McGuire TPR UniLock, TPR User Manual
TPR UniLock
A Division of Systems, LLC
Patent Pending
Vehicle Restraint
Owner’s/User’s Manual
®
McGuire • Division of Systems, LLC • W194 N11481 McCormick Drive • Germantown, WI 53022
800.624.8473 • fax: 262.255.5917 • www.wbmcguire.com • techservices@loadingdocksystems.com
Printed in U.S.A.
© 2018 Systems, LLC - All Rights Reserved
Manual No. 4111-0073
Sept. 2018
Table of Contents
Page
Precautions
Recognize Precautionary Information ................................................ 1
General Operational Precautions ........................................................ 1
Operational Precautions ...................................................................... 2
Safety Decals ......................................................................................... 4
Placard ................................................................................................... 5
Owner’s/User’s Responsibilities ......................................................... 6
Introduction
General Information .............................................................................. 8
Component Identification ..................................................................... 9
Installation
Installation Precautions ...................................................................... 10
Installation Overview ........................................................................... 11
Roller Track Installation - Without Embed ........................................ 12
Roller Track Installation - With Embed .............................................. 14
Carriage Installation ............................................................................ 16
Install Control Panel and Wiring ........................................................ 17
Placard Installation Instructions ........................................................ 18
Operation
Operational Precautions ..................................................................... 20
Operating Instructions ........................................................................ 20
Maintenance
Maintenance Precautions .................................................................... 22
Periodic Maintenance .......................................................................... 23
Adjustments
Drive Chain & Brake Torque Adjustments ........................................ 24
Adjust Dock Leveler & Vehicle Restraint Interlock .......................... 26
Troubleshooting
Limit Switch Test Procedure .............................................................. 28
UniLock Sequence of Operation ........................................................ 29
UniLock Harness Wire Identification ................................................. 30
UniLock Field Wire Diagram ............................................................... 31
UniLock Troubleshooting ................................................................... 32
Parts
Control Box Parts ................................................................................ 34
UniLock Carriage Assembly ............................................................... 36
Roller Track & Springs ........................................................................ 38
Slope Extensions & Spring Plate ....................................................... 39
Cantilever Brackets ............................................................................. 40
OSLA (Outside Light Assembly) ........................................................ 41
Signs ..................................................................................................... 42
Miscellaneous
Customer Information ......................................................................... 45
Warranty ................................................................................ Back Cover
e
PRECAUTIONS
Recognize Precautionary Information
Safety-Alert Symbol
The Safety-Alert Symbol is a graphic representation
intended to convey a safety message without the
use of words. When you see this symbol, be alert
to the possibility of death or serious injury. Follow
the instructions in the safety message panel.
The use of the word DANGER signifies the
presence of an extreme hazard or unsafe practice
which will most likely result in death or severe
injury.
General Operational Precautions
Read and understand the Owner’s/User’s Manual and
become thoroughly familiar with the equipment and its
controls before operating the equipment.
Never operate equipment while a safety device or
guard is removed or disconnected.
Never remove DANGER, WARNING, or CAUTION
signs, Placards or Decals on the equipment unless
replacing them.
The use of the word WARNING signifies the
presence of a serious hazard or unsafe practice
which could result in death or serious injury.
The use of the word CAUTION signifies possible
hazard or unsafe practice which could result in
minor or moderate injury.
The use of the word NOTICE indicates information
considered important, but not hazard-related, to
prevent machine or property damage.
Indicates a type of safety sign, or separate panel on
a safety sign, where safety-related instructions or
procedures are described.
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Figure 1
Do not start the equipment until all unauthorized
personnel in the area have been warned and have
moved outside the operating zone (Figure 1).
Remove any tools or foreign objects from the
operating zone before starting.
Keep the operating zone free of obstacles that could
cause a person to trip or fall.
e
WARNING: This product can expose you to chemicals including lead, which are known to the State of California to
cause cancer or birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov
4111-0073 — Sept. 2018
© 2018 Systems, LLC
1
PRECAUTIONS
Operational Precautions
Learn the safe way to operate this equipment. Read and understand the
manufacturer’s instructions. If you have any questions, ask your supervisor.
Stay clear of dock leveling device when transport
vehicle is entering or leaving area.
Do not move or use the dock leveling device if
anyone is under or in front of it.
Keep hands and feet clear of pinch points. Avoid
putting any part of your body near moving parts.
