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User`s Manual - Curlin, Inc.

1. Inside signal light INSIDE SIGNAL LIGHT 120V LED WALL MOUNTING PLATE FLASHER 12 24V 3 4 PLACARD INSTRUCTION INSIDE 908 899 5 1 DRIVER S CAUTION SIGN OUTSIDE 709 832 3 7 0 2 REM sea renee _ ttem m 583 Eg EUN HE EM EA EN Eg i Ma 15 22 5528 R11 STAR 1 with Truk Alert February 2013 2013 4Front Engineered Solutions Inc WIRING DIAGRAM ele ES Ove WVSOVIG ONISIM 0098009 ASLI OV uos TdS ws MS 8E C RN a3 uonoeuuo JEST ebubuo jou op uonoeuuoj Duuo1u O qx 9 um O NIJI 9 NIII vi 9o0v18 JE qa poe pa EE Nasu yun euoJq 862Z009 Hun 04 U0D ASLL 6658009 S o iL 23 5528 R11 STAR 1 with Truk Alert February 2013 2013 4Front Engineered Solutions Inc KIT INSTRUCTIONS INSTALLATION INSTRUCTIONS 4 1 Place hook in the down position 2 Located ltem 1 directly above the existing pin guard See Fig 34 with its bottom edge aligned as shown in 5 detail A 3 Using ltem 1 as a template drill four 1 2 dia x 3 1 2 deep mounting holes NOTE To Eliminate drilling through the curb angle weld the upper end of the pin guard to the curb angle as noted below Do not weld Item 1 to the exi
2. OO ESO I o STANDARD INSTALLATION oo 9 o o Oo jm eo Corte 5 o 9e Oo O9 Do not install the vehicle restraint anchor bolts into 95 s Mm Does aged or unsound concrete oo Sig O O o o omo B oO Os o 2000 9 Use standard anchors on smooth 4 000 PSI concrete walls only For aggregate cinder block or tilt walls consult factory Oversized holes in the base material will make it difficult to set the anchor and will reduce the anchor s load capacity NOTICE Do not use an impact wrench to set or tighten the wedge anchors Co O Ge i Q 0 oo Os 1 Usinga 1 2 diameter bit drill a hole into the base material Pm a O to a depth of at least 1 2 deeper than the embedment s is The minimum embed depth of the 1 2 anchor is 3 3 8 p NEA TURIN Thetolerances ofthe drill bitshould meetthe requirements 2 895 So 5 5 E of ANSI Std B212 15 o ogl B oe el 0 2 Blow the hole clean of dust and other material Do not expand the anchor or screw the bolt in the anchor assembly prior to installation 3 Drive the anchor through the fixture into the anchor hole until the bolt head is firmly seated against the fixture Be sure the anchor attains the minimum embed depth of 3 3 8 4 Tighten the anchor by applying 40 ft Ibs torque See
3. esse 19 Parts Br ea 20 Wiring Diagram iuuicuee essa o etur Ext pre ER exa Ruin 23 Pivot Pin Guard Kit Installation Instructions 24 Warranty Information sseeeeeeeees 27 Distributor Information cccccceccsseeeseeeeeeeeeeeeeees 28 INTRODUCTION Welcome and thank you for buying your vehicle restraint from Kelley This User s Manual contains information that you need to safely install operate and maintain the vehicle restraint It also contains a complete parts list and information about ordering replacement parts Please keep and read this User s Manual before using your new vehicle restraint SAFETY SIGNAL WORDS You may find safety signal words such as DANGER WARNING or CAUTION throughout this Owner s Manual Their use is explained below This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible death or injury A DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury 2 5528 R11 STAR 1 with Truk Alert 2013 4Front Engineered Solutions Inc Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury NOTICE
4. KELLEY This manual applies to vehicle restraints manufactured beginning February 2013 with the serial numbers 61070042 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 STAR TRUK STOP Vehicle Restraint STAR 1 with Truk Alert User s Manual Installation Operations Maintenance and Parts Part No 5528 R11 TABLE OF CONTENTS Introduction C 2 Safety Signal VVORISG ataasectidessid tiec uda iere ae iiid Noe 2 Safety FACS t 3 INtroOdUCUON rm 4 LI E377 1 rz uro ro Cr Gates 5 Mounting Considerations ssssss 5 Tools Required eeeeesesssesseeeseeere 5 Wedge Anchor Installation Std Installation 5 Installation with Pit Type Dock Levelers 7 Installation with EOD Type Dock Levelers 10 Optional Snow Plow Guard Placement 11 Standard Wall Mounting Procedure 12 Optional Stanchion Mounting 14 Operatlorn tti xen eer e a RR ask EwEYS 15 Operational Checks ccccceccceeceeeaeeeeseseeceeeeeaeaees 17 Parts Replacement Instructions 18 Subframe Reinforcing Kit
