in material or workmanship shall be as set forth in this Limited Warranty This Limited Warranty will be null and void if the original purchaser does not notify APS Resource s warranty department within ninety 90 days after the product deficiency is discovered THERE ARE NO WARRANTIES EXPRESS OR IMPLIED WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF INCLUDING BUT NOT LIMITED TO AWARRANTY OF MERCHANTABILITY OR OF FITNES
31. tion light Loose or damaged components must be repaired 1 Perform all daily operational checks 2 Perform operational test after servicing the Vehicle Restraint 5609 RN 01 14 1 Perform all daily and 180 day cleaning 2 Clean the drive chain with solvent 1 Perform 180 day lubrication 2 Lubricate the limit switch mounting bracket between the drive sprocket and cam Use a lithium and synthetic oil based moly grease 1 Perform all daily and 180 day inspection and adjustments 2 Inspect the motor drive chain and tighten if necessary See CHAIN ADJUSTMENT PROCEDURE 1 Perform all daily and 180 day operational checks 2 Perform operational test after servicing the Vehicle Restraint PAGE 15 2014 4Front Engineered Solutions Inc APS Resource Move the hook to horizontal position and remove motor cover See Figure 18 Check the drive chain slack It should not have more than 1 4 slack See Figure 18 If the chain needs adjustment loosen the three nuts on the motor mounting carriage bolts and move the motor toward the front of the carriage Make sure the sprockets are in line and tighten the mounting bolts Recheck the slack in the chain See Figure 18 Reinstall the motor cover Turn power on and press RELEASE push button to store the hook PLANNED MAINTENANCE CHAIN ADJUSTMENT PROCEDURE 1 FIGURE 18 CHECK WITH HORIZONTAL POSITION S CHAIN JA
32. us injury 2014 4Front Engineered Solutions Inc APS Resource 5609 RN 01 14 ITEM DESCRIPTION Weldment Roller Track AP5591 Label Safety Products 713757 Kit Bolt On Lip Deflector AP5664 Label Warning 138861 Bolt Anchor 5 8 x 4 AP6821 Nut Serrated Flange 7 16 14 131535 2 Label APS 2000 AP2523 9 2 Bolt Hex Head 5 16 18 x 3 4 000799 Nut Cage 5 16 131527 Screw Flat Head Socket 5 16 18 x 1 131528 Spring Extension 101097 Spring Cover Left Hand 156098 Spring Cover Right Hand 713574 Spring Bar AP1559 Washer Flat 5 16 x 3 4 x 1 16 000055 Washer Lock 5 16 000501 Screw 5 16 18 x 3 4 AP2548 Nut U Clip 5 16 18 C51556 Bolt On Lip Deflector AP5636 21 Washer Flat 1 2 000524 22 Bolt Hex Head 1 2 13 x 1 75 131370 23 Nut Hex 1 2 13 5 214241 19 PARTS LIST CARRIAGE ASSEMBLY 4 25 26 P d 2 E OW 21 QTY DESCRIPTION 1 Weldment 9 Restraint Carriage AP5587 4 Roller Carriage C15782 Sprocket Drive 713579 Key 131539 Screw Set 5 16 18 x 1 2 AP4773 E 4 o BH KA CN E BELA 5 ITEM DESCRIPTION 2 22 1 2 3 4 5 7 10 11 12 13 14 15 16 17 8 2014 4Front Engineered Solutions Inc APS Resource 5609 RN 01 14 PAGE 20 PARTS LISTS CONTROL PANEL 13 15 17 14 16 18 6 1
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