NORDOCK TRUCK-LOCK Series User manual

i
TRUCK-LOCKTM SERIES
ATL-450
Low Profile Automatic
Vehicle Restraint
Owner’s Manual
This manual applies to ATL-450 series restraints manufactured on or
after 2013/06/01 with serial numbers 25005 and greater.
P/N: 59-0007-P
NORDOCK INC.
Website: nordockinc.com ~ Email: [e-mail] ~ Toll free: 866-885-4276
Nordock Inc. reserves the right to make changes to specifications without notice or obligation. Nordock products may be covered by
various U.S. and foreign patents or pending application.

1
Contents
Contents ............................................................................................... 1
Preface ................................................................................................. 2
Problems, Errors and Omissions.................................................................................2
Restraint Identification.................................................................................................2
Copyright.....................................................................................................................2
Warranty............................................................................................... 3
Safety Practices ..................................................................................... 4
Labels..........................................................................................................................5
Installation ............................................................................................ 6
Mounting Requirements...............................................................................................7
Tools Required ............................................................................................................7
Installation with Pit Type Levelers................................................................................8
Installation of Optional Driveway Mounting Plate.......................................................14
Operating Procedure ............................................................................ 16
To Hitch Truck: ..........................................................................................................16
To Release Truck: .....................................................................................................17
Troubleshooting................................................................................... 18
Restraint Operating Function Check..........................................................................18
Maintenance Schedule.......................................................................... 21
Acceptable Lubricants and Oils .................................................................................22
Hydraulic............................................................................................................................................. 22
Grease ................................................................................................................................................ 22
Parts Replacement............................................................................... 23
Removing Hook From Track......................................................................................23
Re-installing Hook Into Track.....................................................................................23
Wiring Diagram.................................................................................... 24
Parts List............................................................................................. 25

Nordock Inc. Owner’s Manual – ATL-450 TRUCK-LOCK 59-0007-P
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Preface
PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY
This manual gives detailed information and instruction on how to operate and
maintain your equipment correctly. Failure to do so could result in personal injury,
and/or equipment damage. Please consider this manual a permanent part of the unit
and keep it near the restraint for reference whenever needed.
If you have any questions about this manual, the restraint, its components, or our
products and services, please call us at 1-866-885-4276 and we will be happy to assist
you. With proper care and maintenance, this restraint is designed to work effectively
and efficiently for many years to come.
Problems, Errors and Omissions
This manual has been prepared with the utmost care and attention to detail to
provide accurate parts and service information should the need arise. Nordock
Incorporated believes this manual will provide the operators of this restraint all the
necessary information required to operate and maintain it for many years. If you believe
there is an error, if you have a problem following the guidelines, or if there is information
that you feel is missing from this manual, please contact us at the above number so that
we may resolve the issue immediately.
Restraint Identification
It is very important that in order to obtain the best possible service from Nordock Inc.,
please provide the model and serial number of the restraint whenever you contact us.
Below is the same serial number decal that will be found on the left hand hook side
plate (standing outside facing the restraint). Please record the information from the
decal on the restraint in the area below. This will greatly reduce the possibility of
improper parts being shipped to you.
Model:
Capacity:
Copyright
This manual is copyright to Nordock Incorporated. All information, text, drawings, and
technical data contained herein are for reference only. No part of this manual may be
copied, altered, or stored on electronic media, and cannot be revealed to others for the
purpose of competition.

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1. Replace the product or the defecteof without charge to the purchaser; or,
2. Alter or repair the product on site or elsewhere, as Nordock Inc. may deem advisable,
without charge to the purchaser.
In addition to the above, the structural components are covered by an extended Five-Year
period. In the event a structural component proves defective in years two through five, Nordock
will provide a replacement part at no l be responsible for the cost to ship and install the
replacement part during this extended period.
The warranty stated herein is that offered by Nordock Inc. and expressly disclaims all implied
warranties including those of merchantability and fitness. This warranty does not cover any
failure caused by improper installation, misapplication, overloading, abuse, negligence, or
failure to do prescribed maintenance and protect the equipment from vehicle impact. Nordock
Inc. or its representative assume no responsibility or liability for any incidental or consequential
damages of any kind including loss of use of any equipment, damage or failure resulting from
the use of unauthorized replacement parts or equipment modification, or damages resulting
from the misuse of the equipment.
Nordock Inc. warranties extend only to the product itself. Nordock Inc. disclaims all liability of
any kind arising out of the workmanship, methods and materials used by the installer or
premature product wear, product failure, property damage or bodily injury arising from improper
installation.
These warranties as stated herein are the exclusive remedies for all claims.
Warranty
Nordock Inc. expressly warrants that the Model ATL-450 Vehicle Restraint shall remain free
of defects in material and workmanship under normal use for One-Year from the date of
delivery to the purchaser. The purchaser must maintain & operate the product in accordance
with proper procedures. In the event the product proves defective in material or workmanship,
Nordock Inc. will at its option within the first year either:

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Safety Practices
The operators of this unit must read these safety practices before installing, operating or
servicing the TRUCK-LOCKTM. Failure to follow these safety practices may result in
bodily injury, property damage or death.
READ AND FOLLOW THE OPERATING INSTRUCTIONS CONTAINED IN THIS
MANUAL BEFORE OPERATING THE TRUCK-LOCKTM. If you do not understand the
instructions, contact your supervisor for explanation and instruction on the safe
operation of this unit.
Improper installation of the TRUCK-LOCKTM could result in serious injury or death to
dock workers or other users of the restraint.
The following guidelines are to be used in conjunction with all laws, governances and
codes in effect where the TRUCK-LOCKTM is installed.
1. Use by untrained people can cause property damage, serious injury and/or
death. Your supervisor should instruct you on the safe and proper way to use
the TRUCK-LOCK. Read and follow the complete OPERATIING procedure on
page 15 before use.
2. DO NOT USE THE TRUCK-LOCK IF IT IS NOT WORKING RIGHT. Tell your
supervisor it needs repair.
3. Be certain all people in the driveway stand clear when the TRUCK-LOCK is
being operated.
4. Do not stand in the driveway between the dock and a backing truck.
5. Keep all body parts clear of restraint guide tracks and moving parts at all times.
6. Do not install the TRUCK-LOCK anchor bolts into concrete of questionable
integrity.
7. Do not load or unload any truck until you make certain that the TRUCK-LOCK
has securely engaged the truck’s ICC bar and the brakes are set. If the TRUCK-
LOCK does not hitch the truck’s ICC bar for any reason, BE CERTAIN TO
CHOCK THE TRUCK WHEELS BEFORE PROCEEDING WITH LOADING OR
UNLOADING.
8. Do not use the TRUCK-LOCK as a step.
9. All electrical troubleshooting and repair must be done by a qualified technician
and must meet all applicable codes. Before doing any electrical work, make
certain the power is disconnected and properly tagged or locked out.
!
WARNING

Nordock Inc. Owner’s Manual – ATL-450 TRUCK-LOCK 59-0007-P
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10.If the TRUCK-LOCK fails to operate using the procedures contained in this
manual, do not use the TRUCK-LOCK. Contact Nordock Inc. or an authorized
service representative for service.
11.Whenever any maintenance or repair is to be performed on the restraint,
barricade the area around the dock floor and driveway and place clear signage
on the perimeter that the dock and restraint are not to be operated.
12.If you have any questions, contact your supervisor or your local Nordock
Incorporated representative.
Labels
The labels and decals on the TRUCK-LOCK must be kept in clean, legible condition at
all times. The diagram below shows the decals and their placement on the restraint.
Please check their condition on a daily basis, and replace them immediately if they
become unreadable.
Capacity:
Model:

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Installation
IMPROPER INSTALLATION OF THIS TRUCK-LOCK COULD RESULT IN SERIOUS
INJURY OR DEATH TO DOCK WORKERS OR OTHER RESTRAINT USERS
A typical TRUCK-LOCK restraint installation is shown below:
The following installation materials are included with the restraint:
13 pcs. 5/8” x 5” concrete wedge anchors
1 pc horizontal shear plate
1 pc pre-wired weatherproof junction box
All other materials required are to be provided by the installer.
!
WARNING

