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User`s Manual - Curlin, Inc.

1. Fig 17 Control Panel Mounting 120V supply Door 4 frame X F7 r 71 j Eye level Conduit through approx 62 wall to exterior light Conduit through wall to restraint bumper projection 1 Allow for door seals jH r j 1 approx 15 rr T 6G Mount sign below light 2 PS pS iSi unit Keep light and sign in eo one area to concentrate 4 BROWN BLACK visual warning display Mn 9 o 2 srow 1 amp BLACK n IL IL T IL IL T AIL TL Tr TIL ILID 3L ILI ii G ISS Centerline of T BLACK eg Eod LP AA light in line with C rev d osc etl vehicle mirror pr fie cron approx 90 T1 8E 1 BLUE QO moror T2 ORANGE ORANGE O 3 4 conduit TERMINALS G ED COMPONENTS Pd Note 120V power supply must be 4A minimum 12 6005639H STAR 4 with Linear Actuator Vehicle Restraint February 2013 2013 4Front Engineered Solutions Inc Before operating the vehicle restraining d
2. Linear actuator SR LS4 proximity sensor 26 6005639H STAR 4 with Linear Actuator Vehicle Restraint February 2013 2013 4Front Engineered Solutions Inc SENSOR BAR SWITCH ADJUSTMENT The operation range for RIG sensing of the vehicle restraints is from 11 to 30 above the drive If the 11 minimum specification cannot be achieved the proximity switch cam and sensor bar have come out of adjustment When properly adjusted a slight about 3 16 deflection of the sensor bar will turn the proximity switch LS4 on Readjustment is accomplished as follows 1 Loosenthe socket head cap screw thatlocks the proximity Switch can to the pivot shaft See Fig 25 This screw is located in place at the factory with Loctite 222 and may have to be heated to loosen the Loctite and prevent breaking the screw 2 Apply Loctite 222 to the screw threads Keep the sensor bar up against the bottom of the hook and rotate the proximity switch cam counterclockwise until the proximity switch turns on and then clockwise until the switch just turns off Atthis position tighten the socket head cap screw to 60 inch pounds Check to make sure that the proximity switch LS4 does not turn on until the sensor bar is deflected slightly Readjust the cam as necessary to achieve a slight approximately 3 16 deflection of the sensor bar before the proximity switch turns on Stepping on the sensor arm or otherwise manually deflecting the sensor arm farther tha
3. 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 4 LA User s Manual Installation Operations Maintenance and Parts Part No 6005639H TABLE OF CONTENTS INtrODUCTION 0 ccccccecceeeceeeeeeeceeeceeeeeeceaeeceeeeeeeeteeeess 2 Safety Signal Words err pnt oeettn Fic ie tag ice beni ds 2 cias HL HE 3 Installation sess 4 Operation eee 12 Operational Checks cccccccecececeeeeeeeeeeeeeeeeeeteees 14 Troubleshooting 15 PLC DIagngsll Ss eei Pai nido tes ase etat xad eas kan eaaa 19 Electrical Schematic ccsccceeeceeceeeeeeeeaeeeeeeees 23 Parts Replacement Instructions 24 ets BUE PRENNENT iiaa 25 Subframe Reinforcing Kit ssssessssss 27 Parts LIS tri e d REA RE RR ER ERR Run 28 Pivot Pin Guard Kit Instructions 36 Warranty IpfOFTDelllOni usitata eite rte passe 39 Distributor Information ssssssssss 40 INTRODUCTION Welcome and thank you for buying this v
4. 19 18 Pole Female Backplate Panel Mount Plug not shown 6003315 Push button For Wago Field Terminals not shown 6003319 Fuse holder 6000538 2 each included in replacement bulb kit AP1579 LRU package 34 6005639H STAR 4 with Linear Actuator Vehicle Restraint February 2013 2013 4Front Engineered Solutions Inc PARTS LIST INPUT OUTPUT BOARDS Fig 33 10 OOOOOOOOQ D I I U F m NUN jooo0000000000000Q ogg NG 8 ESN I U E 060000000000 O OO 17 Um Hem LIGHTS 48 Na amp L February 2013 6005639H STAR 4 with Linear Actuator Vehicle Restraint 35 2013 4Front Engineered Solutions Inc PARTS LIST INPUT OUTPUT BOARDS continued 7 Position Field Terminal Block Included in assy 6005664 36 6005639H STAR 4 with Linear Actuator Vehicle Restraint 2013 4Front Engineered Solutions Inc Part Number 6005664 3AG 0 25A 6004803 6004801 6005665 AST 15A 32V 6004806 6004807 February 2013 PIVOT PIN GUARD KIT INSTRUCTIONS INSTALLATIO
5. 4 Boltthe vehicle restraint to the stand off See Fig 13 5 Boltthe lip deflector if supplied to the STAR lip deflector using 5 8 11 x 2 bolt and nut See Fig 14 10 2013 4Front Engineered Solutions Inc 6005639H STARS 4 with Linear Actuator Vehicle Restraint Fig 12 Centerline of dock leveler and stand off Oo oO o iod e 5 3 4 10 1 2 13 x 1 1 2 capscrews 10 1 2 13 locknuts 20 1 2 flat washers Supplied by others Fig 14 February 2013 6 Movethe hookup and down to be certain the hook does not touch 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 INSTRUCTION Hook Arm and Gas Spring on page 24 for instructions on how to remove the hook to gain access to the rear shim washers 7 Follow instructions 11 through 20 on pages 9 10 8 Consult factory for size of stand off OPTIONAL STANCHION MOUNTING For Open Docks 1 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 Permanently mount the driver s instruction signs on the dock wall under the signal light assembly See Fig 15 3 Mount the control box to the stanchion See Fig 15 Fig 15 IN STALLATION continued Signal lights