5. 5528 R11 STAR 1 with Truk Alert 2013 4Front Engineered Solutions Inc February 2013 Improper installation of anchoring devices or installation into aged or unsound concrete could result in death or serious injury Anchors must be installed in a minimum of six 6 back plate mounting holes 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 tight against the back plate to prevent interference with the hook arm and gas spring 9 Anchor the horizontal mounting plate to the pit floor using the concrete anchors provided with the vehicle restraint The anchor bolts must be torqued to 40 ft lbs to achieve maximum holding strength A minimum of 4 anchors across the plate must be used See Fig 9 and wedge anchor installation instructions on page 6 10 Move the hook up and down to be certain the hook does not contact the track Washers on the pivot pin may be moved from front to rear or vice versa to shim hook in or out as required See PARTS REPLACEMENT INSTRUCTIONS Hook and Gas Spring on page 18 for instructions on how to remove the hook to gain access to the rear shim washers Operate the vehicle restraint per the operating instructions on page 18 Check for smoothness of operation and positive latching in the latched position 11 Install pivot pin guard per instructions on page 23 12 Permanentl
6. 5528 R11 STAR 1 with Truk Alert 13 2013 4Front Engineered Solutions Inc INSTALLATION TRUK ALERT continued OPTIONAL STANCHION MOUNTING a Open Docks Anchor the stanchion to the dock floor at the left side of the dock position in a location so that the signal light assembly will be easily visible to the vehicle driver 2 Mount the outside signal lights to the stanchion See Fig 19 NOTE The inside lights may have to be hard wired if an outlet is not available or local codes do not allow the use of a power cord Before doing any electrical work make certain the power is disconnected and properly locked or tagged off Failure to do so could result in property damage death or serious injury All electrical work must be done by a qualified technician and must meet all applicable codes 3 Wire and mount the inside signal light assembly to the stanchion See Fig 19 and use the wiring diagram on page 23 5 Plug power cord into the electrical outlet or turn power on at the fused disconnect Fused disconnect by others if required 6 Check for proper operation One light must be on inside and outside at all times When the GREEN inside light is flashing the RED outside light must be flashing When the RED inside light is flashing the GREEN outside light must be flashing 7 Ifthe lights do not operate properly TURN OFF POWER TO THE CONTROL BOX and rewire as required Then repeat steps 5 and 6 a
7. Notice is used to address practices not related to personal injury February 2013 Read these safety practices before installing operating or servicing the 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 VEHICLE RESTRAINT If you do not understand the instructions ask your supervisor to teach you how to use the vehicle restraint Improper installation of 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 OPERATION 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 RIGHT Tell your supervisor it needs repair Be certain bystanders in the driveway stand clear when vehicle restraint is operated 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 set the brakes If the vehicle restraint does not hitch the vehicle s RIG for any reason BE CERTAIN TO CHOCK THE VEHICLE WHEELS BEFORE LOADING OR UNLOADING Keep hands and feet clear at all times
8. M Green light INSIDE LIGHTS AND PLACARD February 2013 MOUNTING CONSIDERATIONS Before installation read and follow the Safety Practices on page 3 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 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 Place barricades around pit on dock floor and drive while installing maintaining or repairing vehicle restraining device Be certain bystanders in the driveway stand clear when 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 Thedockfaceon whichthe vehicle restraint will be mounted must be flat to prevent binding of the mechanism If the dock face is not flat 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 pivot pin as well as at the anchor bolts Vehicle restraints require a 4 bumper projection from the front of the bumper to the rear of the back plate of the restraint the mounting surface Le
9. Stay clear of vehicle restraint when it is moving Before chocking wheels or engaging vehicle restraint dump air from air ride suspensions and set parking brakes February 2013 SAFETY PRACTICES INSTALLATION 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 your local Kelley distributor for service Place barricades around pit on dock floor and drive while installing maintaining or repairing trailer restraining device Do not stand in the driveway between the dock and a backing vehicle Do not use the vehicle restraint as a step Do not install the vehicle restraint anchor bolts into aged or unsound concrete Keep hands and feet clear of guide tracks and moving parts at all times Do not weld on ductile iron hook casting item 2 page 18 All electrical troubleshooting and repair must be done by a qualified technician and meet all applicable codes Before doing any electrical work including changing bulbs make certain the power is disconnected and properly tagged or locked off If you have any problems or questions contact your local Kelley distributor for assistance 5528 R11 STAR 1 with Truk Alert 3 2013 4Front Engineered Solutions Inc INTRODUCTION The vehicle restraint is a combination of two separate and independent products There is no electrical co
