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User`s Manual

1. Fig 59 SV5 iC Lock pin cylinders D eer 1 aes SV4 Thm SC eu SE B Check valve Velocity fuse Lo a WI leg cylinders S VI L Lip cylinder Sequence valve SV2 A A ES d BF d f ela R Shuttle valve ai 60 PSI ER MHA Primary relieve gt valve _ 2000 PSI May 2012 6009080C Dock Leveler and Lift Combo 55 2012 4Front Engineered Solutions Inc HYDRAULIC VALVE CROSS SECTION LEVELER Fig 60 Lip extend port Main port a eet AD o 5 d Adjustable NY Ta sequence valve O OMO ae bail If Secondary relief valve h SS Pilot check Di EG valve 56 6009080C Dock Leveler and Lift Combo 2012 4Front Engineered Solutions Inc valve 2000 PSI Ma
2. ae Hydraulic reservoir Clean pit replace oil annually quarterly and inspect level Visually inspect quarterly holes and cables not shown 44 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc PLANNED MAINTENANCE continued Every 90 days quarterly inspect all safety labels and tags to ensure they are on the dock leveler and lift combo and are easily legible If any are missing or require replacement please call 1 800 525 2010 or 972 466 0707 for replacements A DANGER 921 217 x2 6008485 x2 ADANGER SAFETY INSTRUCTIONS iow Fig 52 921 075 G ES ool sesuli Sie JY gt SCH A DANGER CRUSH HAZARD Do not work under dock leveler unless this maintenance strut has been secured in the upright position See user s manual for proper procedures 921 0748 4 DANGER CRUSH HAZARD 92 1 070 DO NOT ENTER PIT unless dock leveler is bzi securely supported by the maintenance strut Place barriers on driveway and dock floor to indicate service work being performed Failure to comply will result in death or serious injury Refer to user s manual for proper maintenance procedures DANGER 6007121 x2 PINCH
3. Countersunk screws Auxiliary port Cover plate Rear of unit Solenoid cable Temporary power cord 20 6009080C Dock Leveler and Lift Combo 2012 4Front Engineered Solutions Inc May 2012 INSTALLATION lt PIT MOUNT continued 10 Ensure the routing of lift solenoid cable and the wiring to the temporary power cord avoid any pinch points or other hazards as the dock leveler and lift combo will rise 11 Ensure all electrical connections are made and power is supplied to the control panel 12 Enter Service Mode by pressing and holding the reset pushbutton located on the righthand side of the control panel for 5 seconds Within the panel verify the PLC has booted and the PLC run light is solidly illuminated Ensure the input 19 door interlock is illuminated if it is not jumper wires must be correctly installed to satisfy this condition 13 Verify Service Mode is active The red and green lights located on the panel should be flashing Press and hold the LIFT RAISE pushbutton and note that the scissor lift motor is running The lift should start to rise If within 10 seconds the lift does not rise the motor polarity may need to be reversed 14 With the platform raised to floor level the frame must be shimmed so that all four corners of the platform are level with the floor Measure and record the height from each corner of the dock leveler and lift combo to the floor Then select shims ap
4. THE FOLLOWING TOOLS ARE REQUIRED e Crane or heavy forklift truck capable of lifting the appropriate weight at 6 2m load center See Fig 4 for expected weight e Roto hammer with 3 4 bit e Hydraulic jack e Welder e Short and long pry bars e Assorted SAE open end wrenches e Allen wrench set Fi 1 Check the entire dock leveler and lift combo pit for proper construction to certified approval drawings Ensure the pit walls are square and plumb Scrape clean the three embeds in the pit floor Sweep clean the entire pit floor Check electrical service running to the pit to ensure it agrees with the phase and voltage of the pump motor and control box supplied with the dock leveler and lift combo See tag attached to pump motor electrical cord and wiring diagram located inside the control box cover ADANGER Power to control box must be from fused disconnect supplied by others Fuse size for a dual element motor protected time delay type fuse can be no greater than 225 of motor FLA Before doing any electrical work make certain the power is disconnected and properly tagged or locked out All electrical work must done by qualified technician and must meet all applicable codes If it is necessary to make troubleshooting checks inside the control panel with the 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 c
5. A WARNING Before servicing the dock leveler and lift combo read and follow the Safety Practices on pages 3 4 and the Operation section of this manual LIFT MODE LED DISPLAY The LED display below represents the standard LIFT MODE condition at dock height with the deck raised and resting on the maintenance struts and the lip pendant This can be used as a troubleshooting starting point to help diagnose the area of concern Fig 56 LS9 deck support legs up LS Weer pine ramana amber light illuminated amber light illuminated _ LS3 lip pendant amber light illuminated SCH a LS4 dock height indicator amber light illuminated _ Power indicator green light illuminated LS1 and LS2 deck level indicator if the leveler is not raised and resting on O O the maintenance struts both LS1 and LS2 will have the amber light illuminated 50 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc Use the Troubleshooting Guide if ever the leveler fails to perform properly Find the condition that most closely matches your situation and make the recommended adjustments Observe all safety warnings before attempting TROUBLESHOOTING continued A WARNING Before servicing the dock leveler read and follow
6. Make sure the scissor arms are firmly resting against safety stop blocks then disconnect the hydraulic hose at the auxiliary port Before disconnecting raise the hose assembly above floor level to ensure excess hydraulic fluid will drain back to the tank Cap both connections Reattach the auxiliary port cover plate to the deck assembly The two countersunk screws should not protrude above the deck surface 22 Route the remote hydraulic hose through the 4 conduit located near the remote mounted motor From the pit area retrieve the remote hydraulic hose and connect it to the hydraulic tee fitting connected to both scissor cylinders Pull excess hydraulic hose from the conduit for travel above finished floor See Fig 10 for detail and location Fig 8 Front Shim Detail Fig 9 Scissor Rear frame frame embed Rear Shim Detail May 2012 6009080C Dock Leveler and Lift Combo 13 2012 4Front Engineered Solutions Inc INSTALLATION REMOTE MOUNT continued 23 24 While in the pit route the bundle of electrical cables through the 3 conduit Leave excess cable length in the pit area for travel above finished floor These cables will connect to the proper receptacle on the bottom surface of the control panel The yellow cable cable 617 with a 19 pin connector contains 24V signal wiring for the proximity switches The gray cable cable 615 with an 8 pin connector contains the 24V signal wiring for the