6. OUTPUTS EN MOTOR LABEL 6005667 BOARD 6005665 COMMON www KelleyCompany com STAR 4 output board February 2013 6005639H STAR 4 with Linear Actuator Vehicle Restraint 23 2013 4Front Engineered Solutions Inc ELECTRICAL SCHEMATIC 6005663 Flore NOTE For 24V incoming power consult factory POWER SUPPLY TERMINALS L1 No 120V 1PH 60HZ INCOMING POWER GREEN _G GROUND FIELD TERMINALS INPUTS NOTE 120V 1PH 60HZ INCOMING SERVICE c1 FUSING AND DISCONNECT BY OTHERS reo TET ILC 24VDC FOR RESTRAINT SWITCHES FLA 4AMPS OV PLC OVDC FOR OPTIONAL SWITCHES 8 OV Li N O aren Fon eT GREEN FROM RESTRAINT BLACK 1 RESTRAINT LOWERED PROXIMITY SWITCH LS1 4 BROWN 2 RESTRAINT RAISED PROXIMITY SWITCH LS2 RED GA 3 INPUT BOARD SWITCH SETTINGS BROWN WHITE 4 ICC BAR ENGAGED PROXIMITY SWITCH LS4 F1 1
7. Item Quantity Part Description Part Number Outside Sign Normal Lettering 709 832 Light Assembly Complete LEDs 24VDC 6007798 3 Red LED Light Assy 24VDC 6007800 4 Green LED Light Assy 24VDC 6007801 Part of Item 2 Light Assembly Complete 32 6005639H STAR 4 with Linear Actuator Vehicle Restraint February 2013 2013 4Front Engineered Solutions Inc PARTS LIST CONTROL PANEL Fig 32 KELLEY ENTER VEHICLE ON GREEN LIGHT ONLY ALWAYS RESTRAIN VEHICLE BEFORE LOADING OR UNLOADING TO HITCH VEHICLE PRESS HITCH BUTTON IF VEHICLE CANNOT BE HITCHED RED LIGHT WILL CONTINUE TO FLASH MAKE CERTAIN VEHICLE WHEELS ARE CHOCKED AND THE BRAKES ARE SET PRESS RESTRAINT OVERRIDE BUTTON LIGHTS WILL FLASH RED GREEN TO RELEASE VEHICLE STORE DOCK LEVELER PRESS RELEASE BUTTON VEHICLE MAY NOW PULL OUT RESTRAINT OVERRIDE ES FUSE 4 AMPS OL February 2013 6005639H STAR 4 with Linear Actuator Vehicle Restraint 33 2013 4Front Engineered Solutions Inc PARTS LIST CONTROL PANEL continued Quantity Part Description Part Number Transformer 350VA 120 24V 6000443 Gould CC Class fuse holder 6003299 CC Class fuse 4 amps FU1 FNQ R 4 Fuse FU1 MDA15 13 Operating Label not shown 6000534 4 Terminal Endplate not shown 6000539 15 Plain Marker not shown 6000540 16 Terminal 2 Conductor 6000542
8. Outside sign Stanchion weldment available from Kelley Part number 6005009 Mounting hardware by others Dock floor Driver s 4 Mountthe signal light assembly to the stanchion See Fig RA instruction 15 sign A WARNING AC P mK Q r Before doing any electrical work make certain the power Mounting is disconnected and properly locked or tagged off hardware Failure to do so may result in death or serious injury All by others electrical work must be done by a qualified technician Driveway and must meet all applicable codes All motor power wires or other high voltage wires must Fig 16 3 4 ke Dock face be run in a separate conduit from all low voltage control circuit wiring f Ia Vehicle 5 Follow instructions 12 through 20 pages 9 10 1 restraint e 36 l OPTIONAL SNOW PLOW GUARD PLACEMENT Concrete filled posts If desired install concrete filled posts for protection from damage that may be caused by snow removal equipment PLAN VIEW See Fig 16 for suggested placement Dock face Vehicle restraint 9 9 ON i Driveway Concrete filled posts FRONT VIEW February 2013 6005639H STAR 4 with Linear Actuator Vehicle Restraint 11 2013 4Front Engineered Solutions Inc IN STALLATION continued
9. 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 Using a 1 2 diameter bit drill a hole into the base material to a depth of at least 1 2 deeper than the embedment The minimum embed depth of the 1 2 anchor is 3 3 8 Thetolerances ofthe drill bitshould meetthe requirements of ANSI Std B212 15 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 Fig 1 February 2013 6005639H STAR 4 with Linear Actuator Vehicle Restraint 5 2013 4Front Engineered Solutions Inc IN STALLATION y continued 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 Operating Instructions contained in this manual Failure to do so could result in death or serious injury ALWAYS USE DOCK LEVELER SUPPORT
10. 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 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 serious injury 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 1 Position the stand off so that it is centered on the dock face in front of the dock leveler See Fig 12 2 Place the 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 anchor installation instructions on page 5 3 Position and anchor the pin support as shown in Fig 12 using the remaining anchor fasteners 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
11. LS1 causes actuator clutch to slip c Faulty proximity sensor LS1 18 6005639H STARS 4 with Linear Actuator Vehicle Restraint 2013 4Front Engineered Solutions Inc SOLUTION a Open control panel and check if PLC LED input 2 indicator light is on when LS2 is engaged Replace or adjust LS2 as required b Check if LED on LS2 indicates If no signal check wiring from PLC to LS2 Replace or adjust proximity sensor LS2 as required a Check for obstruction preventing restraint from restoring b Open control panel and check if PLC LED input 1 indicator light is off when LS1 is engaged Replace or adjust LS1 as required c Check if LS1 LED on If signal present check LS1 for short circuit Replace or adjust proximity sensor LS1 as required February 2013 TROUBLESHOOTING GUIDE continued RESTRAINT RAISES AND LOWERS BUT LIGHTS ARE PROBLEMATIC POSSIBLE CAUSE a LED light s burned out PROBLEM 1 No panel face lights b Disconnected or damaged wires 2 Outside light s do not come on a Light s burned out b Disconnected or damaged wires c LED polarity incorrectly wired 3 Outside light s do not flash a Flash No Flash switch on STAR 4 Output Board is set to No Flash position b Faulty STAR 4 Output Board February 2013 SOLUTION a Check lights Replace if necessary b Look at the STAR 4 Output Board Inside Lights status LED If the LED i