10. Dock leveler subframe front angle February 2013 5528 R11 STAR 1 with Truk Alert Back plate Front pit curb angle 19 2013 4Front Engineered Solutions Inc PARTS LIST Fig 31 To ensure proper function durability and safety of the ey 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 y way alter the product from its normal working condition at the time of purchase from KELLEY could result in product malfunction breakdown premature wear death or serious injury 20 5528 R11 STAR 1 with Truk Alert February 2013 2013 4Front Engineered Solutions Inc PARTS LIST VEHICLE RESTRAINT continued ream BEARING BALL INCLUDED IN ITEM 2 091 097 T1523 1 RING RETAINING TF EE 1 ewsmRNG 7947 2 ROD END INCLUDED IN ITEM 11 708 829 1 mRN amp T 7 Cit 3 HORIZONTAL MOUNTING PLATE GREENPANT 709470 GREASE FITTING USED FOR ITEM 5 127 002 708 779 ANCHORS 14 PER PACKAGE NOT SHOWN 287 510 709 624 RING RETAINING INCLUDED IN ITEM 2 049 067 LATCH ASSEMBLY PLATED 713 025 Included in Item 26 February 2013 5528 R11 STAR 1 with Truk Alert 21 2013 4Front Engineered Solutions Inc PARTS LIST mn TRUK ALERT continued Fig 32
11. February 2013 5528 R11 STAR 1 with Truk Alert 7 2013 4Front Engineered Solutions Inc IN STALLATION y continued Place the bottom edge of vehicle restraint 1 2 above the driveway and align the backplate with the horizontal mounting plate See Fig 6 If the driveway is affected by heaving from frost follow NOTICE on page 5 to prevent damage from the driveway movement Tack weld the vehicle restraint to the horizontal mounting plate using the tabs on the front of the plate See Fig 6 Pull the vehicle restraint and mounting plate away from the dock and weld the full width of the horizontal mounting plate with a 1 4 fillet weld on the top side Paint welded area to prevent rust See Fig 7 Slide the Vehicle Restraint Mounting Plate assembly back into position on the dock See Step 1 page 7 for location If shimming is required it is necessary to shim behind the pivot pin as well as at the anchor bolts The pivot pin is shimmed to prevent bending the back plate if the pivot area is struck The pivot pin area must not be fastened but left free to float Before anchoring vehicle restraint operate the dockleveler with the vehicle restraint in its intended mounting position Check that the vehicle restraint does not interfere with below dock operation and that the pendant dock leveler lip does not support the weight of the dock leveler on any part of the vehicle restraint Operate in the below dock and dock level end load
12. Fig 1 5528 R11 STAR 1 with Truk Alert 2013 4Front Engineered Solutions Inc February 2013 INSTALLATION WITH PIT TYPE DOCK LEVELERS Do not install operate or service this product unless you have read and followed the Safety Practices Warnings and Installation and Operation Instructions in this manual Failure to do so could result in death or serious injury ALWAYS USE THE DOCK LEVELER SUPPORT WHEN WORKING UNDER A DOCK LEVELER RAMP OR LIP Place barricades around pit on dock floor and drive while installing maintaining or repairing dock leveler 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 or 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 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 serious injury 1 Insert the horizontal mounting plate into the gap between the dock leveler front angle and the pit floor NOTE For the Kelley Mechanical MK model dock levelers and Kelley 60 000 pound capacity hydraulic dock leveler