7. 3 The power is disconnected and properly tagged or locked out Before servicing the dock leveler and lift combo read and follow the Safety Practices on pages 3 4 and the Operation section of this manual Place barricades on the dock floor around the dock leveler and lift combo pit and in the driveway in front of the pit while installing maintaining or repairing the unit May 2012 Fig 57 Motor 6009080C Dock Leveler and Lift Combo Sequence valve Secondary relief valve Reservoir Breather cap with dip stick Sequence valve valve Secondary Primary relief valve relief valve Reservoir 53 2012 4Front Engineered Solutions Inc Shuttle ADJUSTMENTS LEVELER HYDRAULIC POWER continued Primary Relief Valve Controls maximum pressure in the hydraulic Remove threaded cap Turn screw clockwise to system and protects the other components increase relief pressure Relief pressure will be from excessive force factory set at 2000 PSI and should not require adjustment Note a suitable hydraulic pressure gauge MUST BE USED when adjusting Flow Control and Controls the lowering speed of the ramp Remove threaded cap Turn the screw Shuttle Valve plate and directs fluid to the cylinders when clockwise to decrease lowering speed Adjust the pump is running the lowering speed to approximately equal the ramp raise speed Sequence Valve Controls lip plate retraction and exten
8. H46 H3 H1 TUL 380 220 200V PRI xF 311 110 23V SEC Ge 250A X4 LIFT AND LEVELER MOTOR DETAILS d x3 380 480V THREE PHASE 50 60HZ CH RD WH BK NOTE VISUALLY CONFIRM MOTOR TAG LEGEND PANEL WIRING FIELD WIRING BY OTHERS PC BOARD TRACES WIRE COLOR GAUGE unless otherwise specified 208 600VOLT BLACK 14GA 24VAC 120VAC RED 16GA from 600 24VAC RED BLK 16GA 120 24VAC NEUTRAL WHT 16GA 24VDC BLUE 18GA 120VAC NEUTRAL 24VDC OVDC BLU WHT 18GA from 601 from 602 12VOLT AC OR DC PURPLE 18GA 12VOLT PUR WHT 18GA 66 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc Fig 69 480V 3 PHASE 60 HZ E LECTRICAL SCH EMATIC continued INCOMING SERVICE TO BE TERMINATED AT DISCONNEC LEVELER MAIN MOTOR PANEL BULKHEAD PANEL FLA 10 8AMPS DS40 CONTACTOR SCCR 5KA SA FU401 M618 OL1 ia t t i 7 Lem Sik i 1 l MOT402 1 oD 4 sat me Oeog WAT ceio Hp LEVECER i MOTOR H So Te 4 z5 ren RED f AFLA 460v 60H2 UT v4 G MOTOR gt i CONTACTOR M621 OL2 TL OTT l MOT405 eo 48 Er 3L2 412 P MOTOR 10 1FLA 460V 60HZ Brg FOIL Erg 1770RPM 11A bg NOTE Power to control panel must be from fused disconnect supplied by others Max Type CC fuse size s
9. Kelley 6008548 May 2012 6009080C Dock Leveler and Lift Combo 71 2012 4Front Engineered Solutions Inc PARTS LIST continued Deck subframe assembly Fig 72 Qty Part Description Part Number Deck Subframe Assembly 6 ft wide x 8 ft long 6009309 Deck Subframe Assembly 6 5 ft wide x 8 ft long 6005445 Deck Subframe Assembly 7 ft wide x 8 ft long 6009312 Deck Subframe Assembly 6 ft wide x 10 ft long 6009310 Deck Subframe Assembly 6 5 ft wide x 10 ft long 6008304 Deck Subframe Assembly 7 ft wide x 10 ft long 6009313 Deck Subframe Assembly 6 ft wide x 12 ft long 6009311 Deck Subframe Assembly 6 5 ft wide x 12 ft long 6005880 Deck Subframe Assembly 7 ft wide x 12 ft long 6009314 Lock Pin Adapter Right 6005484 Lock Pin Adapter Left Lock Pin Socket Head Cap Screw 5 8 11 x 3 long Item 1 1 1 1 1 1 1 1 1 ea Deck Level Target Assembly Cap Tube Deck Level Cotter Pin 5 32 x 2 long Deck Pivot Pin 3 4 Dia 5861467 4 72 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued Deck subframe assembly Qty Part Description Hitch Pin Clip Maintenance Strut Clevis Pin 1 2 Dia x 2 1 4 long Cotter Pin 1 8 x 3 4 long 8 Plain Washer 9 16 I D 2 Pin Deck Support Leg Keeper Assy 8 ft units 6005496 2 Pin Deck Support Leg Keeper Assy 10 and 12 ft units 6008407 Socket H
10. by others Max Type CC fuse size shown above FU509 H1 H2 D123 DAT mm PRI XF511 120V 8 24V 2 SEC gt 350A Se Ep LIFT AND LEVELER MOTOR DETAILS X2 11 600V THREE PHASE 60HZ ae RD T M WH T1 BK HALDEX NOTE VISUALLY CONFIRM MOTOR TAG LEGEND PANEL WIRING FIELD WIRING BY OTHERS PC BOARD TRACES WIRE COLOR GAUGE unless otherwise specified 208 600VOLT BLACK 14GA 24VAC 120VAC RED 16GA from 600 24VAC RED BLK 16GA 120 24VAC NEUTRAL WHT 16GA 24VDC BLUE 18GA 120VAC NEUTRAL 24VDC OVDC BLU WHT 18GA from 601 from 602 12VOLT AC OR DC PURPLE 18GA 12VOLT PUR WHT 18GA 68 6009080C Dock Leveler and Lift Combo 2012 4Front Engineered Solutions Inc May 2012 PARTS LIST Top plate and lip plate assembly 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 4Front Engineered Solutions Inc could result in product malfunction breakdown premature wear death or serious injury Fig 71 May 2012 6009080C Dock Leveler and Lift Combo 69 2012 4Front Engineered Solutions Inc PARTS LIST continued Top plate and lip pl
11. interfere with the operation of the dock leveler and lift combo KEEP HANDS CLEAR OF ALL HINGES AND PINCH POINTS AT ALL TIMES Do not use hands to position the leveler portion in a vehicle or in storing the leveler Stay clear of the leveler portion unless the lip is supported by the vehicle platform or the ramp is stored An unsupported leveler can lower unexpectedly SAFETY PRACTICES OPERATION continued Do not use the dock leveler and lift combo if it looks broken or does not seem to work properly Inform your supervisor at once Do not stand in the driveway between the dock leveler and lift combo and a backing vehicle Before chocking wheels or engaging vehicle restraint dump air from air ride suspensions and chock vehicle wheels or lock vehicle in place with a vehicle restraining device and set brakes before loading or unloading Ensure lip plate avoids contact with vehicle sides and cargo If the lip does not lower to vehicle platform reposition the vehicle Do not use a fork truck or other material handling equipment to lower the ramp Move all equipment material or people off the dock leveler and lift combo and store unit at dock level before allowing the vehicle to pull out Store the dock leveler and lift combo at dock level after use If the dock leveler and lift combo does not operate properly using the procedures in this manual DO NOT USE THE DOCK LEVELER AND LIFT COMBO Call your local distributor for serv
12. level adjustment Fig 27 Sensor back plate Socket head cap screws Scissor leg Contact Sensor arm May 2012 6009080C Dock Leveler and Lift Combo 25 2012 4Front Engineered Solutions Inc INSTALLATION F PIT MOU NT continued 31 After the latch blocks have been tack welded supply power back to the panel Place the unit in Service Mode and retract the lock pins Lower the dock leveler and lift combo several feet below floor level and remove the installation shim bushing from each latch block Now raise the platform to floor level It will stop automatically Extend the lock pins Carefully inspect the lock pin for proper engagement into the latch blocks If a pin does not engage properly note the area of interference If necescary remove the latch blocks and repeat the block installation procedure 32 When the blocks have been properly positioned lower the dock leveler and lift combo and fully weld the latch blocks in place See Fig 29 for weld details NOTE Fine adjustments can be made to floor level sensing using the PLC s potentiometer see Fig 14 Using a jewelers screwdriver or equivalent rotate the potentiometer clockwise to increase or raise the point at which the deck will stop Rotate the potentiometer counter clockwise to decrease or lower the point at which the deck will stop This affects the automatic stop feature when raising the deck while in