12. 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 Improper installation of anchoring devices or installation into aged or unsound concrete could result in death or serious injury 1 Insert the horizontal mounting plate into the gap between the dock leveler front angle and the pit floor NOTE When used with older style Kelley Mechanical MK or K series and Kelley Hydraulic EHD 60 000 Ib capacity dock levelers 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 Fig 2 Centerline of dock leveler 3 8 min Pa Dock leveler front frame Horizontal mounting 7 plate de of horizontal E mounting plate Centerline of LABES leveler Fig 3 Dock leveler front frame Horizontal mounting plate Centerline of horizontal mounting plate front angle and additional anchor plates installed to fasten the Fig 4 dock levele
13. light will continue to flash ENTER VEHICLE ON GREEN LIGHT ONLY a Be certain wheels are chocked and the brakes are set b Press RESTRAINT OVERRIDE push button Lights will flash RED GREEN February 2013 6005639H STAR 4 with Linear Actuator Vehicle Restraint OPERATION Fig 18 Red signal light Green signal light 0 SX hy Se js ENTER VEHICLE ON x GREEN LIGHT ONLY ALWAYS RESTRAIN VEHICLE BEFORE LOADING OR UNLOADING H i tc h Release SS Restraint LU override Fig 19 Vehicle vec RIG EN d o 7 e gt o Se Hook 3 ERU 8 f e 7 ee gt Vehicle restraint DU HITCHED REAR IMPACT GUARD RIG 13 2013 4Front Engineered Solutions Inc OPERATIO N continued TO RELEASE VEHICLE 1 Store dock leveler 2 Press RELEASE push button 3 Vehicle may now pull out SEMI AUTOMATIC OPERATION See Fig 18 19 and 20 TO HITCH VEHICLE 1 Press HITCH push button or extend dock leveler lip if the dock leveler is interlocked with restraint 2 If vehicle cannot be hitched RED light will continue to flash ENTER VEHICLE ON GREEN LIGHT ONLY a Be certain wheels are chocked and the brakes are set b Press RESTRAINT OVERRIDE push button Lights will flash RED GREEN TO RELEASE VEHICLE 1 Store dock leveler 2 Press RELEASE push button 3 Vehicle may now pull out If the vehicle restraint fails to release the RED light on the control p
14. 4VDC indicated on the meter If yes then also check for 20 24VDC at then actuator If yes then replace the faulty actuator If no then check the wiring to the actuator for damage and replace as required b If no voltage is found between STAR 4 Output Board terminals T1 and T2 Then check for 20 24VDC between the PLC output terminal 4 and ground and 5 and ground when the outputs are on Note you will see 10VDC between the PLC output terminals and ground when the outputs are off If 20 24VDC is present when the outputs are on then replace the STAR 4 Output Board c If 20 24VDC is not present when the outputs are on then replace the faulty PLC a Free sensor bar a If restraint is stored LS2 is faulty If restraint is raised LS1 is faulty Replace or adjust proximity sensor February 2013 6005639H STAR 4 with Linear Actuator Vehicle Restraint 17 2013 4Front Engineered Solutions Inc TROUBLESHOOTING GUIDE continued RESTRAINT DOES NOT RAISE PROPERLY PROBLEM 1 Restraint raises ratchets then after 6 seconds PLC stat LED is flashing POSSIBLE CAUSE a No signal from proximity sensor LS2 causes actuator clutch to slip b Faulty proximity sensor LS2 RESTRAINT DOES NOT RESTORE PROPERLY 1 Restraint restores ratchets then stops PLC LED input 1 on Inside RED light flashes PLC stat LED is flashing a Obstruction in mechanism prevents lowering b Signal from proximity sensor
15. 6005093 SWITCH PROXIMITY 12 36V 061551 SWITCH MAGNETIC READ 061812 BRACKET T STRIP MOUNT STAR4LA 6005084 TERMINAL STRIP NINE POLE 6013766 CAM ASSEMBLY PROXIMITY SWITCH 713384 BRKT STAR LIFTING 6007732 SPRING TORSION SENSOR BAR 101079 LABEL STAR LOGO 709624 ROLL PIN 1 2 DIA X 2 LONG 6006267 TAG SAFETY PRODUCTS 711266 24 8 PW 1 1 16 1 0621D x 1 5 OD 000064 HEX SOC SET SCR OVAL 1 2 13 UNC x 1 25 131519 HHMB 1 2 13 UNC X 1 3 4 ZINC 131370 1 2 13 UNC LOCK NUT 000035 HJN 1 2 13 UNC 214242 COVER STEEL STAR4 LA 6005095 ROLL PIN 1 2 DIA X 1 1 4 LONG 35100 RP 3 8 x 1 1 2 35031 CLEVIS PIN 231505 NLN 3 8 16 UNC 214538 HHMB 3 8 16 X 1 1 4 ZINC 212104 30 6005639H STAR 4 with Linear Actuator Vehicle Restraint February 2013 2013 4Front Engineered Solutions Inc PARTS LIST LM RESTRAINT continued 9 HB 3 8 16 UNC 0 5 GR 000310 LINK HOOK ACTUATOR PLATED 6005083 METAL TACK AMTACK 3126 G0324 CLAMP DOUBLE TUBE 9 16 DIA 709683 HHMB 5 16 18 UNC X 2 1 4 LONG GR8 ZINC 6005097 LN 5 16 18 NYLOCK 214522 BACK PLATE ASSEMBLY STAR 4 LA 6005071 February 2013 6005639H STAR 4 with Linear Actuator Vehicle Restraint 31 2013 4Front Engineered Solutions Inc PARTS LIST EXTERIOR SIGNS AND LIGHTS a Fig 31 A A CAUTION r MOVE ON 3 GREEN 24 ONLY 2 11 44 WO 3VOM a W390 ud YMO Y NT 3913
