User`s Manual - Curlin, Inc.
Contents
1. Fig 10 n n na N fot Pushbar Mount dock workers hanger 1 instruction sign on left bracket m 1f side of door or door jamb SE sda Pushbar Approx 4 Ft ae Ai d ri MOUNTING HARDWARE PROVIDED BY OTHERS Fig 11 Centerline of dock leveler _and stand off 10 1 2 13 x 1 1 2 Capscrews 10 1 2 13 Locknuts 20 1 2 Fiat washers Supplied by others MOUNTING HARDWARE SUPPLIED BY OTHERS 8 5343 R18 STAR 1 Vehicle Restraint February 2013 2013 4Front Engineered Solutions Inc INSTALLATION WITH EOD TYPE DOCK LEVELERS Fig 13 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 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 tip2. Fig 3 Dock leveler front angle Horizontal mounting plate Centerline of horizontal mounting plate Fig 4 Dock leveler front angle Horizontal mounting plate 2 lt u Vehicle restraint Suggested anchor holes holes A minimum of four 4 anchor holes spaced across Bo A the plate mustbe accessible Drill additional 9 16 diameter anchor holes through the mounting plate if required See Fig 4 6 5343 R18 STAR 1 Vehicle Restraint February 2013 2013 4Front Engineered Solutions Inc 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 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 5 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 6 Slide the Vehicle Restraint Mounting Plate assembly back into position on the dock See Step 1 page 6 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 be
3. Bearing Ball Included in Item 2 091 097 T1302 131951 709 472 2 Rod End included in item 11 708 829 A 708 470 708 779 709 624 Ring Retaining Included in Item 2 049 067 Latch Assembly Plated 713 025 Grease Fitting Used for item 5 127 002 Included in Item 26 February 2013 5343 R18 STAR 1 Vehicle Restraint 15 2013 4Front Engineered Solutions Inc KIT INSTRUCTIONS INSTALLATION INSTRUCTIONS 4 1 Place hook in the down position 2 Located Item 1 directly above the existing pin guard See Fig 26 with its bottom edge aligned as shown in 5 detail A 3 Using Item 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 existing pin guard This area of the restraint must be free to move Fig 26 Installation instructions auxiliary pivot pin guard for Star Truk Restraints Part No 908 854 1 4 Ore Fasten Item 1 to the dock face using the 4 anchor bolts two anchor bolt if welding torqued to 40 ft lbs See Wedge Anchor installation instructions on page 5 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 Q ES ae 40 Ft LBS naos J p Grind smooth R ee if required Hoc t
4. 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 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 n
5. Installation with EOD Type Dock Levelers 9 Optional Snow Plow Guard Placement 9 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 CAUTION or NOTICE 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 ADANGER ACAUTION Indicates an imminently hazardous situation which Indicates a potentially hazardous situation which if if not avoided will result in death or serious injury not avoided may result in minor or moderate injury LA WARNING NOTICE Indicates a potentially hazardous situation which if Notice is used to address practices not related to not avoided could result in death or serious injury personal injury 2 5343 R18 STAR 1 Vehicle Restraint February 2013 2013 4Front Engineered Solutions Inc Read these safety practices before installing operating or servicing the vehicle restraint
6. RESTRAINT or the defective portion of either without charge to the owner 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 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 4FRONT ENGINEERED SOLUTIONS INC 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 4FRONT ENGINEERED SOLUTIONS INC sole obligation with regard to a VEHICLE RESTRAINT that proves to be defective in material or workmanship shall be as set forth in its standard warranty above i e 4FRONT ENGINEERED SOLUTIONS INC 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
7. 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 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 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 13 2 Check access to the horizontal mounting plate anchor Centerline of dock leveler Fig 2 Dock leveler front angle Horizontal mounting ty ee ine gue of horizontal mounting plate Centerline of P ii leveler
8. 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 Thedock face on which 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 5 bumper projection from the front of the bumper to the rear of the back plate of the restraint the mounting surface Less than 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 3 Docks 46 and lower may require a specially modified vehicle restraint or operation of the dock leveler may need to be restricted Contact your local Kelley distributor for information 4 A3 8 gap is required between the doc
9. 12 Hutton Dr Suite 140 Carrollton TX 75006 Tel 972 466 0707 Fax 972 323 2661 2013 4Front Engineered Solutions Inc Part No 5343 R18