13. shall be placed 1 2 from the front of the scissor frame and 1 2 from the outside edge After the shims are in place loosen the leveling bolts so that the weight is resting only on the shim plates See Fig 24 for more detail on shim locations Repeat the measurements and adjust the shimming until the platform is level The platform does not need to be at the same height as the floor but all four corners must be the same distance above or below the floor The front of the dock leveler and lift combo may be up to 1 8 higher than the rear but should not be lower Check that there is a space of 3 4 between the rear of the platform and the pit wall Ensure that there is an equal space on both sides of the platform If the spaces are not correct the frame can be shifted using a pry bar or small hydraulic jack between the pit wall and the ends of the frame Do not use the jack near the middle of the frame side angles If the dock leveler and lift combo has been repositioned re check the platform for level and shim as required Fig 22 Scissor assembly 4 x 10 Scissor shim frame Leveling bolt Fig 23 Roller Scissor frame 22 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc INSTALLATION PIT MOUNT continued 18 When the dock leveler and lift combo is properly positioned remove the safety stop blocks from the lift frame Operate the unit through the entire
14. solenoids The black cable cable 302 with a 4 pin connector contains the power wiring for the leveler power unit Review electrical schematics for wiring details if the control panels is not fitted with electrical connectors Once all electrical connections have been made Place unit in Service Mode and verify all mode functions are available as follows e Press Lift Lower and verify the lift lowers e Press Lift Raise and verify the lift raises Continue to raise the dock leveler and lift combo above floor level to the highest point of travel Ensure the remote hydraulic hose and all electrical cables have sufficient slack in the line If needed put the safety stop blocks in place and pull extra hose cable length through the conduit D Press Leveler Raise and verify the deck portion leveler raises There may be a slight delay but the leveler deck should start to rise If the deck does not rise the motor may be running in reverse Review the electrical schematics to reverse the motor connections within the control panel and try again Raise the leveler deck to its full height and before it can float back down press the Stop button This will hold the deck in the raised position Extend both maintenance struts and lower the leveler deck by pulling the Stop button out D Press Lip Extend and verify the lip extends e With the deck raised and positioned on the maintenance struts press and hold the Leveler Mode pushbutto
15. the Safety Practices on Pages 3 4 and the Operation section in this manual any maintenance procedure PROBLEM 1 Leveler does not raise Motor is silent 2 Leveler does not raise motor starts then stops motor starter relay chatters POSSIBLE CAUSE a No electrical power to control panel b Electrical connections incorrect or broken a Overload relay main circuit breaker or leveler control circuit breaker tripping out b Voltage drop due to long wiring distance from power source SOLUTION a Check that voltage is present at terminal connections to the control panel b Check that wiring matches the wiring diagram a Check overload setting and current draw b Check voltage when motor is started Voltage drop is more often a problem 3 Leveler does not raise Motor hums a Voltage drop b Loss of 1 phase 4 Leveler does not raise Motor runs b Pump not running or pressure insufficient c Pump running in reverse d Primary relief valve setting too low May 2012 a Low fluid level in reservoir on single phase motors Acquire conductor specifications from your distributor a Check voltage when motor is started Voltage drop is more often a problem on single phase motors Acquire conductor specifications from your distributor b Check for voltage at all three motor connections T1 T2 T3 in control panel a The hydraulic fluid level should be check
16. which extend down to the lift frame Loosen the nuts which secure the lifting lugs and then remove the threaded rods Keep all lifting hardware in case the dock leveler and lift combo must be removed in the future 6 Locate the temporary power cord and the lift solenoid cable that can be found through the auxiliary port See Fig 21 for location 7 Loosen the two countersunk screws from the auxiliary port Remove the auxiliary port cover plate from the deck surface of the dock leveler and lift combo Keep all hardware the cover plate will be reattached after this phase of installation AADANGER Before doing any electrical work make certain the power is disconnected and properly tagged or locked out All electrical work must done by qualified technician and must meet all applicable codes If it is necessary to make troubleshooting checks inside the control panel with the 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 cause electrical shock death or serious injury 8 Connection to the temporary power cord should be made from the auxiliary port to the control panel Review electrical schematics for termination details 9 The lift solenoid cable should be pulled from the auxiliary port and connected to the appropriate receptacle on the bottom side of the panel Review electrical schematics for termination details Fig 21
17. will rotate into place 1 Remove the rear chains swing gate or any other device blocking traffic access to the dock leveler and lift combo See Fig 40 2 Rotate the MLS switch to ENTER VEHICLE This should change the inside light to green and the outside light to flashing red 3 Drive lift truck onto leveler deck and set brakes 4 After the load is on the lift platform reapply the rear chains or close the swing gate or any other device blocking traffic access See Fig 46 40 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc OPERATING INSTRUCTIONS LIFT MODE continued 5 Fully extend the leveler lip by pressing and holding the lip extend pushbutton 6 Press and hold the lift LOWER button to lower the lift to a position where the leveler lip is supported either by the driveway surface or by a vehicle bed See Fig 47 RAISING LIFT 1 Press and hold the lift RAISE button to raise the lift from a lowered position The unit will continue to rise while holding the RAISE button until the unit reaches dock level the unit will then stop See Fig 48 and 49 2 Remove the rear chains swing gate or any other device blocking traffic access to the dock leveler and lift combo See Fig 40 3 Drive the lift truck into the building and completely remove the load from the dock leveler and lift combo Before allowing vehicle to leave always return the dock leveler and lift com
18. x o ZS Q Deck Level amp Above LS1 A AT A not required Deck Level amp Below LS2 A AT A not required Lip Pendant LS3 X X X not used Lock Pins Extended LS6A amp LS6B X X X not required Lock Pins Retracted LS7A amp LS7B X X X not required Lip Keepers Up LS8 A X X not required Deck Support Legs Up LS9 X X X not required X adjusted in either mode see Fig 63 on page 61 for proper sensor location X position can only be achieved in Service Mode 60 6009080C Dock Leveler and Lift Combo 2012 4Front Engineered Solutions Inc May 2012 ADJUSTEMENTS PROXIMITY SWITCHES continued The deck position sensors must be positioned correctly for the Dock Leveler and Lift Combo to function properly See Fig 63 for correct position for the LS1 and LS2 sensors Fig 63 Deck position arm Top plate Rear hinge end p14 1 4 3 7 8 O washers and nuts are removed for clarity LS2 sensor LS1 sensor With the sensors positioned correctly the sensors should be ON under the following conditions Sensor Deck Level 0 3 Above and Beyond Below Dock LS1 ON LS2 ON ON May 2012 6009080C Dock Leveler and Lift Combo 61 2012 4Front Engineered Solutions Inc ADJUSTEMENTS PROXIMITY SWITCHES contnueo Fig 64 1 16 to 1 8 separation Proximity sw