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Mounting Requirements
1. The dock face on which the TRUCK-LOCK is to be mounted must be flat and
vertically plumb for correct operation. If the dock face is not flat, it may be
necessary to use shims behind the backplate of the restraint or to modify the
dock face to provide a flat mounting surface. If shimming is required, it is
necessary to place shims at all of the anchor hole locations where the backplate
does not contact the wall. This will prevent distortion of the backplate when the
anchors are tightened.
2. The TRUCK-LOCK vehicle restraint requires a 4” bumper projection from the
front of the bumper to the rear of the back plate of the restraint. Less than 4” of
projection can allow trailer ICC bars to damage the restraint.
3. Some types of dock levelers that use lip saddles may interfere with the TRUCK-
LOCK vehicle restraint. Depending upon the lip length, dock height, bumper
projection, use of standoffs etc., modification to the restraint and/or dock leveler
may be required. Consult the factory for specific applications.
4. The standard concrete anchors (5/8” x 5” wedge style) provided with this restraint
may only be used on docks constructed of solid concrete. Docks constructed of
other materials require special mounting considerations. Refer to the end of this
section for optional driveway plate mounting. Contact your local Nordock
distributor for application specific information.
5. A 3/8” gap is required between the dock leveler front angle and the pit floor for
installation of the horizontal shear plate.
6. Do not install the TRUCK-LOCK anchor bolts into concrete of questionable
integrity.
7. If the driveway beneath the TRUCK-LOCK is affected by frost, additional
clearance between the TRUCK-LOCK and the driveway may be required to
prevent damage due to heaving.
Tools Required
-Welder
-Hammer drill with 5/8” diameter masonry bit
-15/16” Wrench
-General hand tools
-Touch up paint (Silver)
-Torque wrench (100 ft-lbs. min.)
-5/8” Wrench

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Installation with Pit Type Levelers
1. Place barricades around pit on dock floor and driveway while installing the
TRUCK-LOCK.
2. The horizontal shear plate MUST BE INSTALLED to achieve the full rated
restraining capacity of the TRUCK-LOCK.
The installation method for the horizontal shear plate will depend upon the height
of the front curb steel off grade and if there is a sufficient gap under the dock
leveler front angle.
The diagrams below illustrate acceptable shear plate mounting methods for the
most common types of restraint installations.
Please consult the factory if your particular site conditions prohibit installation of
the shear plate using the above methods.

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ALWAYS USE DOCK LEVELER MAINTENANCE SUPPORT WHEN WORKING
UNDER A DOCK LEVELER RAMP OR LIP
3. If there is sufficient clearance, insert the horizontal shear plate into the gap
between the dock leveler front angle and the pit floor.
Otherwise use one of the methods illustrated on the previous page.
4. Place the bottom of the TRUCK-LOCK ½” above the driveway and centre it with
the dock leveler pit.
a. If the horizontal shear plate is above the top of the backplate, weld the full
width of the shear plate to the dock leveler front angle. If there is no dock
leveler front angle (clean frame design), weld the full width of the shear
plate to the front pit curb angle.
b. If the horizontal shear plate is level
with or below the top of the backplate,
tack the shear plate to the backplate at
both ends. Pull the restraint and shear
plate away from the dock and weld the
full width of the plate on the topside
using a ¼” fillet. Refer to adjacent
diagram.
Paint welded areas to prevent rust.
5. Slide the TRUCK-LOCK and shear plate
back into position.
6. Before anchoring the TRUCK-LOCK, operate
the dock leveler through its full range of motion.
a. Check that the TRUCK-LOCK does not interfere with the below dock
operation and that the dock leveler lip does not come to rest on the
TRUCK-LOCK in such a way that it supports the weight of the dock
leveler.
b. In the full below dock position, check that the pendant dock leveler lip
does not project beyond the face of the bumpers when it is resting on the
top of the restraint.
!
WARNING

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Improper installation that allows the pendant dock leveler lip to support the weight of
the dock leveler could result in serious injury or death. It is sometimes necessary to
install lip deflector plates to prevent the possibility of the pendant lip storing on top of
or behind the restraint backplate.
An optional bolt-on lip deflector plate is available for use with this restraint. It is
shown in the diagram below. If the optional deflector is insufficient to prevent the
dock leveler lip from resting on top of or in behind the restraint, the installer must
provide additional steel.
If the optional deflector plate interferes with the storing of the dock leveler lip, it may
be removed.
7. Anchor the TRUCK-LOCK backplate to the dock face using the wedge anchors
provided. The anchor bolts must be torqued to 90 ft-lbf to achieve maximum
holding strength.
Anchors must be installed in a minimum of six (6) back plate-mounting holes.
The anchors should be installed as the holes are drilled to prevent the TRUCK-
LOCK from shifting.
8. Anchor the shear plate to the pit floor using the concrete anchors provided. The
anchor bolts must be torqued to 90 ft-lbf to achieve maximum holding strength.
NOTE
!
WARNING

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Before doing any electrical and hydraulic work, the power must be disconnected and
properly locked/tagged off. Failure to do so could result in death or serious injury.
All electrical and hydraulic work must meet all applicable codes and be carried out
by a qualified technician.
The control voltage for this restraint is 24 VDC. All motor power wires or other high
voltage wires should be run in a separate conduit.
9. Mount the control box inside the building, to the left of the doorway, 4 ft. above
the floor. Refer to diagram below.