16. 8 OPTIONAL DOOR CLOSED SWITCH DIP SWITCH LOCATED ON SIDE OF BOARD Q OPTIONAL LEVELER STORED OR LIP LIMIT SWITCH STANDARD SHITCH POSITIONS SHOWN WHITE 14GA 1 2 s 4 s OJO ON FIELD TERMINALS OUTPUTS o Ojo orr 7 RED OUTSIDE LIGHT 24VOLT POSITIVE TE 8 GREEN OUTSIDE LIGHT 24VOLT POSITIVE t RED 186A Q 24VOLT OUTSIDE LIGHTS COMMON NEGATIVE LEVELER Lx m RED 146A c DOOR 4 WHITE 18GA CLOSED gt eer INTERLOCK SPARE 120V La HI H4 MAU BLUE T1 TRI 350VA a p RESTRAINT MOTOR PO RED WHITE 14GA ORANGE T2 x S ging an 24y RED BLACK 14GA OPTIONAL UIP EMIT BK FUSE 15 LEVELER STORED 4 EL F2 DIP SWITCH 3 OFF FIELD DOOR TERMINALS CONTROLLER 19 OPTIONAL DRY CONTACT DOOR CLOSED 18 DIP SWITCH 2 OFF SEE DRAWING 6001045 FOR MORE OPTIONS 17 C BN 0 7 a gt e ALAR 2 4 c x D c z T DES v C T2 or 9 um 54 S 7 Bo RED LED BN WH new RIG CONTACT gt p NAN 4 n 2 8 Gy GREEN LED 3 r 9 Z RAISED S Z BN 6 E RACE 20 e 15 LEVELER INTERLOCK 1 5 ROR BEC SIRS 14 RESTRAINT ENGAGED OR L O LS1 o UJ FIELD LOWERED C 1 BK Ov Q TERMINALS a 3 RD c E s S WHITE RED 18GA Vox NGE a 48r RELEASE a GENENG RED LIGHT PRA O TERMINALS a BLUE 18GA HITCH 4 s PBI 5 WHITE GREEN 186A Nc acie 49 93 7 477 GREEN LIGHT ds TUE c WHITE BLACK 18GA C KEYED OPTIONAL MANUFACTURING 5 KIT PARTI 632223 TERMINALS o NOTE UNUSED TERMINALS NOT SHOWN i BLACK RED 18GA GVERRIDE B
17. 9H STAR 4 with Linear Actuator Vehicle Restraint 39 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 is 1612 Hutton Dr Suite 140 Carrollton TX 75006 Tel 972 466 0707 Fax 972 323 2661 2013 4Front Engineered Solutions Inc Part No 6005639H
18. G N OSTICS y continued RESTRAINT ERRORS Match the PLC LED display with the chart to determine the error that has occurred and check the corresponding equipment for problems When the PLC is in Jog Mode the restraint will raise or lower only while a button is pressed and will stop when the button is released Jog Mode is entered when a failure to find LS1 while lowering has occurred Use this to position the restraint but disconnect power before attempting to make adjustments If the vehicle restraint fails to release the RED light on the control panel will remain flashing If the hook is jammed on the trailer back the trailer to free it then press and hold the RELEASE button until the hook is properly stored Fig 21 STAR 4 input board RED BLACK BROWN BROWN WHITE CLOSED STORED KELLEY ld E C C OovOvG6 1 2 3 4 c c 7 18 19 pee www KelleyCompany com LED TURNS l og Ul OFF WHEN INPUT FUSE OOOOOOOOQ MDL 0 26 IS BLOWN LABEL 6005666A BOARD 6005664 Input power Field terminal Field terminal Input power supply energized LED 9 position 5 position supply fuse 1 4 Amp Actuator supply Fuse and light Field terminal Alarm fuse 15A diagnostic LEDs 7 position socket RESTRAINT INSIDE FUSE MOTOR LIGHTS MINI 15 LED S TURN OFF OR FLASH TA R WHEN SHORT CIRCUIT OCCURS SL ORISAEUSEIS BLOWN 14139 8 7 T Te KELLEY NTERLOCK RED GRE
19. LACK WHITE 18GA i S oN WHITE 18GA VERR WHITE GRAY_18GA PBS RED 18GA 39 94 BLUE 18GA R PLC CONTROLLER L BLUE 186A NOTE UNUSED TERMINALS NOT SHOWN 24 6005639H STAR 4 with Linear Actuator Vehicle Restraint February 2013 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 dock leveler or vehicle restraint HOOK ARM AND GAS SPRING 1 Remove BLACK cover 2 Disconnect linear actuator rod from lever If linear actuator rod is not retracted it is necessary to push down on the hook to release tension on linear actuator linkage 3 Hold hook arm down and remove top spring pin 4 Slowly release the hook arm to allow the gas spring to fully extend 5 Support the hook so that it does not fall when the gas spring is removed Carefully pry the gas spring off of the ball stud on each end of the gas spring 6 Remove the klipring from the pivot pin 7 Disconnect actuating linkage 8 With the hook in its highest position carefully slide arm from pin 9 Reverse above sequence to replace parts Lubricate the following parts pivot pin ball st
20. LE 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 12 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 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 servi
21. N INSTRUCTIONS 4 Fasten Item 1 to the dock face using the 4 anchor bolts 1 Place hook in the down position two anchor bolt if welding torqued to 40 ft lbs See 2 Located Item 1 directly above the existing pin guard Yedda Anenor installation stevens on pages See Fig 34 with its bottom edge aligned as shown in 5 Grind smooth the mating surfaces of Item 1 and existing detail A pin guard Repaint this area and any welds to prevent 3 Using Item 1 as a template drill four 1 2 dia x 3 1 2 nisi 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 Torque to weld Item 1 to the existing pin guard This area of the restraint 40 ft Ibs must be free to move Grind smooth Fig 34 if required T to assure no Installation instructions catch point auxiliary pivot pin guard n for vehicle restraints 1 4 centered F part no 908 854 i E E Existing pin guard it Detail A Do not weld at A Curb angle deal K 75 A c Note weld here as p shown if upper anchor bolt is not used Lower anchors bolt must be used Existing pin guard Item Quantity Description Part Number Pivot Pin Guard 712 634 Anchor Bolt 1 2 x 3 1 2 131 260 February 2013 6005639H STAR 4 with Linear Actuator Vehicle Restraint 37 2013 4Front Engineered
22. RE 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 Thedockface onwhich the 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 Lessthan 4 of projection can allow vehicle RIG to damage the restraint Some lip saddle type dock levelers may require modifications consult 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 Bull