Chock/restrain all transport vehicles. Never
remove the wheel chocks or release the
restraining device until loading or unloading is
finished, and transport driver has been given
permission to drive away.
Do not use a broken or damaged dock leveling
device or restraining device. Make sure proper
service and maintenance procedures have been
performed before using.
2
Make sure lip overlaps onto transport vehicle bed
at least 4 in. (102 mm).
Keep a safe distance from both side edges.
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© 2018 Systems, LLC
Operational Precautions
Do not use dock leveling device if transport vehicle
is too high or too low.
PRECAUTIONS
Do not overload the dock leveling device.
Do not operate any equipment while under the
influence of alcohol or drugs.
Do not leave equipment or material unattended on
dock leveling device.
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3
PRECAUTIONS
1751-1051 Rev A
1.50"
1751-0736 Rev A
1.50"
1751-0857 Rev A
Safety Decals
NO
1751-0149
STEP
1751-0149 Rev B
Dock Face
Hook
RIG
TPR Hook must securely
capture Rear Impact Guard
(RIG). Visually inspect before
loading/unloading transport
vehicle.
• Area around RIG should be
free of plates, lift gates or other
obstructions for hook to
securely capture the RIG.
If hook is NOT able to securely capture the RIG, transport vehicle
must be secured by other means.
TPR UniLock Hook must
securely capture Rear Impact
Guard (RIG). Visually inspect
before loading/unloading
transport vehicle.
Obstructions
Dock Face
RIG
Hook
Lift Gates
Arc Flash and
Shock Hazard
PPE [Personal Protection
Equipment] Required
De-energize equipment before
working on or inside. Do not
open cover without appropriate
PPE. Refer to NFPA 70E for
PPE requirements. This panel
may contain more than one
power source.
Hazardous Voltage
Will Result in Death
or Serious Injury
1751-0736
*Control box appearance may vary depending on options.
4
• Inspect all lights and alarm (if equipped) daily for proper
operation.
• Only authorized personnel who have read and understand
the owner’s/user’s manual should operate TPR vehicle
restraint.
• Maintain TPR vehicle restraint in accordance to
owner’s/user’s manual.
Call Systems Inc. for assistance at (800) 643-5424
1751-1051
Figure 2
Lockout/Tagout
power before
servicing.
Comply with
OSHA 1910.147
1751-0857
4111-0073 — Sept. 2018
© 2018 Systems, LLC
Placard
1. To release restraint press the RELEASE
1. If restraint is unable to secure transport
vehicle’s RIG, use wheel chocks to secure
wheel chocks are removed. Manual reset
of BY-PASS is accomplished by pressing
the RELEASE button or turning switch to
OPERATING
PRECAUTIONS
DANGER
DANGER
• Read and follow all instructions, warnings, and maintenance schedules in
the manual and on placards.
• Vehicle restraint operation and servicing is restricted to authorized
personnel.
1. Before using the vehicle restraint:
• Remove any debris, snow, or ice that may obstruct vehicle restraint
operation.
• Alert personnel in the area of potential vehicle restraint operation and
ensure area is clear.
• Operate the vehicle restraint through one complete cycle inspecting
it for proper operation and light sequence. Advise maintenance
personnel of any damage or improper operation immediately. Remove
all malfunctioning or damaged vehicle restraints from service using
approved lockout/tagout procedures.
2. Before attempting to restrain a transport vehicle:
• Verify that transport vehicle is positioned squarely against dock
bumpers.
• Inspect the transport vehicle’s rear impact guard (RIG). Damaged or
missing RIGs, lift gates, plates or other obstructions may not allow the
vehicle restraint to securely capture the RIG. Wheel chocks must be
used whenever the ability for the vehicle restraint to capture the RIG is
in question. (NOTE: The transport vehicle’s suspension and load
condition will affect trailer height.)
3. After activating vehicle restraint:
• Verify that the transport vehicle’s RIG has been restrained successfully.
In the event this cannot be determined, use wheel chocks in addition
to restraint.
• If equipped with a light communication system, load and unload on
GREEN light only.
4. Maintenance or service must be performed by authorized personnel only.
Follow approved lockout/tagout procedures.
FAILURE TO FOLLOW THESE INSTRUCTIONS WILL RESULT IN
DEATH OR OTHER SERIOUS INJURY.