10.The outside signal light is to be placed approximately 9 ft above the driveway on
the driver’s side of the door opening as shown in the diagram on the next page.
Drill a hole through the wall at the centre of the signal light mounting position.
11.Run a length of 16/3 electrical cable (not supplied) from the control box location
through the wall. Make connections in panel and signal light assembly as
indicated in the wiring diagram located at the back of this manual.
!
WARNING
NOTE

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12.Fasten the signal light housing to the wall.
13.Mount the “Move On Green Only” sign provided to the exterior wall under the
signal light as shown in the diagram above.
14.Mount the supplied electrical junction box to the exterior wall adjacent to the
restraint in the location shown in the diagram above.
15.Run a length of 18/2 electrical cable (not supplied) from the control box to the
exterior junction box. Make connections inside the control box and junction box
as indicated in the wiring diagram located at the back of this manual.
16.If this installation includes an optional dock leveller “stored” limit switch, wire in
the normally closed contact. This will prevent the restraint from being released
until the dock leveler is stored.
17. Bring 110/1/60 power to panel and wire according to the diagram located in the
control panel. DO NOT APPLY POWER AT THIS TIME. Running the pump
without oil can cause permanent damage.
18. Cap both ends of the 16’ length of ¼” hydraulic hose (supplied) with the restraint.
CAUTION
MOVE ON
GREEN
ONLY

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19.Route the hose through conduit from the control box to the bulkhead hose
connection on the restraint back plate.
20.Clip the hose to the wall as necessary to prevent any tension on the hose ends.
21.Connect one end of the hose to the control box port.
22.Connect the other end of the hose to the bulkhead fitting on the backplate hose-
mounting bracket.
23.Tighten all connections.
24.Remove the filler cap from the hydraulic pump reservoir.
25.Using the supplied hydraulic oil, fill the reservoir to the top. Leave the filler cap
off, as oil will need to be added while the pump is running.
26.Apply power to the control panel.
27.The outside light should be flashing green and the inside light solid red. If the
lights are not on or not as described, verify power and all field wiring connections.
28.Press and release the “LOCK” button. The pump will turn on and the outside
light will change to flashing red. If the pump does not turn on, verify that the
restraint sensor bar is not deflected. If the sensor bar is not deflected, then the
field wiring between the restraint sensor and the control box needs to be verified.
29.After the pump runs for several seconds, the hook will slowly start to rise. The
motion will be “jerky” at first due to the air in the line. This is normal.
30.As the hook raises and the accumulator charges, the oil level in the reservoir will
drop significantly. Add oil as the motor is running to keep the reservoir
approximately 1/2 full.
31.The pump will shut off automatically when the pressure reaches a preset value.
32.Turn the “RESTRAINT BYPASS” switch to OFF. The inside light will change to
solid red and the exterior light will flash green. If equipped with the optional
alarm, turn the switch to OFF when the alarm sounds.
33.Check for oil leaks at all hose connections.
34.Press the “RELEASE” button to store the hook.
35.Add hydraulic oil as necessary to bring the fluid level up to the “MAX” line on the
side of the reservoir.
36. Replace filler cap on hydraulic oil reservoir.
37. Operate the TRUCK-LOCK control box “LOCK” and “RELEASE” pushbuttons
several times to release any remaining air that is trapped in the system.

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38.Verify that the hook raises and lowers smoothly.
39.Verify correct operation as follows:
a. One light must be on, both interior and exterior at all times.
b. With the restraint in the stored position, the exterior light will flash GREEN
and the interior light will turn RED.
40.If the lights do not operate as described, there is a field-wiring problem. Turn off
the power and check the wiring per the Wiring Diagram at the back of this
manual. Rewire as required.
41.Instruct the dock workers how to correctly use the TRUCK-LOCK. The Operating
Procedure can be found in the next section.
Installation of Optional Driveway Mounting Plate
When the optional driveway mounting plate is used, the driveway material must be
concrete. For driveway materials other than concrete, a stepped concrete pad must be
poured as shown next page. Allow concrete to properly cure before installing restraint.
Place plate on driveway or concrete pad.
Place bottom of TRUCK-LOCK on the driveway plate. Keep both the TRUCK-LOCK
and driveway plate centered with the dockleveler pit.
Make sure the horizontal shear plate is welded to the restraint back plate as previously
noted in Installation Instruction 4a and b.
Weld the bottom of the TRUCK-LOCK back plate to the driveway plate, as shown on
next page. Paint welded areas to prevent rust.