19. 0 Roller curtain Scissor frame Curtain bracket Fig 31 Front pit wall Pretension Pit floor Fig 32 Hanger bracket Keeper pin Leg Curtain rod cross tube May 2012 6009080C Dock Leveler and Lift Combo 27 2012 4Front Engineered Solutions Inc SERVICE TOOLS Fig 33 Before servicing the dock leveler and lift combo read and follow the Safety Practices on pagse 3 4 and the Operation section of this manual Be certain before entering the dock leveler and lift combo pit or doing any maintenance or repair under the dock leveler and lift combo that 1 The safety blocks are in place on the scissor frame A reg SA 2 The both maintenance struts are securely supporting D ae A r the leveler portion ey a d 3 The power is disconnected and properly tagged or eee Sole locked out es GE MAINTENANCE STRUTS AND LIP MAINTENANCE BAR 1 To raise the maintenance struts two people are needed a Ensure the dock leveler and lift combo is in Leveler Mode with lock pins engaged Follow the Operation Maintenance struts section of this manual to achieve this position Fig 34 b Press and hold the RAISE button on the leveler side Raised iti of the control panel so the leveler is fully raised sal tea c Use the second person to raise two maintenance struts to the vertical position d Release the RAISE button 2 If the lip is extended or you need it ext
20. 0V 8 24V 2 SEC 250VA X3 P LIFT AND LEVELER MOTOR DETAILS li x2 200 240V THREE PHASE 50 60HZ GN 13 3 G RD T2 4 WH e ar NS M gt BK 7 HALDEX NOTE VISUALLY CONFIRM MOTOR TAG LEGEND PANEL WIRING FIELD WIRING BY OTHERS PC BOARD TRACES WIRE COLOR GAUGE unless otherwise specified 208 600VOLT BLACK 14GA 24VAC 120VAC RED 16GA from 600 24VAC RED BLK 16GA 120 24VAC NEUTRAL WHT 16GA 24VDC BLUE 18GA 120VAC NEUTRAL 24VDC OVDC BLU WHT 18GA from 601 from 602 12VOLT AC OR DC PURPLE 18GA 12VOLT PUR WHT 18GA May 2012 6009080C Dock Leveler and Lift Combo 65 2012 4Front Engineered Solutions Inc ELECTRICAL SCHEMATIC continued Fig 68 380V 3 PHASE 50 HZ INCOMING SERVICE TO BE TERMINATED AT DISCONNEC LEVELER MAIN MOTOR PANEL BULKHEAD PANEL FLA 10 8AMPS DS30 CONTACTOR SCCR 5KA SOA ROTARY FU301 M618 OL1 g Tt T Cea alk i 1 l MOT302 1 oof T 4 3 m Oep T ceisoz up LEVELER i MOTOR H SNe Te 4 a3 ren RED A J SFLAG400v S0H2Z UT AJ G MOTOR S E CONTACTOR M621 OL2 M GEN l MOT305 to Cro 12 LET 3L2 412 EI MOTOR apg Weg 19 16 A 380V 50HZ 11A bg NOTE Power to control panel must be from fused disconnect supplied by others Max Type CC fuse size shown above FU309
21. 41 313239 313102 313105 313106 313219 6000595 313246 6008755 6003815 6008756 6008757 6008052 6008054 5861066 6001832 5861063 May 2012 PARTS LIST continued Hydraulic and electrical Pin Lip Keeper Front 8 ft units Pin Lip Keeper Front 10 and 12 ft units 6008407 Pin Lip Keeper Rear 8 ft units Pin Lip Keeper Rear 10 and 12 ft units 6008405 Socket Head Cap Screw 1 4 20 x 2 long 4 Port Solenoid Junction Box 6008051 18 mm Proximity Switch 6008404 Lip Pendant Cable QD 4 meters long 8 ft units 6008695 Lip Pendant Cable QD 5 meters long 8 ft units 6008696 Lip Pendant Cable QD 7 meters long 8 ft units 6008698 Dock Height Limit Switch Socket Head Cap Screw 3 8 16 x 1 Long Fitting Tee Male 1 2 031390 _ ech 61 es e a May 2012 6009080C Dock Leveler and Lift Combo 83 2012 4Front Engineered Solutions Inc PARTS LIST continued Guard Rail Fig 78 Part Number Guard Rail 800 31 Rail Length 6008420 Guard Rail 1000 43 Rail Length 6008421 Guard Rail 1200 55 Rail Length 6008422 Label Warning Guard Rail 6008880 84 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued Control Panel and Pendant Fig 79 Additional Warnings and Instructions On Side Of Enclosure COMMUNICATIONS HOL LOAD AN
22. 9344 Pushrod 6 5 ft wide 18 lip 6009345 Pushrod 7 ft wide 18 lip 6009346 Pushrod 6 ft wide 20 lip 6009347 Pushrod 6 5 ft wide 20 lip 6009348 Pushrod 7 ft wide 20 lip 6009349 76 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc ty 1 1 1 1 1 1 1 Item 1 EA ES PARTS LIST continued Roller curtain and push rod Lock Nut 3 8 16 000030 May 2012 6009080C Dock Leveler and Lift Combo 77 2012 4Front Engineered Solutions Inc PARTS LIST continued Hydraulic and electrical Fig 75 78 2012 4Front Engineered Solutions Inc 6009080C Dock Leveler and Lift Combo May 2012 PARTS LIST continued Hydraulic and electrical Fig 76 79 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued Hydraulic and electrical Fig 77 May 2012 6009080C Dock Leveler and Lift Combo 80 2012 4Front Engineer PARTS LIST continued Hydraulic and electrical Qty Part Description Part Number Scissor Lift Cylinder 8 ft long 6005439 Scissor Lift Cylinder 10 ft long 6005461 Scissor Lift Cylinder 12 ft long 6005462 Pin Scissor Cylinder 1 1 4 Dia 6005277 Remote Mounted Scissor Power Unit 208 Volt 6009350 Remote Mounted Scissor Power Unit 240 Volt 6009351 Remote Mounted Scissor Power Unit 480 Volt 6008423
23. A ADANGER Before doing any electrical work make certain the power is disconnected and properly tagged or locked off All electrical work must be done by a qualified technician and meet all applicable codes If it is necessary to make troubleshooting checks inside the control box with the power on USE EXTREME CAUTION Do not place your 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 64 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc E LECTRICAL SCH EMATIC continued Fig 67 240V 3 PHASE 60 HZ INCOMING SERVICE TO BE TERMINATED AT DISCONNEC LEVELER MAIN OTOR PANEL BULKHEAD PANEL FLA 21 3AMPS DS20 CONTACTOR SCCR 5KA SOA ROTARY FU201 M618 OL1 L T ul E ER l l MOT202 1 ere 30 5 217 eOe WHT CBL202 D IER i oS oO Au 5 Ze Se ars RED 7 32FA230V 60HZ UT G MOTOR gt W CONTACTOR M621 OL2 TET er l l MOT205 7 5 HIE X RES SJ Wlan bo po 20 2FLA 240V 60HZ SLS 613 1770RPM 22A Kg NOTE Power to control panel must be from fused disconnect supplied by others Max Type CC fuse size shown above FU209 HIS H3 gH2 e D15 480 40V PRI xF211 12
24. D UNLOAD ON GREEN LIGHT ONLY TI i A May 2012 6009080C Dock Leveler and Lift Combo 85 2012 4Front Engineered Solutions Inc PARTS LIST continued Control Panel and Pendant lm Pat eawripion ae 7 Rotary Disconnect 30 Amp ii Fuse LP CC 30 208 V amp 240 V units 6009537 Fuse LP CC 20 380 V amp 480 V units 6009538 Fuse LP CC 15 600 V units 6009539 Fuse LP CC 5 208 V amp 240 V units 6009542 Fuse LP CC 4 380 V amp 480 V units 6009543 Fuse LP CC 2 600 V units 6009544 Fuse FNQ R 4 208 V amp 240 V units Fuse FNQ R 2 380 V 480 V units amp 600 V units 6009546 EE ES ES ES J oo NIO LRU Red 10 28 VAC VDC 2 1 Contactor Lift Motor NINININI NINIJIN AT zl Oo JI INJ gt 1o90 86 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued Control Panel and Pendant Qty Part Description Part Number Relay
25. Diagnostics E 53 Adjustments Leveler Hydraulic Power Unit 53 Hydraulic Schematic Leveler 0 eee 55 Hydarulic Valve Cross Section Leveler 56 Adjustments Lift Hydraulic Power Unit 57 Adjustments Proximity Zwitches eee 59 Hydraulic Schematic mt 63 Electrical Shematics 0eeseeeeeeeeeeeeeeeeeeeeeees 64 Pans ESE tii sac ae e EE 69 War ramtnhy ccccteindicaterccnietorencnnisnionaiantariateneaincentancareuiar 91 Manufacturer Contact Information 92 INTRODUCTION Welcome and thank you for choosing this dock leveler and lift combo from 4Front Engineered Solutions Inc This user s manual contains information that you need to safely install operate and maintain the dock leveler and lift combo 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 dock leveler and lift combo 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 AADANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially
26. Dock Leveler and Lift Combo k RL CT i SE tals S Zi E SH ol Cs This manual applies to dock leveler and lift combos manufactured beginning May 2012 with the serial numbers 61045677 and higher Do not install operate or service this product unless you have read and understand the Safety Practices Warnings Installation and Operating Instructions contained in this User s Manual Failure to do so could result in death or serious injury User s Manual Installation Operations Maintenance and Parts Part No 6009080C TABLE OF CONTENTS Introduction eee 2 Safety Signal WORKS EE 2 Safety PIACICCS tect se cvrs eat g et 3 Owner s Responsibilities 5 Ramp and Lip Grades ccseceeeeeeeeeeeeereeeeseeneeees 7 Installation Remote Mount 6 Installation Pit Mount 18 Service TOOIS ccccccccceeccececeecceeeceeceeeeeeeeeeeeeeeeteess 28 Components and Specifications seoseeeeeeeeeeeeeeee 30 Hydraulic System Operation 33 1 6 1 0 5 ecaa E a E e eaa 36 Operating Instructions Leveler Mode 37 Operating Instructions Lift Mode 40 Operating Instructions ARTD reen 42 Planned Maintenance 43 Troubleshooting EE 46 PLC
27. ER Stop raise e Sequence valve and shuttle valve return e Top plate floats down forcing fluid to reservoir e Speed controlled by flow control in shuttle valve Lip extend e With leveler above dock height pump starts as above Solenoid valve shifts locking main cylinder in partial raised position e Pressure increases sequence valve shifts and lip extends Stop e Solenoid valve shifts locking main cylinder and lip cylinder e Power cut off from motor control circuit May 2012 6009080C Dock Leveler and Lift Combo 33 2012 4Front Engineered Solutions Inc HYDRAULIC SYSTEM OPERATION LIFT Fig 38 Additional Warnings and Instructions On Side Of Enclosure COMMUNICATIONS Lift Mode white leveler indicator light is on Raise e Pump starts and solenoid shifts allowing lift to rise Raising from below dock e Lift will continue to rise while holding the RAISE button until reaching dock height e At dock height the solenoid valve will shift e The unit will then stop Raising from dock height Service Mode only e Lift will rise approximately 4 to 6 while holding the RAISE button e Hydraulic lift cylinders will reach the maximum stroke and unit will stop Lower Solenoid shifts allowing lift to lower e Hydraulic fluid is displaced from the lift cylinders to the reservoir as the unit has a controlled descent e Lift will continue to lower while holding the LOWER button until reachi
28. LIFT mode 33 The dock leveler and lift combo has two principal operating modes LIFT and LEVELER Note panel indications for mode status 34 If the unit is not already in LIFT Mode press the LIFT Mode pushbutton indicator This will initiate a transition which will place the dock leveler and lift combo into the valid LIFT Mode When sequencing is complete verify indications represent a valid LIFT Mode configuration the Lift pushbutton should be solidly lit Place the light communications switch to the ENTER VEHICLE position and verify the lip operates normally 35 Place the light communications switch to the DO NOT ENTER VEHICLE position and press the LEVELER pushbutton indicator The dock leveler and lift combo unit will fall approximately 4 and then raise to finished floor ensuring a dock level condition The deck will then rotate upward the rear lock pins will extend as the lip keepers rotate into place The deck will then fall until the lip is resting in the lip keepers and the leveler motor will stop When sequencing is complete verify indications represent a valid LEVELER Mode configuration The indicator light should be solidly lit If a failure occurs and diagnostics are being reported refer to the Diagnostics section for details and correct the problem as required Place the light communications switch to the ENTER VEHICLE position and verify the leveler operated normally Fig 28 Latch block Chamfere
29. NTS AND SPECIFICATIONS The main components of the dock leveler and lift combo are shown below See the parts list for specific part numbers Fig 35 Lip plate assembly Top plate assembly Auxiliary port Deck subframe Lip rod assembly Telescopic toe guards cher Lock pin Main deck cylinder Lip keeper deck support assembly Leveler power unit Curtain support bracket Maintenance strut Pushrod support bracket left and right hand Sci bl Scissor stop blocks cissor assembly l l l Scissor frame Scissor lift cylinders assembly 30 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc COMPONENTS AND SPECIFICATIONS continued Fig 36 Strobe light Additional Warnings and Instructions On Side Of Enclosure COMMUNICATIONS Le ja D d Lift mode Si d Leveler mode ushbutton pushbutton ele SEENEN selector switch ales ON GREEN LIGHT ONLY and indicator and light LEVELER indicator light Lift raise Pree ana ld ev whan nisl mse om Leveler raise pushbutton AE pushbutton LIFT AND LEVELER MODE when in lift mode up ean Lift lower iF aes pushbutton Press to silence alarm f e ie i DEE Lip extend pushbutton Silence LIGHT COMMUNICATIONS alarm d pushbutton SN e System stop mer TO o i S j pushbutton MLS selector emm switch May 2012 6009080C Dock Leveler and Lift Combo 31 2012 4Front Engineere
30. OLE AND EXCLUSIVE WARRANTY WITH RESPECT TO THE DOCK LEVELER AND LIFT COMBO AND IS IN LIEU OF ANY OTHER GUARANTEES OR WARRANTIES EXPRESS OR IMPLIED 4FRONT warrants that this DOCK LEVELER AND LIFT COMBO 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 4FRONT or 2 the date of installation of the DOCK LEVELER AND LIFT COMBO by the original purchaser provided that the owner maintains and operates the DOCK LEVELER AND LIFT COMBO in accordance with this Owner s Manual 4FRONT expressly warrants that the MOTOR GASKETS FITTINGS and SEALS will be free from flaws in material and workmanship under normal use for a period of five 5 years from the earlier of 1 60 days after date of shipment or 2 the date of installation of the DOCK LEVELER AND LIFT COMBO by the original purchaser provided the purchaser maintains and operates the DOCK LEVELER AND LIFT COMBO in accordance with the Owner s Manual In the event that this DOCK LEVELER AND LIFT COMBO proves deficient in material or workmanship within the applicable Limited Warranty period owner shall so notify 4FRONT and 4 Front will at its option 1 Replace the DOCK LEVELER AND LIFT COMBO or the deficient portion s thereof without charge to the owner or 2 Alter or repair the DOCK LEVELER AND LIFT COMBO on site or elsewhere without charge to the owner This Limited Warranty does
31. Overload 1 6 2 5 Amp 6000473 Relay Overload 9 13 Amp 6000477 _ Selector Switch Maintained 2 Position 632217 CH Body Mounting Collar 6000515 Block Contact Normally Open 632228 Block Contact Normally Closed Stop Button 632229 Pendant Station Up Down Controller 6009553 Cord Grip 1 2 Conduit Pendant 6006860 Lock Nut 1 2 Pendant 6006864 Twido PLC 6008746 Terminal Block 4 Conductor 6006846 Terminal Block 2 Conductor 6000542 Label pendant operation 6009318 en EJEN PAES PAES May 2012 6009080C Dock Leveler and Lift Combo 87 2012 4Front Engineered Solutions Inc PARTS LIST continued Lights and Signs Fig 80 A CAUTION MOVE ON GREEN 24 ONLY M0 IVOM EE VK A Le D Item Quantity Part Description Part Number Outside Sign Normal and Reverse Lettering 709 832 Light Assembly Complete LEDs 6007798 Red LED Light Assy 6007800 Green LED Light Assy 6007801 Part of Item 2 Light Assembly Complete 88 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc NOTES May 2012 6009080C Dock Leveler and Lift Combo 89 2012 4Front Engineered Solutions Inc NOTES 90 2012 4Front Engineered Solutions Inc 6009080C Dock Leveler and Lift Combo May 2012 LIMITED WARRANTY THIS LIMITED WARRANTY IS 4FRONT S S