13. on inside signal lights to turn on the GREEN inside light signaling the dock worker that he may proceed with the loading or unloading operation The RED outside light will flash signaling the vehicle driver not to pull out See Fig 22 TO RELEASE VEHICLE 1 16 When loading or unloading is complete use the pushbar to push the hook to the latched position at the bottom of the track See Fig 23 The hook will automatically latch Operate switch on inside signal lights to turn on the RED inside light signaling the dock attendant not to enter the vehicle The GREEN outside light will flash signaling the vehicle driver that he may pull away from the dock See Fig 22 5528 R11 STAR 1 with Truk Alert 2013 4Front Engineered Solutions Inc Latch lever Push bar Red light Green light 459 Driver s caution sign rn MOVE ON GREEN ONLY oU d 3 OUTSIDE LIGHTS AND SIGN Red light Green light Placard Switch INSIDE LIGHTS AND PLACARD i Push bar February 2013 Do not service this product unless you have read and followed the Safety Practices Warnings and Operation instructions contained in this manual Failure to do so could result in death or serious injury Before doing any electrical work including changing bulbs make certain the power is disconnected and properly tagged or locked off DAILY 1 Operate the vehicle restrai
14. or modification of the VEHICLE RESTRAINT KELLEY sole obligation with regard to a VEHICLE RESTRAINT that proves to be deficient in material or workmanship shall be as set forth in its standard warranty above i e KELLEY will at its option repair or replace the VEHICLE RESTRAINT or portion thereof without charge to the purchaser This limited warranty does not cover any failure caused by improper installation abuse negligence or failure to properly maintain and adjust the VEHICLE RESTRAINT This limited warranty will be void or of no effect if the original purchaser does not notify KELLEY warranty department within ninety 90 days after the product deficiency is discovered Parts requiring replacement due to damage resulting from vehicle impact abuse or improper operation are not covered by this warranty KELLEY disclaims any responsibility or liability for any loss or damage that results from the use of unauthorized replacement parts or modification of the VEHICLE RESTRAINT THERE ARE NO WARRANTIES EXPRESS OR IMPLIED WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF AND THERE IS NO WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE February 2013 5528 R11 STAR 1 with Truk Alert 27 2013 4Front Engineered Solutions Inc Please direct questions about your vehicle restraint to your local distributor or to 4Front Engineered Solutions Inc Corporate Head Office Your local Kelley distributor i
15. qualified technician and must meet all applicable codes NOTE The inside lights may be hard wired if an outlet is not available or local codes do not allow the use of a power cord See page 23 for wiring diagram 6 10 11 12 13 February 2013 Wire the inside signal light assembly See Fig 17 and Wiring Diagram on page 23 Re install GREEN light into signal light housing Plug the power cord into the electrical outlet or turn on power at fused disconnect Check for proper operation One light must be on inside and outside at all times When the GREEN inside light is flashing the RED outside light must be flashing When the RED inside light is flashing the GREEN outside light must be flashing Ifthe lights do not operate properly TURN OFF POWERTO LIGHTS and rewire as required Repeat step 8 above Permanently mount ENTER VEHICLE ON GREENLIGHT ONLY placard as close as possible to inside signal light See Fig 16 on page 12 Permanently mount the driver s caution sign on the outside building wall under the signal light See Fig 18 Instruct all dock workers on the proper use of the vehicle restraint TRUK ALERT using the OPERATION PROCEDURE on pages 15 and 16 Fig 17 Fig 18 Red Black common INSIDE SIGNAL LIGHT signal light assembly oy Outside ge a Driver s caution e sign MOVE ON GREEN ONLY MOUNTING HARDWARE BY OTHERS
16. 11 STAR 1 with Truk Alert 17 2013 4Front Engineered Solutions Inc PARTS REPLACEMENT INSTRUCTIONS Do not service this product unless you have read and followed the Safety Practices Warnings and Operation instructions contained in this manual Failure to follow these safety practices could result in death or serious injury Place barricades around pit on dock floor and drive while installing maintaining or repairing trailer restraining device LATCH MECHANISM Fig 24 1 Release hook by pressing down the latch lever 2 Remove three 3 3 8 16 x 3 1 2 capscrews 3 Carefully remove pretensioned spring 4 Slide lever off of mounting pin HOOK ARM AND GAS SPRING Fig 25 1 Release hook by pressing down the latch lever 2 Hold hook partially down and drive the top spring pin through the track 3 Slowly release the hook arm to allow the gas spring to fully extend 4 SUPPORT THE HOOK SO THAT IT DOES NOT FALL WHEN THE GAS SPRING IS REMOVED Remove clips on gas spring ball studs Carefully pry the gas spring off Gas spring of the ball stud on each end of the gas spring 5 Remove the klipring from the pivot pin 6 With the hook arm in the highest position slide the arm off of the pin 7 Reverse above sequence to replace parts Lubricate the ball studs and pivot pin before reassembly 18 5528 R11 STAR 1 with Truk Alert February 2013 2013 4Front Engineered Solutions Inc Fig 24