10. 3 Slowly release the hook arm to allow the gas spring to fully extend 4 SUPPORT THE HOOK SO THAT IT DOES NOT FALL Gas spring WHEN THE GAS SPRING IS REMOVED Remove clips on gas spring ball studs Carefully pry the gas spring off 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 12 5343 R18 STAR 1 Vehicle Restraint February 2013 2013 4Front Engineered Solutions Inc Fig 18 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 20 21 and 22 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 23 For dock levelers with angled front angles reinforce as shown in Fig 24 Loca
11. Back plate Dock leveler front angle Butt wetd mounting plate tabs to aon back plate Dock face Ba 1 4 Fillet weld top side full width of back plate paint after welding Add lip deflector n i plates if required Install anchors in min of six 2 A 6 mounting holes N Shim between back Backplate plate and face of a dock if back plate is 6 gt not plumb and flush with dock face Weld shims in place Horizontal Dock leveler mounting piata front angle Sa L SA yp Suggested anchor holes Ge eel February 2013 5343 R18 STAR 1 Vehicle Restraint 7 2013 4Front Engineered Solutions Inc IN STALLATION y continued LAWARNING 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 b
12. STAR TRUK STOP Vehicle Restraint 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 1 User s Manual Installation Operations Maintenance and Parts Part No 5343 R18 TABLE OF CONTENTS Introduction ee Aan oY 5 11 0 nenene rnnt n nenn nr annen annan anena nnne 10 Safety Signal WordS f mnslutecccttsnniaiieidanceaiimmuncsiabeadules 2 Operational CHECKS scicttsateiarinianetdadhnineetl i cacedebladsaieiy 11 Safety VACUO OS toeccectsrectenetseresccacduanteaatetaaeanasdsecatens 3 Parts Replacement Instructions ceeeeeeee 12 Installation cada ele a ticctaec eee ai 4 Subframe Reinforcing Kit cee eeeeeeeeeeeeeeee 13 Mounting Considerations cc cceeeeeeeeeeeennneees 4 s Parts iStrane 14 Tools Required ccccccsecccecceeeceeceeeeeeeeeeeeeeeeeees 4 Pivot Pin Guard Kit Installation Instructions 16 Wedge Anchor Installation Std Installation 5 Warranty Information ecccsdicasvcesctnaceceesetaostsgetenmeniead 19 Installation with Pit Type Dock Levelers 6 Distributor Information ccceeeeeeeeteeeeeeeeeeee 20
13. anders in the driveway stand clear when the vehicle restraint is operated TO HITCH VEHICLE 1 Position vehicle against dock bumpers and set brakes 2 Using the pushbar supplied with the vehicle restraint push down the latch lever The hook will rise and hitch the vehicle RIG See Fig 16 3 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 4 Tell the vehicle driver Your vehicle must stay at the dock 5 Afterthe vehicle RIG is hitched or the wheels are chocked you may load or unload the vehicle 10 2013 4Front Engineered Solutions Inc 5343 R18 STAR 1 Vehicle Restraint Fig 16 Ti Push bar Latch lever Fig 17 Push bar TO RELEASE VEHICLE 1 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 17 The hook will automatically latch 2 Tell the vehicle driver Your vehicle may now pull away from the dock February 2013 OPERATIONAL CHECKS LA WARNING 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 DAILY Operate the vehicle restraint to assure that it operates sm
14. d install concrete filled posts for protection from damage that may be caused by snow removal equipment See Fig 14 and 15 for suggested placement February 2013 5343 R18 STAR 1 Vehicle Restraint 9 2013 4Front Engineered Solutions Inc OPERATION LA WARNING Before operating the vehicle restraining device read and follow the Safety Practices Warnings and Operation instructions contained in this manual Use by untrained people could result in death or serious injury Do not load or unload any vehicle unless you make certain the vehicle restraint has securely hitched the vehicle s 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 byst
15. depth of the 1 2 anchor is 3 3 8 The tolerances of the drill bit should meet the 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 5343 R18 STAR 1 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 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
16. e torqued to 40 ft lbs to achieve maximum holding strength A minimum of 4 anchors across the plate must be used See Fig 8 and wedge anchor installation instructions on page 5 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 9 for instructions on how to remove the hook to gain access to the rear shim washers 11 Permanently mount the Back In or Pull Out with Hook Down Only sign on the outside of the building See Fig 9 12 Permanently mount the dock workers instruction sign to the inside building wall See Fig 10 13 Mount the pushbar hanger bracket to the inside building wall See Fig 10 14 Operate the vehicle restraint per the Operation instructions on page 10 Check for smooth operation and positive latching in the latched position 15 Install pivot pin guard per instructions on page 16 16 Instruct the dock workers on how to use the vehicle restraint using the instructions on page 10 Fig 12 Fig 9 Mount sign on right side of Llo door opening vehicle driver s side Back in or i pull out with hook down only a i Approx 8 Ft
17. k 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 4 5343 R18 STAR 1 Vehicle Restraint 2013 4Front Engineered Solutions Inc February 2013 IN STALLATION y continued WEDGE ANCHOR INSTALLATION Fig 1 ca es STANDARD INSTALLATION 2 Stgo te A WARNING regs soho o og o sere 0 Do not install the vehicle restraint anchor bolts into aged or unsound concrete 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 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