INSTRUCTIONS
VEHICLE RESTRAINTS
ENGAGE RESTRAINT
1. Open overhead door and visually check that
transport vehicle is positioned squarely against
dock bumpers and has a RIG bar. Inside light
is RED and outside light is GREEN.
2. Press the ENGAGE button to activate restraint.
3. Once RIG has been secured, inside light is
GREEN and outside light is RED
RELEASE RESTRAINT
button. When safely stored, inside light is RED
and outside light is GREEN.
BY-PASS
transport vehicle at the dock.
2. Turn switch to BY-PASS. Inside light is GREEN
and outside light is RED.
3. Loading/unloading may proceed with caution.
BY-PASS RESET
1. When loading or unloading is completed and
(RETURN TO NORMAL OPERATION)
Scan to view our owner’s/user’s manuals online.
www.LoadingDockSystems.com
1.800.643.5424
Call for additional placards, or manuals, or with questions
regarding proper use, maintenance, and repair of dock leveler.
WARNING: CANCER AND REPRODUCTIVE HARM
www.P65Warnings.ca.gov
1751-0880
4111-0073 — Sept. 2018
© 2018 Systems, LLC
1751-0880 Rev F
NORMAL. Lights change to RED inside and
GREEN outside.
Use for PowerHook, PowerHold, HoldTite and TPR series
5
OWNER’S/USER’S RESPONSIBILITIES
1) The manufacturer shall provide to the initial
purchaser and make the following information
readily available to the owners/users and their
agents, all necessary information regarding
Safety Information, Operation, Installation and
Safety Precautions, Recommended Initial and
Periodic Inspections Procedures, Planned
Maintenance Schedule, Product Specifications,
Troubleshooting Guide, Parts Break Down,
Warranty Information, and Manufacturers Contact
Information.
2) The owner/user should recognize the inherent
dangers of the interface between the loading
dock and the transport vehicle. The owner/user
should, therefore, train and instruct all operators
in the safe operation and use of the restraining
device in accordance with manufacturer’s
recommendations and industry standards.
Effective operator training should also focus on
the owner’s/user’s company policies, operating
conditions and the manufacturer’s specific
instructions provided with the restraining device.
Maintaining, updating and retraining all operators
on safe working habits and operation of the
equipment, regardless of previous experience,
should be done on a regular basis and should
include an understanding and familiarity with all
functions of the equipment. Owners/users shall
actively maintain, update and retrain all operators
on safe working habits and operations of the
equipment.
3) When selecting a restraining device, it
is important to consider not only present
requirements but also future plans and any
possible adverse conditions, environmental
factors or usage. The owners/users shall provide
application information to the manufacturer
to receive recommendations on appropriate
equipment specifications.
4) The owner/user must see all nameplates,
placards, decals, instructions and posted
warnings are in place and legible and shall not
be obscured from the view of the operator or
maintenance personnel for whom such warnings
are intended for. Contact manufacturer for any
replacements.
5) Modifications or alterations of restraining devices
shall be made only with prior written approval
from the original manufacturer. These changes
shall be in conformance with all applicable
provisions of the MH30.3 standard and shall
also satisfy all safety recommendations of the
original equipment manufacturer of the particular
application.
6) An operator training program should consist of,
but not necessarily be limited to, the following:
a) Select the operator carefully. Consider the
physical qualifications, job attitude and
aptitude.
b) Assure that the operator reads and fully
understands the complete manufacturer’s
owners/users manual.
c) Emphasize the impact of proper operation
upon the operator, other personnel, material
being handled, and equipment. Cite all rules
and why they are formulated.
d) Describe the basic fundamentals of the
restraining device and components design as
related to safety, e.g., mechanical limitation,
stability, functionality, etc.
e) Introduce the equipment. Show the control
locations and demonstrate functions. Explain
how they work when used properly and
maintained as well problems when they are
used improperly.
f) Assure that the operator understands
nameplate data, placards and all
precautionary information appearing on the
restraining device.
g) Supervise operator practice of equipment.
h) Develop and administer written and practical
performance tests. Evaluate progress during
and at completion of the course.
i) Administer periodic refresher courses. These
may be condensed versions of the primary
course and include on-the-job operator
evaluation.
7) It is recommended that the transport vehicle
is positioned as close as practical to the dock
leveling device and in contact with both bumpers.