32. POINT 6003451 x2 A DANGER e Do not put hands Do not work X or feet under top X under lift without maintenance To avoid bodily injury read all device instructions before operating or servicing lift 6008547 Serco x2 921 050 6008548 Kelley x2 MAXIMUM RATED LIFTING CAPACITY ADANGER 921 052 0 000 Ibs P 921 053 Located on power unit 6008880 x4 DO NOT USE THIS EQUIPMENT WITHOUT THE GUARDRAILS IN PLACE 921 147 921 027 921 234 x2 6008834 BE ADANGER eg 6007074 x2 Do not work under lift Warning ne F without maintenance operation placar device Mounted on wall near leveler For lip extend on lower bs 600931 8 Press and hold the DOWN button twice and hold May 2012 6009080C Dock Leveler and Lift Combo 45 2012 4Front Engineered Solutions Inc TROUBLESHOOTING Fig 53 8 PORT HUB 4 PORT HUB Leg LEGS UP e Kmec 3 B _ _ Ls8 KEEPERS UP LS7A B PINS IN S _ LS6A B PINS OUT LS5 PIT FLOODED OPTIONAL LS4 FLOOR LEVEL N C NOT USED S LS4 FLOOR LEVEL N O POWER LED LS3 LIP PENDANT 4 2 L s2 LEVEL amp BELOW LS1 LEVEL am
33. Remote Mounted Scissor Power Unit 600 Volt 6009352 Pit Mounted Scissor Power Unit 208 Volt not shown 6009353 Pit Mounted Scissor Power Unit 240 Volt not shown 6009354 Pit Mounted Scissor Power Unit 480 Volt not shown 6008739 Pit Mounted Scissor Power Unit 600 Volt not shown 6009355 DU Bearing 1 1 4 I D Spherical Bearing 1 1 4 1 D Hydraulic Hose 1 2 I D 30 long Hydraulic Hose 1 2 1 D Remote mount 8 ft units 711229 Hydraulic Hose 1 2 I D Remote mount 10 and 12 ft units 711228 Hydraulic Hose 1 2 I D Pit mount all units not shown 6006897 Socket Head Cap Screw 1 4 20 x 2 long lectrical Cable Lift Solenoids Remote Mounted lectrical Cable Lift Solenoids Pit Mounted not shown 6008735 Leveler Hydraulic Power Unit 208 480V Three Phase 313549 Leveler Hydraulic Power Unit 575V Three Phase 313550 Deck Lift Cylinder 8 ft units 313046 Deck Lift Cylinder 10 and 12 ft units 313563 Lip Keeper Cylinder 313043 Lock Pin Cylinder 6003030 Hose Assy Keeper Cylinder Retract Tee 6 ft wide units Hose Assy Keeper Cylinder Retract Tee 6 5 ft wide units Hose Assy Keeper Cylinder Retract Tee 7 ft wide units 3 CO Hose Assy Keeper Cylinder Extend Tee 6 ft wide units Hose Assy Keeper Cylinder Extend Tee 6 5 ft wide units Hose Assy Keeper Cylinder Extend Tee 7 ft wide units 2 2 1 1 1 1 1 1 1 ES 1 1 1 oO May 2012 6009080C Dock Leveler and Lift C
34. See Fig 20 for expected weight e Roto hammer with 3 4 bit e Hydraulic jack e Welder e Short and long pry bars e Assorted SAE open end wrenches e Allen wrench set Fi 1 Check the entire dock leveler and lift combo pit for proper construction to certified approval drawings Ensure the pit walls are square and plumb Check electrical service running to the pit to ensure it agrees with the phase and voltage of the pump motor and control box supplied with the dock leveler and lift combo See tag attached to pump motor electrical cord and wiring diagram located inside the control box cover ADANGER Power to control box must be from fused disconnect supplied by others Fuse size for a dual element motor protected time delay type fuse can be no greater than 225 of motor FLA Before doing any electrical work make certain the power is disconnected and properly tagged or locked out All electrical work must done by qualified technician and must meet all applicable codes If it is necessary to make troubleshooting checks inside the control panel with the 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 cause electrical shock death or serious injury 18 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc INSTALLATION PIT MOUNT continued 2 Verify that the voltage of t
35. ads input signals from pushbuttons and proximity sensors and closes the appropriate output relays to the motor solenoid valves audible alarm and warning lights CONTROLLER FAULT CONDITIONS RUN LED green O Application not executed Controller is in RUN mode F Controller is in STOP mode or execution fault HALT ERR LED red DU ok Internal faults watchdog etc F Application not executable or execution error HALT STAT LED green O Controlled by the user or application through system bit S69 Controlled by the user or application through system bit S69 F Program transfer in progress PLC DIAGNOSTICS LIFT MODE Normal operating sequence at any floor level and ready to operate So DS Ca a x Se NS Os 89 SU 01 NOS woo oO 8 oOooOs NOoOS ol Ss oft son ASO PWRES SIO RUNS O LEVELER MODE Normal operating sequence stored and ready to operate So DS Ww S So wood ASO 0 1 SU E D aw LEGEND LED OFF LED ON LED flashing LED ON or OFF either condition may be present during the course of given sequence mm o sO ADJUSTMENTS LEVELER HYDRAULIC POWER UNIT ADANGER Be certain before entering the dock leveler and lift combo pit or doing any maintenance or repair under the dock leveler and lift combo that 1 The safety blocks are in place on the scissor frame 2 The maintenance struts are securely supporting the leveler portion
36. ase or raise the point at which the deck will stop Rotate the potentiometer counter clockwise to decrease or lower the point at which the deck will stop This affects the automatic stop feature when raising the deck while in LIFT mode 33 The dock leveler and lift combo has two principal operating modes LIFT and LEVELER Note panel indications for mode status NOTE The light communications switch must be in DO NOT ENTER VEHICLE position to perform a transition sequence 34 If the unit is not already in LIFT Mode press the LIFT Mode pushbutton indicator This will initiate a transition which will place the dock leveler and lift combo into the valid LIFT Mode When sequencing is complete verify indications represent a valid LIFT Mode configuration the Lift pushbutton should be solidly lit Place the light communications switch to the ENTER VEHICLE position and verify the lip operates normally Fig 13 Ge Latch block edge Latch block embed Lock pin Fig 14 YO GPG GPG PPS GW PG GW PGW HPP PGW POPP PGP OGVY or tom O 1 2 3 4 5 6 7 B YQ 10 Meg 121314151617 1819 20 22 22 23 Telemecanique eZee eS ou za A SMUG e oi vu ofuabiliw ROUT as DADDDDDDDDDODDDDDDODODOPODDODOOD TOOV 240VAC TO L N WE Potentiometer PLC Fig 15 Latch block embed Latch block 16 6009080C Dock Leveler and Lift Com
37. ate assembly Item Qty Part Description Part Number 1 1 Top Plate Assembly 6 ft wide x 8 ft long 6008866 Top Plate Assembly 6 5 ft wide x 8 ft long 6005402 Top Plate Assembly 7 ft wide x 8 ft long 6008867 Top Plate Assembly 6 ft wide x 10 ft long 6008868 Top Plate Assembly 6 5 ft wide x 10 ft long 6008308 Top Plate Assembly 7 ft wide x 10 ft long 6008869 Top Plate Assembly 6 ft wide x 12 ft long 6008870 Top Plate Assembly 6 5 ft wide x 12 ft long 6005568 Top Plate Assembly 7 ft wide x 12 ft long 6008871 Top Plate Assembly 6 ft wide x 10 ft long DGL 6008881 Top Plate Assembly 6 5 ft wide x 10 ft long DGL 6008882 Top Plate Assembly 7 ft wide x 10 ft long DGL 6008883 Top Plate Assembly 6 ft wide x 12 ft long DGL 6008884 Top Plate Assembly 6 5 ft wide x 12 ft long DGL 6008885 Top Plate Assembly 7 ft wide x 12 ft long DGL 6008886 Lip Plate Assembly 6 ft wide x 18 in long 6009291 Lip Plate Assembly 6 ft wide x 20 in long 6009292 Lip Plate Assembly 6 5 ft wide x 18 in long 6005459 Lip Plate Assembly 6 5 ft wide x 20 in long 6005583 Lip Plate Assembly 7 ft wide x 18 in long 6009293 Lip Plate Assembly 7 ft wide x 20 in long 6009294 Lip Plate Assembly 6 ft wide x 18 in long DGL 6009295 Lip Plate Assembly 6 ft wide x 20 in long DGL 6009296 Lip Plate Assembly 6 5 ft wide x 18 in long DGL 6009297 Lip Plate Assembly 6 5 ft wide x 20 in long DGL 6009298 Lip Plat