17. Do not install this product unless you have read and followed the Safety Practices Warnings and Operation instructions contained in this manual Failure to follow these safety practices could result in death or serious injury SUBFRAME REINFORCING KIT Use the Dock Leveler Reinforcing Kit P N 901 323 when a horizontal mounting plate cannot be used to anchor the top of the vehicle restraint This kit provides brackets that can be used to securely anchor the dock leveler to the pit so that the vehicle restraint can be anchored to the dock leveler See Fig 26 27 and 28 Weld reinforcing bars between the back of the vehicle restraint back plate and the front of the subframe front angle Reinforcing bars provided by the installer See Fig 29 For dock levelers with angled front angles reinforce as shown in Fig 25 Locate horizontal mounting plate and vehicle restraint as shown in Fig 3 or 4 page 7 Anchor horizontal mounting plate to pit floor per Fig 5 page 7 SUBFRAME REINFORCING KIT Fig 26 Fig 29 Weld bracket here and anchor to pit floor Reinforcing bracket one on each side of power pack Reinforcing brackets welding on and anchored Reinforcing brackets welding on and anchored Subframe front angle Reinforcing bar Fig 30 3 4 dia rod 14 Ig weld to front angle and back plate Rod supplied by others Remove tabs from horizontal mounting plate and weld to front angle lu
18. all operate or service this product unless you have read and followed the Safety Practices Warnings and Installation and Operation Instructions in this manual Failure to do so could result in death or serious injury Place barricades around pit on dock floor and drive while installing maintaining or repairing TRUCK ALERT 3 Run signal cable from outside lights through hole in the wall and fasten outside signal lights to outside wall Make sure to install gasket provided between lights and wall See Fig 15 4 Seal hole in inside building wall around cable 5 Mount the inside signal lights on the inside of the building wall as close as possible to the left side of the door so that it is obvious to the dock worker that the lights refer to that particular door See Fig 16 12 2013 4Front Engineered Solutions Inc 5528 R11 STAR 1 with Truk Alert Fig 15 M pa A sera mak t lights Allow space for seal or shelter Outside building wall MOUNTING HARDWARE BY OTHERS Fig 16 Outlet 120V supplied by others Inside building wall Inside lights with power cord MOUNTING HARDWARE BY OTHERS February 2013 INSTALLATION TRUK ALERT continued Before doing any electrical work make certain the power is disconnected and properly locked or tagged off Failure to do so could result in property damage death or serious injury All electrical work must be done by a
19. bove 8 Permanently mount the ENTER ON GREEN LIGHT ONLY placard on the stanchion under the inside signal lights 9 Permanently mount the driver s caution sign on the dock wall side of the stanchion under the outside signal light See Fig 20 10 Instruct all dock workers on the proper use of the TRUK ALERT using the OPERATION PROCEDURE on pages 15 and 16 nae Inside signal lights Outside signal lights Outside sign Stanchion weldment available from Kelley Part number 6008726 Mounting Hardware By Others Fig 20 Dock floor 14 5528 R11 STAR 1 with Truk Alert 2013 4Front Engineered Solutions Inc mm CAUTION MOVE ON GREEN ONLY MO IVOM n3349 YMO Signal lights Driver s caution sign February 2013 OPERATION LA WARNING Before operating the vehicle restraint 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 Do not use the Restraint if it looks broken or does not seem to work right Tell your supervisor right away Keep hands and feet clear at al times Stay clear of vehicle restraint when it is moving Vehicles not restrained move unexpectedly Vehicles leaving or moving when loading and unloading are in process could result in death or serious injury Donotloadorunloadany vehicle unless you make certain the
20. ers The pin support is used to prevent bending of the back plate if the pin area is struck The pivot pin area must not be fastened but left free to float 4 Boltthe vehicle restraint to the stand off See Fig 12 5 Boltthe lip deflector if supplied to the STAR lip deflector using 5 8 11 x 2 bolt and nut See Fig 13 6 Follow applicable instructions 10 through 14 on page 9 for remaining installation 10 5528 R11 STAR 1 with Truk Alert February 2013 2013 4Front Engineered Solutions Inc IN STALLATION continued OPTIONAL SNOW PLOW GUARD PLACEMENT Fig 14 9 If desired install concrete filled posts for protection from damage that may be caused by snow removal equipment See Fig 14 for suggested placement s 48 Concrete filled posts PLAN VIEW Pd Dock face G Vehicle restraint 9 9 Y Y Driveway Concrete filled posts FRONT VIEW February 2013 5528 R11 STAR 1 with Truk Alert 11 2013 4Front Engineered Solutions Inc INSTALLATION TRUK ALERT STANDARD WALL MOUNTING PROCEDURE 1 Position the outside signal lights on the vehicle driver s side of the outside building wall so that they can be seen by the vehicle driver when he is backing the vehicle to the dock Mark this location See Fig 15 2 Drill a hole through the wall at the center of the light assembly location large enough to allow the signal cable to be run to the inside lights Do not inst