23. Solutions Inc NOTES 38 6005639H STAR 4 with Linear Actuator Vehicle Restraint February 2013 2013 4Front Engineered Solutions Inc LIMITED WARRANTY KELLEY warrants that this VEHICLE RESTRAINT will be free from flaws in material and workmanship 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 cove
24. adjust mounting position as required The vehicle restraint may be moved such that the horizontal mounting plate is up to 12 off center February 2013 6005639H STAR 4 with Linear Actuator Vehicle Restraint 7 2013 4Front Engineered Solutions Inc IN STALLATION continued LA WARNING 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 Fig 7 to avoid any chance of the pendant lip storing on top of or behind the backplate Materials supplied by installer 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 8 Anchor the vehicle restraint 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 7 and wedge anchor installation instructions on page 5 9 Anchorthe 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 Ibs to achieve maximum holding strength A minimum of 4 anchors across the plate must be used See Fig 8 and
25. 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 Fig 29 Subframe front angle Reinforcing bar February 2013 PARTS LIST RESTRAINT LA WARNING 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 KELLEY could result in product malfunction breakdown premature wear death or serious injury i February 2013 6005639H STAR 4 with Linear Actuator Vehicle Restraint 29 2013 4Front Engineered Solutions Inc PARTS LIST RESTRAINT continued ENSE URN HOOK ARM BEARING ASSEMBLY 675411 jaja AN LEVER ASSY HOOK ACTUATOR PLATED STAR4 LA 6005085 EJ WELDMENT SENSOR BAR STAR 4 amp 5 TRUK STOPS 712914 LINEAR ACTUATOR 341008 GAS SPRING 709472 6f 2 CLIP WIRE 562 DIA 1 2 ROUND 154202 1 8 DIA HITCH PIN CLIP 231503 RE A BRACKET PROX SWITCH 154134 EN SE Ni SHAFT SENSOR BAR 155643 i Arar 067 5 PW 3 8 4375ID x 0 062 OD 234101 LINK ASSY ACTUATOR STAR4 LA 6005088 BUSHING 503 I D X 748 O D X 563 LONG 154485 BUSHING ACTUATOR STAR4LA
26. anel will remain flashing If the hook is jammed on the trailer back the trailer to free it then press and hold the RELEASE button until the hook is properly stored 14 6005639H STAR 4 with Linear Actuator Vehicle Restraint 2013 4Front Engineered Solutions Inc Fig 20 Vehicle RIG Vehicle restraint RELEASED REAR IMPACT GUARD RIG February 2013 ADANGER Before doing any electrical work including changing lights make certain the power is disconnected and properly tagged or locked off 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 After checking lights be certain lights 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 lit 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 lit and the red outside light should be flashing OPERATIONAL CHECKS DAILY 1 Operate the vehicle restraint to assure that it operates smoothly and that the hook moves freely along the entire length of track 2 Check the lights on the control box The RED or GREEN light must be on at all times Push button on control box to be certain both lights are wo
27. bly into the control box using terminal 7 for red 8 for GREEN and 9 for common Terminals are located on the STAR 4 output board in the control panel See Fig 10 and wiring diagram on page 24 13 Mount electrical junction box not supplied near vehicle restraint See Fig 11 and 16 14 Route supplied wires from the terminal strip on the STAR backplate through conduit to the junction box and then to the control panel terminals as shown in the wiring diagram on page 24 See Fig 16 15 If this installation includes an optional dock leveler lip limit switch wire per instructions contained in the limit switch kit and connect leads to terminals marked 19 and C on the STAR input board in the control panel Change the DIP switch setting on the input board in the control panel on switch 3 from ON to OFF When limit switch is installed the unit will function in Semi Automatic mode See page 14 If no lip limit switch is to be used leave the DIP switch 3 setting in the factory ON position The unit will function in Manual mode See page 13 16 Wire power to the control box using terminals provided in the control box See Fig 16 and Electrical Schematic on page 24 17 Permanently mount the vehicle driver s instruction signs on the outside wall under the signal light when installing RED GREEN Light Assembly See Fig 16 18 Operate the vehicle restraint following the Operation instructions on page 13 Check for smooth
28. ce Place barricades around pit on dock floor and drive 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 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 1 page 28 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 itis necessary to make troubleshooting checks inside the control box with power on USE EXTREME CAUTION Do not place fingers or uninsulated tools inside the control box Touching wires or other parts inside the control box could result in electrical shock death or serious injury If you have any problems or questions contact your local Kelley distributor for assistance 6005639H STAR 4 with Linear Actuator Vehicle Restraint 3 2013 4Front Engineered Solutions Inc INSTALLATION 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 BEFO