18. nding 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 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 7 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 7 and wedge anchor installation instructions on page 5 Fig 6 Fig 7 Fig 8 IN STALLATION y continued
19. no effect if the original purchaser does not notify 4FRONT ENGINEERED SOLUTIONS INC s warranty department within ninety 90 days after the product defect is discovered Parts requiring replacement due to damage resulting from vehicle impact abuse or improper operation are not covered by this warranty 4FRONT ENGINEERED SOLUTIONS INC 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 4FRONT ENGINEERED SOLUTIONS INC limited warranties extend only to the VEHICLE RESTRAINT itself 4FRONT ENGINEERED SOLUTIONS INC DISCLAIMS all warranties express or implied responsibility or liability for loss or damage of any kind associated with the installation or maintenance of the vehicle restraint including any liability for premature product wear product failure property damage or bodily injury arising from improper installation or maintenance of the VEHICLE RESTRAINT February 2013 5343 R18 STAR 1 Vehicle Restraint 19 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 16
20. o assure no le catch point View A A Existing pin guard 1 Detail A Do not weld at A Vee angle Detail A N i Note Weld here as Ae shown if upper anchor bolt is not used Lower anchors bolt must be used Tem Quant Description Guard Pivot Pin Anchor Bolt 1 2 x 3 1 2 16 5343 R18 STAR 1 Vehicle Restraint 2013 4Front Engineered Solutions Inc Existing pin guard Part Number 712 634 131 260 February 2013 NOTES February 2013 5343 R18 STAR 1 Vehicle Restraint 17 2013 4Front Engineered Solutions Inc NOTES 18 5343 R18 STAR 1 Vehicle Restraint February 2013 2013 4Front Engineered Solutions Inc WARRANTY Base Limited Warranty 4FRONT ENGINEERED SOLUTIONS INC warrants that this VEHICLE RESTRAINT will be free from defects 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 4FRONT ENGINEERED SOLUTIONS INC 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 Owner s Manual In the event that this VEHICLE RESTRAINT proves defective in material or workmanship within the applicable warranty period 4FRONT ENGINEERED SOLUTIONS INC will at its option 1 Replace the VEHICLE
21. oothly and that the hook moves freely along the entire length of track and positively latches in the stored position per the Operation instructions page 10 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 page 14 for part numbers QUARTERLY Inspect dock bumpers 4 of protection is required Worn torn or missing bumpers must be replaced February 2013 5343 R18 STAR 1 Vehicle Restraint 11 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 18 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 19 1 Release hook by pressing down the latch lever 2 Hold hook partially down and drive the top spring pin through the track
22. 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 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 using four 4 anchor IN STALLATION y continued Fig 14 gt 1 48 ____ Concrete filled posts PLAN VIEW Fig 15 fasteners See Fig 11 The pin support is used to prevent a we Bec fage bending of the back plate if the pin area is struck The S pivot pin area must not be fastened but left free to float Vehicle restraint 4 Bolt the vehicle restraint to the stand off See Fig 12 t 5 Bolt the lip deflector if supplied to the STAR lip deflector 9 9 using 5 8 11 x 2 bolt and nut See Fig 13 4 J 6 Follow applicable instructions 10 through 15 on page 8 Dri Concrete filled posts for remaining installation sey FRONT VIEW OPTIONAL SNOW PLOW GUARD PLACEMENT If desire
23. ot 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 10 If you have any problems or questions contact your local Kelley distributor for assistance v 5343 R18 STAR 1 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 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
24. te horizontal mounting plate and vehicle restraint as shown in Fig 2 or 3 page 6 Anchor horizontal mounting plate to pit floor per Fig 4 page 6 SUBFRAME REINFORCING KIT Weld bracket here and anchor to pit floor Fig 20 Reinforcing bracket one on each side of power pack Reinforcing brackets welding on and anchored Reinforcing brackets welding on and anchored Fig 23 Subframe front angle Reinforcing bar Fig 24 3 4 dia rod 14 Ig weld to front angle and back plate rod supplied by others Back plate IN Remove tabs from horizontal mounting plate and weld to S api fr i front angle Front pit curb angle front angle February 2013 5343 R18 STAR 1 Vehicle Restraint 13 2013 4Front Engineered Solutions Inc PARTS LIST Fig 25 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 IU 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 14 5343 R18 STAR 1 Vehicle Restraint February 2013 2013 4Front Engineered Solutions Inc PARTS LIST continued
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