21. kmanship under normal use for a period of one 1 year from the earlier of 1 60 days after the date of initial shipment by KELLEY or 2 the date of installation of the VEHICLE RESTRAINT by the original purchaser provided that the owner maintains and operates the VEHICLE RESTRAINT in accordance with this User s Manual In the event that this VEHICLE RESTRAINT proves deficient in material or workmanship within the applicable limited warranty period KELLEY will at its option 1 Replace the VEHICLE RESTRAINT or the deficient portion of either without charge to the owner excluding any cost of removal or reinstallation which shall be the sole responsibility of the purchaser or 2 Alter or repair the VEHICLE RESTRAINT on site or elsewhere without charge to the owner The limited warranty stated in the preceding paragraph IS EXCLUSIVE AND IT IS IN LIEU OF ANY OTHER GUARANTEES AND WARRANTIES EXPRESS OR IMPLIED The limited warranty does not cover any failure caused by improper installation abuse negligence or failure to maintain and adjust the VEHICLE RESTRAINT properly Parts requiring replacement due to damage resulting from vehicle impact abuse or improper operation are not covered by this warranty KELLEY disclaims any responsibility or liability for any loss or damage including without limitation direct indirect or consequential damages or lost profits or production time that results from the use of unauthorized replacement parts
22. nnection between the vehicle restraint and the TRUK ALERT The hook position of the vehicle restraint does not control the inside or outside signal lights of the TRUK ALERT IT IS THE RESPONSIBILITY OF THE DOCK WORKER TO TURN ON THE APPROPRIATE SIGNAL LIGHTS The vehicle restraint is a manually operated vehicle restraint that requires visual inspection of the hook and rear impact guard RIG to determine a hitched condition The TRUK ALERT establishes positive communications between the dock worker and the vehicle driver through the use of signs and signal lights The TRUK ALERT consists of two sets of RED and GREEN signal lights One set is mounted inside the building and the other set is mounted outside of the building Both sets of lights are controlled by a switch on the inside lights When the GREEN inside light is flashing the RED outside light will flash Likewise when the RED inside light is flashing the GREEN outside light will flash See Fig 1 The sign mounted on the outside tells the vehicle driver to back in or pull out only when the GREEN outside signal light is on The placard on the wall inside the building tells the dock worker to enter the vehicle only when the GREEN light is flashing 4 5528 R11 STAR 1 with Truk Alert 2013 4Front Engineered Solutions Inc Fig 1 Switch Red light Green light g Driver s caution sign Roe MOVE ON GREEN ONLY OUTSIDE LIGHTS AND SIGN
23. nt to assure that it operates smoothly and that the hook moves freely along the entire length of track and positively latches in the stored position per the Operation instructions page 15 2 Check the inside signal lights The RED or GREEN light must be flashing at all times Operate switch on inside signal lights to be certain both lights are working Replace bulbs as required 3 Check the outside signal lights A RED or GREEN light must be flashing at all times Operate switch on the inside signal lights to be certain both lights are working Replace bulbs as required NOTE After checking lights be certain lights are returned to the proper display If no vehicle is at the dock or the vehicle is not chocked or hitched the red inside light should be flashing and GREEN outside light should be flashing If a vehicle is at the dock and is hitched or wheels are chocked the GREEN inside light should be flashing and the RED outside light should be flashing WEEKLY Inspect the vehicle restraint for damage which may weaken the anchoring strength Retighten the concrete anchors if necessary 40 ft lbs MONTHLY Check all operating warning caution labels and signs to be sure they can be read Replace them if required See the Parts List on pages 20 22 for part numbers QUARTERLY Inspect dock bumpers 4 of protection is required Worn torn or missing bumpers must be replaced OPERATIONAL CHECKS February 2013 5528 R