38. ause electrical shock death or serious injury 8 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc INSTALLATION REMOTE MOUNT continued 2 Verify that the voltage of the dock leveler and lift combo matches the facility s power supply Mount the control panel on the wall near the front of the dock leveler and lift combo and connect the power supply The recommended mounting height of the control panel is approximately 60 from the floor to the pushbuttons See Fig 3 for detail review approval drawings for specific details if applicable 3 Mount the lift power unit on the finished floor within close proximity to the 4 conduit that supplies the hydraulic hose from the pit Review approval drawings for specific details if applicable 4 Power needs to be supplied to the lift power unit from the control panel Review electrical schematics for termination details within the control panel 5 Electrical connections to the two solenoid valves SV6 and SV7 will need to be made on the lift power unit Terminate the lift solenoid cable cable 616 to the appropriate receptacle on the bottom side of the control panel Review electrical schematics for termination details Inadequate lifting equipment or practices can cause a lifted load to fall unexpectedly Make sure lifting chain or other lifting devices are in good condition and have a rated capacity exceeding the lifting load for the ang
39. b Lip cylinder damaged 6009080C Dock Leveler and Lift Combo SOLUTION a Check motor full load amperage and overload relay setting b Check for voltage at all three motor connections T1 T2 T3 in control panel a If aload was on the leveler remove the load and jog the RAISE button to unlock the leveler If no load was on the leveler adjust the flow control valve to reduce drop speed See page 54 a Adjust flow shuttle valve for faster flow Turn counterclockwise to increase speed See page 54 a Check fluid level with leveler fully raised Add fluid if required and check for leaks See page 54 Fig 58 b Decrease sequence valve setting See page 54 c Inspect hinge area for damage or trapped debris Lubricate hinge d Set primary relief valve to 2000 PSI See page 54 Note Requires use of pressure gauge or pump will be severely damaged a Turn clockwise to increase pressure so that the lip plate does not extend until the deck is fully raised a Remove and inspect for foreign matter Clean as required b Replace lip cylinder piston seal or replace cylinder May 2012 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 The level lift is controlled by a programmable logic controller PLC which re
40. bo 2012 4Front Engineered Solutions Inc May 2012 35 INSTALLATION REMOTE MOUNT continued Place the light communications switch to the DO NOT ENTER VEHICLE position and press the LEVELER pushbutton indicator The dock leveler and lift combo unit will fall approximately 4 and then raise to finished floor ensuring a dock level condition The deck will then rotate upward the rear lock pins will extend as the lip keepers rotate into place The deck will then fall until the lip is resting in the lip keepers and the leveler motor will stop When sequencing is complete verify indications represent a valid LEVELER Mode configuration The indicator light should be solidly lit If a failure occurs and diagnostics are being reported refer to the Diagnostics section for details and correct the problem as required Place the light communications switch to the ENTER VEHICLE position and verify the leveler operated normally NOTE Again cycle between modes LIFT Mode then again to LEVELER Mode to ensure all sequencing is correctly performed If at any time an error occurs or the sequencing does not finish consult the troubleshooting section of this manual 36 37 38 39 40 The front curtain can be installed only when the unit is in LEVELER Mode Raise the leveler and put the maintenance struts in place Put both safety stop blocks in place Thread the curtain brackets over the rod of the curtain on each en
41. bo to its dock level stored position at dock height with the lip stored in both lip keepers and ensure no equipment material or people are on the dock leveler Failure to do so may leave the dock leveler in a position below the level of the dock floor This condition may result in unexpected drop of personnel or material handling equipment and could result in death or serious injury 4 Reapply the rear chains or close the swing gate or any other device blocking traffic access See Fig 46 5 With the dock leveler and lift combo at dock level rotate the MLS switch to DO NOT ENTER VEHICLE This will change the inside light to red and the outside light to flashing green 6 If desired press the LEVELER mode pushbutton and Fig 47 Press to lower zA Press to raise to stored position Raise to stored Press to raise store the unit in Leveler Mode When the unit is in Leveler Mode the Leveler Mode lighted pushbutton will Raise be lit H E EE 3 May 2012 6009080C Dock Leveler and Lift Combo 41 2012 4Front Engineered Solutions Inc OPERATING INSTRUCTIONS AUTO RETURN TO DOCK A R T D The A R T D automatically res
42. button operates two hydraulic cylinders to raise the lift The lift will continue to rise while holding the lift RAISE button until the unit reaches dock level and will stop Pushing and holding the lift LOWER button will displace the hydraulic fluid from the cylinders and allow the lift to lower The lift will continue to lower while holding the lift LOWER button until the unit reaches grade level Releasing the button while raising or lowering the lift will stop the unit at that height In Leveler Mode the dock leveler is in its stored position at dock height with the lock pins engaged and the ramp being supported by both lip keepers In Lift Mode the lift is in its stored position with the lock pins retracted and the ramp being supported by the deck support legs on the lip end 36 6009080C Dock Leveler and Lift Combo 2012 4Front Engineered Solutions Inc May 2012 OPERATING INSTRUCTIONS LEVELER MODE LAWARNING Always secure the vehicle with a vehicle restraint or wheel chocks before operating the dock leveler Do not operate the dock leveler and lift combo with anyone standing on or in front of the unit Do not drive on the lip until it is fully extended and supported by the vehicle bed or by the drive surface at grade level Do not drive on the leveler when the STOP button is pressed in Always keep hands and feet clear of all moving parts Always restore the dock leveler and lift combo to its saf