29. ehicle 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 User 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 6005639H STARS 4 with Linear Actuator Vehicle Restraint 2013 4Front Engineered Solutions Inc Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury NOTICE 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 VEHIC
30. er and PLC supply wiring and unplug the entire PLC Boards assembly from the backplate replace fuse If fuse blows replace the PLC If fuse does not blow replace the STAR 4 Output Board a Check fuse FU2 If faulty replace fuse b If fuse is good re seat the I O boards by pressing them firmly against the back plate c Check for 24VAC across transformer secondary terminals Replace if faulty a Cycle control panel power OFF ON to reload program If program does not reload automatically contact the factory b Re seat the I O boards by pressing them firmly against the back plate February 2013 PROBLEM 5 Restraint does not operate Motor does not run All panel lights and diagnostic LED s are correct 6 Restraint does not operate Restraint stored PLC input 1 off and 4 on Inside RED light on and GREEN inside light flashing PLC stat LED is flashing 7 Restraint does not operate PLC input 1 off and 2 on PLC stat LED is flashing TROUBLESHOOTING GUIDE continued RESTRAINT DOES NOT RAISE OR LOWER continued POSSIBLE CAUSE a Faulty wiring to actuator or faulty actuator b Faulty STAR 4 Output Board c Faulty PLC a Sensor bar stuck down a Proximity sensors LS1 and LS2 both active at the same time One proximity sensor failed on SOLUTION a Plug DC voltmeter leads into the top of the STAR 4 Output Board terminals T1 and T2 When outputs 4 and 5 are on there should be 20 2
31. etin 311023 Docks constructed with other materials require special mounting consideration Contact your local Kelley distributor for information 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 min gap is required between the dock leveler front frame and pit floor to install the horizontal mounting plate 5 Donotinstall the vehicle restraint anchor bolts into aged or unsound concrete 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 1 2 dia rebar cutting drill Rebar cutting drill bit with rotary only drill motor 4 6005639H STARS 4 with Linear Actuator Vehicle Restraint 2013 4Front Engineered Solutions Inc February 2013 IN STALLATION continued WEDGE ANCHOR INSTALLATION Fig 1 ria Xo n STANDARD INSTALLATION 0 Seton l Do not install the vehicle restraint anchor bolts into Tm sen aged or unsound concrete Use standard anchors on smooth
32. evice 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 wheels or engaging vehicle restraint dump air from air ride suspensions and set parking brake Do not load or unload any vehicle unless you make certain the vehicle restraint has securely hitched the vehicles 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 Enter the vehicle only when the green signal light on the control box is on You must check the green signal light each time that the vehicle is entered If the 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 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 vehicles Be certain bystanders in the driveway stand clear when the vehicle restraint is operated MANUAL OPERATION See Fig 18 19 and 20 TO HITCH VEHICLE 1 Press HITCH push button 2 f vehicle cannot be hitched RED
33. h STEP2 O Sr cR Jo OW 3 0 00 L1 DL sr r L3 Cro o L3 CN oO Os o mO CJIVIS ND O XX3 RY ANAY O LJ SS Md Hook raised LS2 contact ZMONOE STEP 3 D YO Ooo O sr c RS 0o RS OW 0o L1 L3 sF r L1 Dro o LINN oO S LIO vo OLS ND O HH BY ANNY O O SS Md Hook raised LS4 contact STEP 4 cR LO OW RSS tO 0o L DL sF r SS C3 ro o 1 L3 Cx ooo oO vo OLS NOON RS amp S NH O LJ SS JMd Lowering releasing 21 2013 4Front Engineered Solutions Inc 6005639H STAR 4 with Linear Actuator Vehicle Restraint February 2013 F LED flashing LED off LED on PLC D IAG NOSTICS continued DIAGNOSTIC ERROR UNS eS Lo OW MW 0o L1 L3 sr r C3 C39 ogu CN ooo WS YO vo CJIVIS NO OY OANA O O AS YMd LS4 contact while hook is lowered SYSTEM ERROR See controller fault conditions TNF O Sr cR LO O RS MW oo L1 L3 sr r L3 D1ro o L3 CN ooo o vo VIS ND O H8 S SNNNY O LJ S3 Md Truck not found or rear impact guard RIG lost hook raised zp SSOF OVERRIDE NOOoo UNS en 0o OW MIWM oo L1 L3 sr Sogam ogu CN oO Oo vo EJIVIS NO OY E13 ANAY O N amp S Md hook lowered Lights override February 2013 6005639H STARS 4 with Linear Actuator Vehicle Restraint 2013 4Front Engineered Solutions Inc 22 P LC DIA
34. n possible in normal operation can cause this out of adjustment problem ADJ USTM E NTS continued Fig 25 Pivot shaft Proximity switch cam ow Clearance 1 32 min to 3 32 max proximity switch Sockethead capscrew Sensor bar February 2013 6005639H STAR 4 with Linear Actuator Vehicle Restraint 27 2013 4Front Engineered Solutions Inc SUBFRAME REINFORCING KIT LAWARNING 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 Place barricades around pit on dock floor and drive while installing maintaining or repairing dock leveler or vehicle restraint SUBFRAME REINFORCING KIT Use the dock leveler Reinforcing Kit 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 28 2013 4Front Engineered Solutions Inc 6005639H STAR 4 with Linear Actuator Vehicle Restraint Weld bracket here and