24. position with the lip pendant and with the lip extended Store the dock leveler several times to be sure the pendant lip does not come to rest supporting the weight of the dock leveler on the vehicle restraint Readjust mounting position as required The vehicle restraint may be moved such that the horizontal mounting plate is up to 12 off center Improper installation that allows the pendant dock leveler lip to support the weight of the dock leveler could result in death or serious injury It is sometimes necessary to install lip deflector plates as indicated in Fig 8 to avoid any chance of the pendant lip storing on top of or behind the backplate Materials supplied by installer 8 Anchor the back plate to the dock face using the anchors provided The anchor bolts must be torqued to 40 ft lbs to achieve maximum holding strength See Fig 8 and wedge anchor installation instructions on page 6 Fig 7 Fig 8 Back plate Dock leveler front angle Butt weld Aa mounting plate tabs to En back plate Dock face a 1 4 fillet weld top side full width of back plate paint after welding Se Add lip deflector anal plates if required Install anchors o in min of six 6 mounting holes len Backplate Shim between back plate and face of A dock if back plate is not plumb and flush with dock face Weld shims in place
25. 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 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 serious injury Improper installation of anchoring devices or installation into aged or unsound concrete could result in death or serious injury Place barricades around pit on dock floor and drive while installing maintaining or repairing trailer restraining device 1 Position the stand off so that it is centered on the dock face in front of the dock leveler See Fig 11 2 Placethe bottom edge of vehicle restraint 1 2 above the driveway Anchor the stand off to the dock face using the 10 anchors provided The anchors must be torqued to 40 ft lbs to achieve maximum holding strength See wedge Fig 11 Centerline of dock leveler and stand off o TET Lai o o o Pin support A Stand off m e Lee 10 i t 10 5 3 4 Fig 12 p MERE EE 10 1 2 13 x 1 1 2 capscrews Stand off 10 1 2 13 locknuts Vehicle Dra restraint supplied by AYN e afi others py S MOUNTING HARDWARE SUPPLIED BY OTHERS anchor installation instructions on page 6 Fig 13 3 Position and anchor the pin support as shown in Fig 11 using four 4 anchor fasten
26. s 1612 Hutton Dr Suite 140 Carrollton TX 75006 Tel 972 466 0707 Fax 972 323 2661 2013 4Front Engineered Solutions Inc Part No 5528 R11
27. s the mounting plate must be mounted to the left of the dock leveler centerline as shown in Fig 2 This off center mounting is to allow for dock leveler spring adjustment and to prevent interference with lip rod lugs For other dock levelers the horizontal mounting plate may be centered with the dock leveler See Fig 3 If the horizontal mounting plate cannot be used the top portion of the vehicle restraint must be welded to the dock leveler front angle and additional anchor plates installed to fasten the dock leveler subframe securely to the pit floor A dock leveler reinforcing kit Kelley Part Number P N 901 323 is available for this purpose Recommended reinforcing is illustrated on page 17 2 Check access to the horizontal mounting plate anchor IN STALLATION continued Centerline of dock leveler Fig 2 Dock leveler front angle Horizontal mounting ty ee mt gue of horizontal mounting plate Fig 3 Centerline of E leveler Dock leveler front angle Horizontal mounting plate Centerline of horizontal mounting plate Horizontal mounting plate ie Suggested anchor holes Fig 4 Dock leveler front angle Vehicle restraint holes A minimum of four 4 anchor holes spaced across Sa the plate mustbe accessible Drill additional 9 16 diameter anchor holes through the mounting plate if required See Fig 4