When an industrial vehicle is driven on or off a
transport vehicle during loading and unloading
operations, the transport vehicle parking brakes
shall be applied and wheel chocks or a restraining
device that provides equal or better protection of
wheel chocks shall be engaged. Also, whenever
possible, air-ride suspension systems should
have the air exhausted prior to performing said
loading and unloading operations.
6
4111-0073 — Sept. 2018
© 2018 Systems, LLC
OWNER’S/USER’S RESPONSIBILITIES
8) When goods are transferred between the loading
dock and a trailer resting on its support legs/
landing gear instead of a tractor fifth wheel
or converter dolly, it is recommended that an
adequate stabilizing device or devices shall be
utilized at the front of the trailer.
9) In order to be entitled to the benefits of the
standard product warranty, the dock safety
equipment must have been properly installed,
maintained and operated in accordance with
all manufacturer’s recommendations and/
or specified design parameters and not
otherwise have been subject to abuse, misuse,
misapplication, acts of nature, overloading,
unauthorized repair or modification, application in
a corrosive environment or lack of maintenance.
Periodic lubrication, adjustment and inspection
in accordance with all manufacturers’
recommendations are the sole responsibility of the
owner/user.
10) Manufacturer’s recommended maintenance
and inspection of all restraining devices shall
be performed in conformance with the following
practices: A planned maintenance schedule
program must be followed, only trained and
authorized personnel shall be permitted to
maintain, repair, adjust and inspect restraining
devices, and only the use of original equipment
manufacturer parts, manuals, maintenance
instructions, labels, decals and placards or
their equivalent. Written documentation of
maintenance, replacement parts or damage
should be kept. In the event of damage,
notification to the manufacturer is required.
11) Restraining devices that are structurally damaged
shall be removed from service, inspected by a
manufacturer’s authorized representative, and
repaired or replaced as needed or recommended
by the manufacturer before being placed back in
service.
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© 2018 Systems, LLC
7
INTRODUCTION
General Information
Figure 3
This manual provides current information on the TPR
UniLock® vehicle restraint. Due to ongoing product
improvement, some parts may have changed, along
with operation and troubleshooting methods. This
manual describes these changes where applicable.
The TPR UniLock is the only trailer-postioned vehicle
restraint that can automatically remove “RIG Wedge”
pressure. RIG Wedge is caused when the trailer
is pushed forward during loading/unloading and
the trailer’s Rear Impact Guard (RIG) applies so
much pressure to the restraint’s hook that the truck
driver must reverse the trailer in order to release
the restraint. The UniLock has an advanced cam
design that first rotates the hook away from the RIG
to remove the pressure, and then rotates down to a
stored position.
The UniLock vehicle restraint also has an internal
safety mechanism that locks the restraint’s hook in
place when pressure is applied, maintaining a secure
engagement. This makes it universally effective on
any obstructed Rear Impact Guard (RIG), including
intermodal trailers with cover plates that prevent the
restraint’s hook from latching on top of the RIG.
The UniLock is designed to withstand a pulling force
in excess of 32,000 lbs, and has a service range of 4”
to 10” horizontally from the face of the dock bumpers
and 9” to 30” vertically above drive approach. The
integral motor, gear and brake assembly is specifically
designed for the UniLock. The UniLock vehicle
restraint is highly adaptable to new or existing loading
docks.
To illustrate which connections are to be made in the
field at installation, electrical drawings are included
with each order or by contacting Systems, LLC
Technical Services.
Call Systems, LLC to discuss available options to
meet your specific needs.
Technical Service at 800-643-5424 or techservices@loadingdocksystems.com
8
4111-0073 — Sept. 2018
© 2018 Systems, LLC
INTRODUCTION
CAUTION
ONL
CAUTION
PULL
IN OR
OUT ON
GREEN
Component Identification
Inspect package and all components. Report any missing or damaged items immediately
and note on the shipping Bill Of Lading (BOL).
(QTY 15) CONCRETE ANCHORS INCLUDED (not shown)
Figure 4
OUTSIDE SIGNS
PULL
IN OR
OUT ON
GREEN
Y
RIGHT SPRING COVER
ONLY
*Control box appearance may vary depending on options.
4111-0073 — Sept. 2018
© 2018 Systems, LLC
9
INSTALLATION
Installation Precautions
Post safety warnings and barricade the work
area at dock level and ground level to prevent
unauthorized use of the dock leveler before
installation has been completed.