35. nt damage from the driveway movement Dock face 4 Tackthe vehicle restraint to the horizontal mounting plate using the tabs on the front of the plate See Fig 5 Fig 6 4 4 fillet weld top side full width 5 Pull the vehicle restraint and mounting plate away from of back plate the dock and weld the full width ofthe horizontal mounting paint after welding plate with a 1 4 fillet weld on the top side Paint welded hc area to prevent rust See Fig 6 6 Slide the vehicle restraint mounting plate assembly back into position on the dock See step 1 page 6 for location SS 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 7 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 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 Re
36. o pages 20 23 in this manual Use the Troubleshooting Guide if the vehicle restraint fails to perform properly Find the condition that most closely matches your situation and make the recommended adjustments RESTRAINT DOES NOT RAISE OR LOWER PROBLEM 1 Restraint does not operate No Inside lights No PLC LED indicator lights b Primary 4 amp fuse blown 2 Primary fuse blows continually 3 Restraint does not operate No lights on panel Some PLC LED inputs on Not STAR 4 Output Board lights on a Failed FU2 fuse c Faulty transformer 4 Restraint does not operate No lights on panel Some PLC LED inputs on No PLC LED output lights on STAR 4 Output Board LED s on a Program Error 16 2013 4Front Engineered Solutions Inc POSSIBLE CAUSE a No power to control panel a Faulty transformer faulty PLC or faulty STAR 4 output board b Loss of PLC connectivity b Loss of PLC connectivity 6005639H STAR 4 with Linear Actuator Vehicle Restraint ADANGER Before doing any electrical work make certain the power is disconnected and properly tagged or locked off SOLUTION a Check for 120V supply at terminals L and N b Replace fuse a Disconnect the RED 24V wire from transformer secondary side and the RED BLACK 120V supply wire from the PLC Cap the 120V wire and replace fuse If fuse still blows replace the transformer If fuse does not blow reconnect the transform
37. operation and proper light operation according to the Operation instructions on page 13 19 Install Pivot Pin Guard Kit per instructions on page 37 IN STALLATION y continued Fig 9 Mount control box on left side of door opening Mounting hardware by others Fig 10 Red lead from Red light to terminal 7 Red light Black lead common to terminal 9 Green light Green lead from Green light to terminal 8 Fig 11 Mount signal light on right side of door Vehicle driver s side MOVE ON GREEN ONLY b omms sign ET I I l 90 Mounting hardware EU position SW and byothers proximity SW junction box February 2013 6005639H STAR 4 with Linear Actuator Vehicle Restraint 9 2013 4Front Engineered Solutions Inc IN STALLATION continued 20 Instruct the dock workers how to use the vehicle restraint using the operation procedures on page 13 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 Operating Instructions contained in this manual Failure to do so could result in death or serious injury ALWAYS USE
38. r subframe securely to the pit floor A dock leveler Horizontal reinforcing kit Kelley part number 901 323 is available for this E eh mounting plate purpose Recommended reinforcing is illustrated on page 28 Kon enge y 2 Check access to the horizontal mounting plate anchor p a holes A minimum of four 4 anchor holes spaced across the plate mustbe accessible Drill additional 9 16 diameter X anchor holes through the mounting plate if required See Fig 4 Vehicle restraint Suggested anchor holes See 6 6005639H STAR 4 with Linear Actuator Vehicle Restraint February 2013 2013 4Front Engineered Solutions Inc IN STALLATION continued A WARNING ix 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 Butt weld a rated capacity of at least 500 Ibs for the lifting angle modni mg to used Never allow anyone to stand on or near the Dick plate 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 serious injury 3 Place the bottom edge of vehicle restraint 1 2 above the driveway and align the backplate with the horizontal mounting plate See Fig 5 If the driveway is affected by heaving from frost follow NOTICE on page 4 to preve
39. red 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 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 600563
40. rking Replace LEDs as required 3 Check the outside signal lights ARED or GREEN light must be flashing at all times Push button on the control box to be certain both lights are working Replace LEDs as required 4 Inspect dock bumpers Missing bumpers must be replaced 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 and caution labels and signs to be sure they can be read Replace them if required See the Parts List beginning on page 29 for part numbers QUARTERLY Inspect dock bumpers 4 of protection is required Worn torn or missing bumpers must be replaced YEARLY Perform the hook arm adjustment checks described on page 26 of this manual February 2013 6005639H STAR 4 with Linear Actuator Vehicle Restraint 15 2013 4Front Engineered Solutions Inc TROUBLESHOOTING GUIDE LA WARNING Before servicing the vehicle restraint read and follow the Safety Practices on page 3 and the Operation section in this manual Failure to do so could result in death or serious injury The functions of the vehicle restraint are controlled by a Programmable Logic Controller PLC which has LED indicator lights to display errors and the state of input and output signals The PLC also has fuses to protect various electrical circuits For PLC LED diagnostics please refer t