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Operating Procedure
Before operating or maintaining this truck restraint, read and follow the safety practices
contained in this manual. Failure to follow the guidelines in this manual and those in
effect in the workplace can result in serious bodily harm and equipment damage.
Do not load or unload any truck unless you make certain the TRUCK-LOCK has
securely engaged the truck’s ICC bar and that the truck brakes are set. If the TRUCK-
LOCK does not engage the truck’s ICC bar for whatever reason, THE TRUCK’S
WHEELS MUST BE CHOCKED BEFORE LOADING OR UNLOADING CAN BEGIN.
Failure to store the TRUCK-LOCK when not in use could result in damage to the
TRUCK-LOCK and incoming trucks.
To Hitch Truck:
(Initial conditions: –hook stored –outside light
flashing green –inside light red)
1. Press and release the “LOCK” button. The
hook will raise to engage the truck’s ICC
bar.
2. The outside traffic light will change to
flashing red. If the sensor bar is deflected
by the truck’s ICC bar as the hook rises, the
inside light will change to GREEN.
VISUALLY CHECK ICC bar engagement.
3. If the sensor bar is not deflected, the inside
light will remain RED. If equipped, the
alarm will sound.
4. Secure the trailer by chocking the wheels on BOTH sides.
5. Silence the alarm and change the inside light to GREEN by turning the
RESTRAINT BYPASS” selector to the “ON” position
6. The dock leveller can now be used to load/unload the truck.
!
WARNING

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To Release Truck:
1. Ensure the dock leveler is stored.
2. The “RESTRAINT BYPASS” selector must be turned to the “OFF” position before
the hook can be released.
3. Press the “RELEASE” button. The hook
will disengage and begin to lower to its
stored position.
4. The interior light will switch to a solid red.
5. Once the hook has lowered sufficiently
that the sensor bar is no longer
depressed, the outside light will change to
a flashing GREEN.
6. VISUALLY CHECK that the hook is in the
fully lowered position.
7. The truck may now pull out.

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Troubleshooting
Restraint Operating Function Check
Initial Conditions:
-“RESTRAINT BYPASS” in the OFF position.
-Hook stored –Inside solid red light –Outside light flashing green.
Press the LOCK pushbutton:
-The inside red light will remain on and the hook will raise.
-The outside light will change to flashing red.
-The cylinder will extend fully and the pump will shut off at 1000 psi.
-If the sensor bar is deflected before the pump shuts off, the inside light will
change to a solid green.
-If the sensor bar is not deflected, the inside light will remain red. If
equipped with the optional alarm, alarm will sound.
Turn the “RESTRAINT BYPASS” selector switch to the “ON” position:
-The hook will remain in the raised position with the inside light showing
solid green.
-If equipped with the optional alarm, the alarm will silence.
Press the RELEASE pushbutton:
NOTE: The “RESTRAINT BYPASS” selector must be in the “OFF” position
before the hook can be released.
-The inside light will turn red.
-The hook will lower to the stored position.
-The outside light will change to green, once the hook clears the ICC bar.
NOTE:
-Visually check to make sure the hook has fully lowered before instructing
truck driver to leave.

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Troubleshooting
PROBLEM
CAUSE
CORRECTIVE ACTION
No interior or exterior signal
lights.
1.No power to panel.
Check that power is coming
into control panel.
2 Control panel fuse blown.
Check fuse and replace as
necessary.
Interior light stays solid red
even when hook sensor bar
is deflected.
Control panel not “seeing”
change of state in sensor
bar switch.
1. Manually deflect sensor bar
and verify that trigger plate
passes within 1/4” of round
sensing zone.
2. Check for missing or
damaged sensor bar made
switch.
3. Check continuity of sensor
bar made switch wiring to
control panel.
4. If wiring checks out OK,
place a piece of steel
against switch sensing
face. If lights do not
change, replace switch.