DO NOT grind or weld if hydraulic fluid or other
flammable liquid is present on the surface to be
ground or welded.
DO NOT grind or weld if uncontained hydraulic fluid
or other flammable liquid is present. Stray sparks
can ignite spills or leaks near the work area. Always
clean up the oil leaks and spills before proceeding
with grinding or welding.
Always keep a fire extinguisher of the proper type
nearby when grinding or welding.
Only trained installation professionals with the
proper equipment should install this product.
DO NOT connect the vehicle restraint electrical
wiring and ground connections until all welding has
been completed.
DO NOT ground welding equipment to any electrical
components of the vehicle restraint. Always ground
welding equipment to the vehicle restraint base,
NEVER to the moving components.
Failure to follow these instructions may damage the
motor, wiring, and/or control panel.
10
4111-0073 — Sept. 2018
© 2018 Systems, LLC
INSTALLATION
Disconnect
Installation Overview
Note: This is a generic overview of a typical UniLock installation. See full installation
instructions on pages 12-18 for different installation types and all steps.
4” Thick Bumpers
48”
“TPR”
“UniLock”
(supplied by others)
Place control box where best suited, within
arms reach, at eye level near door opening
Allow adequate space
for seals and shelters
Dock Seal
3/4” Conduit or
Diameter per Local Code
(Supplied by others)
5”
Inside
Caution sign
Inside light
and control
box
Outside lights
Outside
Caution
Sign
18”
96”
Junction box
mounted on
dock face, not
to extend out
more than 3”
(Supplied by
others)
Optional imbed
plated (20”x20”)
Center Line of
Dock and TPR
Figure 5
55”
58”
Wire Harness
15”
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© 2018 Systems, LLC
11
INSTALLATION
Roller Track Installation - Without Embed
Anchor Installation
Do not install the UniLock vehicle restraint directly
onto a concrete block or brick dock face; contact
Systems, LLC to purchase a suitable Z-bracket.
Minimum 4” thick bumpers are required at all
positions where a UniLock vehicle restraint is
installed. DO NOT install on docks without minimum
4” thick bumpers. For thicker bumpers, consult the
factory.
Install roller track plate onto dock face at specified
location by using the fifteen (15) concrete anchors
provided, in conjunction with welding to pit steel or a
leveler frame. If required, roller track can be trimmed
up to a maximum of 5” from the bottom.
The roller track plate must be plumb with the dock
face. If not, use and weld (6) shims 2” wide x 255/8” long. Shims must be the full length of the roller
track mounting plate. If shims are over 1/2” thick, use
longer anchors. If shims need to be 1” thick or more,
contact Systems, LLC Technical Services.’
Some levelers are slightly recessed within the pit and
thus require a shim to be inserted between the roller
track plate and the leveler front subframe and welded
in place.
Note: Some mechanical dock levelers have an
adjusting nut access hole in the leveler front
subframe. If the UniLock vehicle restraint roller track
interferes with the access hole, the track plate must
be cut to allow access.
Note: Fifteen (15) concrete anchors are provided
with each UniLock vehicle restraint. An anchor must
be installed in each roller track plate hole except for
those plug-welded to embedded steel.
1. Place roller track at desired location, spaced 5/8”
above the drive.
2. Using the roller track as a guide, drill holes of
5/8” diameter and minimum of 4-5/8” deep at all
locations where roller track is not overlapping
curb steel. Clean out holes.
3. Insert anchors and drive them flush with roller
track plate, making sure that the threaded wedge
is inserted first. Do not disassemble anchors prior
to installation.
4. Once all anchors are installed, torque to 60 ft-lbs.
Welding Instructions
Note: If the installation being worked on is a retrofit
or replacement, make sure that the power source
has been tagged and locked out according to OSHA
regulations and approved local electrical codes, then
remove the motor and limit switch connections from
the control harness located in the outside junction
box.
1. Disconnect power and ground leads to dock
leveler (if equipped).
2. Plug weld all holes that are in contact with
embedded steel. All fifteen (15) holes must
be either plug welded or anchored. Minimum
electrode must be 1/8” 7018 or better.
12
3. Weld across top of roller track plate to curb steel
or leveler frame with 3” long 1/4” fillet welds.
4. Once all welding has been completed, reconnect
power and ground leads to dock leveler (if
equipped).
5. Clean and touch up all welds once complete.
4111-0073 — Sept. 2018
© 2018 Systems, LLC
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