41. s out a short circuit of the lights or wiring has occurred Check for faulty or damaged light wiring Replace as required Cycling the control panel power OFF ON will automatically reset the fuse a Check lights Replace if necessary b Look at the STAR 4 Output Board Outside Lights If the LED is out a short circuit of the lights or wiring has occurred Check for faulty or damaged light wiring Replace as required Cycling the control panel power OFF ON will automatically reset the fuse c Reverse polarity a Change the switch to the Flash position See Fig 33 item 18 b If changing the switch position does not cause the lights to start flashing replace the faulty STAR 4 Output Board 6005639H STAR 4 with Linear Actuator Vehicle Restraint 19 2013 4Front Engineered Solutions Inc PLC DIAGNOSTICS LA WARNING Do not service this product unless you have read and followed the Safety Practices Warnings and Operating Instructions in this manual Failure to follow these safety practices could result in death or serious injury CONTROL PANEL LED DISPLAY The vehicle restraint is controlled by a solid state Programmable Logic Controller PLC which reads input signals from the push buttons and proximity sensors and closes the appropriate output relays to the motor and to the warning lights INPUT SIGNALS 0 Restraint Override push button 1 LS1 Lowered proximity switch normally clo
42. sed 2 LS2 Raised Proximity Switch 3 Unused Input 4 LS4 RIG sensor bar 5 Unused Input 6 Hitch push button 7 Release push button 8 Unused input 9 Optional door closed switch 10 Lip limit switch optional 11 Unused input 12 Unused input 13 VSL error signal optional for VSL integration The face of the PLC has LED indicator lights which show the status of each input and output The STAT LED will indicate when an error condition exists OUTPUT FUNCTIONS 0 Red Light Panel Face 1 Spare 2 Green Light Panel Face 3 Exterior Light Relay Red Off 4 Restraint Raise 5 Restraint Lower 6 Audible Alarm 7 Spare 8 Spare 9 Interlock Restraint Engaged or Restraint Override RUNO O ERRO ON STATO Ow LED on LED off F LED flashing 20 6005639H STAR 4 with Linear Actuator Vehicle Restraint February 2013 2013 4Front Engineered Solutions Inc PLC DIAG NOSTICS continued F LED flashing LED off LED on The chart below shows all of the valid conditions for the standard unit in normal operation HOME UNS eS Jo RS MW oo L1 L3 sF r C3 SS o L3 CN ooo o AO vo CJIVIS NO OY E3 ANAY O LJ RS YMd Hook stored STEP 1 RS Jo OW MW 00 0O SS st r L3 C1ro RSS ON ooo o vo ANIS NO C3 M3 ES ANNY O LJ SS MMd Hook raising attempting hitc
43. uds and linkage pivot pins Fig 23 Top roll pin Klipring February 2013 6005639H STAR 4 with Linear Actuator Vehicle Restraint 2013 4Front Engineered Solutions Inc 25 ADJUSTMENTS HOOK ARM ADJUSTMENT 1 Thehookarm may require adjustmentif the linear actuator is fully retracted and the gap between the hook arm and the lower spring pin on the T rail is greater than 1 4 If this occurs loosen the jam nut on the hook actuator leveler andthenturnthe socket head cap screw counterclockwise until the hook arm is 1 16 from the spring pin shown Verify LS1 is made LS1 senses the stored position of the hook arm by sensing the position of the gas spring LS1 is made when PLC input 1 is off If itis not made loosen the two screws that hold the switch to the back plate and then rotate the switch clockwise until PLC input 1 turns off Cycle the restraint returning it to the stored position The hook arm and LS1 switch have been properly adjusted when the following are true upon restoring the restraint LS1 is made PLC input 1 goes off the linear actuator does not bottom out not fully retracted and the gap between the hook arm and the lower T rail spring pin is 1 16 1 4 Repeat adjustments until the above is true Fig 24 Gas spring LS1 magnetic sensor Jam nut Hook arm Hook actuator lever LS2 proximity 1 16 1 4 sensor gap
44. wedge anchor installation instructions on page 5 10 Move the hook up and down to be certain the hook does not bind on 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 25 for instructions on how to remove the hook to gain access to the rear shim washers Fig 7 Add lip deflector plates if required Install anchors in min of six 6 mounting holes Shim between back plate and face of dock if back plate is not plumb and flush with dock face weld shims in place Fig 8 Dock leveler front frame E7 o NA T Backplate Horizontal WA mounting plate Vehicle restraint Suggested anchor holes Lll dd 8 6005639H STAR 4 with Linear Actuator Vehicle Restraint February 2013 2013 4Front Engineered Solutions Inc 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 applicable codes 11 Mount control box inside the building 60 above the floor to the left of the doorway See Fig 9 and 16 12 Mount and wire outside signal light assem

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