28. ssthan 4 of projection can allow vehicle RIG to damage the restraint Some lip saddle type dock levelers may require modifications Consult the factory 2 The standard anchors provided with this product may only be used on docks constructed of solid concrete For mounting to block walls refer to Service Bulletin 1023 Docks constructed with other materials require special mounting consideration Contact your local Kelley distributor for information INSTALLATION 3 Docks 46 and lower may require a specially modified vehicle restraint or operation ofthe dock leveler may need to be restricted Contact your local Kelley distributor for information 4 A 3 8 gap is required between the dock leveler front angle and pit floor to install the horizontal mounting plate NOTICE If the driveway beneath the vehicle restraint is affected by frost heave 1 Raise restraint sufficient distance to prevent damage or 2 Modify driveway to provide additional clearance Consult registered architect or professional engineer TOOLS REQUIRED Welder Impact or rotary drill with 1 2 diameter concrete drill bit 9 16 wrench General hand tools Touch up paint Gold Torque wrench 45 ft lb min Rebar cutting drill bit with rotary only drill motor February 2013 5528 R11 STAR 1 with Truk Alert 5 2013 4Front Engineered Solutions Inc IN STALLATION continued WEDGE ANCHOR INSTALLATION Fig 2
29. sting pin guard This area of the restraint must be free to move Fig 34 Installation instructions auxiliary pivot pin guard for Star Truk restraints Part no 908 854 1 4 Ox Fasten Item 1 to the dock face using the 4 anchor bolts two anchor bolt if welding torqued to 40 ft lbs See page 6 for wedge anchor installation instructions Grind smooth the mating surfaces of Item 1 and existing pin guard Repaint this area and any welds to prevent rust Curb angle 1 z HE Torque to 2 ee ae 40 Ft LBS d mp Grind smooth ecce eeeet if required nos to assure no Mate catch point View A A Existing pin guard 1 Detail A Do not weld at A c Vee angle Detail A N Note Weld here as Ae shown if upper anchor bolt is not used Lower anchors bolt must be used Tem aunt Description GUARD PIVOT PIN ANCHOR BOLT 1 2 X 3 1 2 24 5528 R11 STAR 1 with Truk Alert 2013 4Front Engineered Solutions Inc Existing pin guard Part Number 712 634 131 260 February 2013 NOTES February 2013 5528 R11 STAR 1 with Truk Alert 25 2013 4Front Engineered Solutions Inc NOTES 26 5528 R11 STAR 1 with Truk Alert February 2013 2013 4Front Engineered Solutions Inc WARRANTY KELLEY warrants that this VEHICLE RESTRAINT will be free from flaws in material and wor
30. vehicle restraint has securely hitched the vehicle s RIG rear impact guard and set the brakes If the vehicle restraint does not hitch the vehicle s RIG for any reason BE CERTAIN TO MANUALLY CHOCK THE VEHICLE WHEELS BEFORE LOADING OR UNLOADING Before chocking wheels or engaging vehicle restraint dump air from air ride suspensions and set parking brakes Failure to place the hook in the stored position when not in use could result in damage to the vehicle restraint and incoming vehicles Be certain bystanders in the driveway stand clear when the vehicle restraint is operated Enter vehicle only after making certain the vehicle is hitched or chocked and the light controls have been switched to indicate a GREEN inside light and brakes are set Vehicles not restrained move unexpectedly If the lights are not properly switched the vehicle driver will see a GREEN light and could pull out unexpectedly February 2013 5528 R11 STAR 1 with Truk Alert 15 2013 4Front Engineered Solutions Inc OPERATIO N continued TO HITCH VEHICLE 1 2 Position vehicle against dock bumpers and set brakes Using the pushbar supplied with the vehicle restraint push down the latch lever The hook will rise and hitch the vehicle RIG See Fig 21 Make certain that the hook has hitched the vehicle RIG If the RIG is not hitched or the vehicle does not have an RIG chock the vehicle wheels before loading or unloading Operate switch
31. y mount the dock workers instruction sign to the inside building wall Leave enough room between the sign and the door opening to mount the TRUK ALERT See Fig 10 13 Mount the pushbar hanger bracket to the inside building wall See Fig 10 14 Install TRUK ALERT per instructions on pages 12 to 14 February 2013 IN STALLATION y continued Fig 9 Horizontal Dock leveler mounting plate mS NI AL Suggested anchor holes Fig 10 og qo d d P d po 1 Pushbar ted l Mount dock workers hanger instruction sign on left bracket Side of door or door jamb TRUK ALERT _ Pushbar Approx 4 ft l p E E MOUNTING HARDWARE PROVIDED BY OTHERS 5528 R11 STAR 1 with Truk Alert 9 2013 4Front Engineered Solutions Inc IN STALLATION y continued INSTALLATION WITH EOD TYPE DOCK LEVELERS AND LOADHOG DOCK BRIDGES Do not install operate or service this product unless you have read and followed the Safety Practices Warnings and Installation and Operation Instructions in this manual Failure to do so could result in death or serious injury ALWAYS USE THE DOCK LEVELER SUPPORT WHEN WORKING UNDER A DOCK LEVELER RAMP OR LIP Inadequate lifting equipment or practices can cause a load to fall unexpectedly Make sure the lifting chain or other lifting devices are in good condition and have a

User`s Manual - Curlin, Inc.

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