43. d Lower the assembly to attach the curtain brackets to the scissor frame mounting location with the provided bolts as shown in Fig 16 Ensure the rod of the curtain assembly extends through the backets on each end Pretension the curtain assembly Rotate the curtain assembly 5 revolutions as shown in Fig 17 Install the rod and the hanger brackets through the curtain fabric Install the hanger brackets as shown in Fig 18 Ensure the hanger brackets are installed over the leg cross tube Operate the dock leveler and lift combo throughout the entire range to check for proper operation of the curtain Raise the dock leveler and lift combo to dock height and store the unit in Leveler mode Fig 16 Scissor frame Curtain bracket Fig 17 Front pit wall Pretension Gen Pit floor Fig 18 Hanger bracket Curtain rod Leg cross tube May 2012 6009080C Dock Leveler and Lift Combo 17 2012 4Front Engineered Solutions Inc INSTALLATION PIT MOUNT continued PIT MOUNT INSTALLATION Fig 19 Before installing the dock leveler and lift combo read i A and follow the Safety Practices on pagse 3 4 and the Operating Instructions on pages 33 42 Failure to follow ES i the Safety Practices could result in death or serious DS Control panel injury 60 THE FOLLOWING TOOLS ARE REQUIRED e Crane or heavy forklift truck capable of lifting the appropriate weight at 6 2m load center
44. d edge Latch block embed Lock pin Fig 29 Latch block Latch block embed 26 6009080C Dock Leveler and Lift Combo 2012 4Front Engineered Solutions Inc May 2012 INSTALLATION lt PIT MOUNT continued NOTE Again cycle between modes LIFT Mode then again to LEVELER Mode to ensure all sequencing is correctly performed If at any time an error occurs or the sequencing does not finish consult the troubleshooting section of this manual 36 37 38 39 40 The front curtain can be installed only when the unit is in LEVELER Mode Raise the leveler and put the maintenance struts in place Thread the curtain brackets over the rod of the curtain on each end Lower the assembly to attach the curtain brackets to the scissor frame mounting location with the provided bolts as shown in Fig 30 Ensure the rod of the curtain assembly extends through the backets on each end Pretension the curtain assembly Rotate the curtain assembly 5 revolutions as shown in Fig 31 Install the rod and the hanger brackets through the curtain fabric Install the hanger brackets as shown in Fig 32 Ensure the hanger brackets are installed over the Press the LIFT pushbutton indicator and operate the dock leveler and lift combo throughout the entire range to check for proper operation of the curtain Raise the dock leveler and lift combo to dock height and store the unit in Leveler mode Fig 3
45. d Solutions Inc COMPONENTS AND SPECIFICATIONS Control Panel NEMA 12 automatic motor starter thermal overload 2 amp resettable control circuit breaker C S A and or U L approved Lift Motor NEMA standard T E N V frame 7 5 h p three phase Lift Pump Fixed displacement gear pump 5 gpm primary relief valve set at factory Lift Reservoir Capacity 10 U S gallons lit level measured by sight gauge Leveler Motor NEMA standard T E N V 56C frame 1 h p three phase Leveler Pump Fixed displacement gear pump 1 gpm primary relief valve set at 2000 psi Leveler Reservoir Capacity 1 U S gallons 3 8 lit level measured by dipstick Hydraulic Fluid An all weather hydraulic fluid with a viscosity of 15 CSt at 40 C 100 F such as Shell Tellus T 15 Mobil Aero HFA 49011 Exxon Univis HV13 N15 J13 Texaco Aircraft Oil 1554 U S Oil Co Inc ZFI 5606 low temp 32 6009080C Dock Leveler and Lift Combo 2012 4Front Engineered Solutions Inc May 2012 HYDRAULIC SYSTEM OPERATION LEVELER Fig 37 Leveler Mode white leveler indicator light is on Raise e Pump starts and shuttle valve shifts Pe e Main lift cylinder extends and lip cylinder retracts Instructions On Side Of Enclosure D Pilot check valve opens COMMUNICATIONS Fully raised e Pressure increases LOAD AND UNLOAD e Sequence valve shifts ON GREEN LIGHT ONLY D Lip cylinder extends LEVEL
46. d lift table It has been assembled as a self contained unit which requires installation in a pit and electrical connection to the control panel The dock leveler portion is designed to span and compensate for the space and height differences between a loading dock and freight carrier to allow safe efficient freight transfers The dock leveler uses a pushbutton control to position the ramp Pushing and holding the leveler RAISE button operates a hydraulic cylinder to raise the ramp Releasing the leveler RAISE button allows the ramp to lower When the dock leveler reaches its full raised position a second hydraulic cylinder extends the lip The dock leveler with its lip extended settles onto the vehicle platform forming a bridge After loading pressing and holding the leveler RAISE button allows the ramp to rise The lip will retract as the leveler is raised Releasing the leveler RAISE button lowers the ramp into its level stored position For below dock end loading press the leveler RAISE pushbutton until the leveler is about 6 above dock Press the lip extend pushbutton until the lip extends 2 3 clearing the lip keepers Release the lip extend pushbutton and the leveler will float down for end loading The lift table portion is designed to lower or raise a load up to the rated lifting capacity between dock and grade level The lift table uses pushbuttons to control the position of the lift Pushing and holding the lift RAISE
47. e Assembly 7 ft wide x 18 in long DGL 6009299 Lip Plate Assembly 7 ft wide x 20 in long DGL 6009300 Lip Hinge Pin 6 ft wide 5860287 Lip Hinge Pin 6 5 ft wide 5861495 Lip Hinge Pin 7 ft wide 5860392 Toe Guard 1st Stage LH 8 ft long 5860438 Toe Guard 1st Stage RH 8 ft long 5860439 Toe Guard 1st Stage LH 10 ft long 5861043 Toe Guard 1st Stage RH 10 ft long 5861042 Toe Guard 1st Stage LH 12 ft long 5862737 Toe Guard 1st Stage RH 12 ft long 5862738 Toe Guard 2nd Stage LH 8 ft long 5860440 Toe Guard 2nd Stage RH 8 ft long 5860441 Toe Guard 2nd Stage LH 10 ft long 5861045 Toe Guard 2nd Stage RH 10 ft long 5861044 Toe Guard 2nd Stage LH 12 ft long 5862739 Toe Guard 2nd Stage RH 12 ft long 5862740 Plain Washer 7 16 I D 234101 Hex Nut 3 8 Nylock 214538 Cover Auxilliary Port 6008349 Flat Head Cap Screw 1 4 20 x 1 Long 211710 ee vc sech ch sech vc zech sch ch vch ch wech ch 2 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 4 1 1 1 1 1 1 5 1 1 1 1 1 1 6 6 EES 2l 70 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued Top plate and lip plate assembly Qty Part Description Part Number Clevis Pin 1 2 Dia X 2 3 4 Long 231502 Lip Plate Maintenance Bar 5862969 Plain Washer 9 16 LD 234121 1 Label Lift Rated Capacity Serco 6008547 1 Label Lift Rated Capacity
48. e dock level position after servicing the vehicle RAISING LEVELER Ensure a vehicle restraining device is engaged or wheel chocks in place before operating the dock leveler Ensure the dock leveler and lift combo is in Leveler Mode When the unit is in Leveler Mode the Leveler Mode lighted pushbutton will be lit Verify the lock pins are engaged and lip is supported by both lip keepers If the unit is not in Leveler Mode rotate the Light Communications MLS switch to DO NOT ENTER TRUCK and press the LEVELER pushbutton The unit will lower approximately 8 and then rise back to dock level This step ensures that the unit is at dock level After this step the leveler will rise then the lock pins engage and the lip keepers will rotate into place 1 Remove the rear chains swing gate or any other device blocking traffic access to the dock leveler and lift combo See Fig 40 2 Rotate the MLS switch to ENTER VEHICLE This will change the inside light to green and the outside light to flashing red May 2012 6009080C Dock Leveler and Lift Combo 37 2012 4Front Engineered Solutions Inc OPERATING INSTRUCTIONS LEVELER MODE continued 3 Press the RAISE button on the control panel to raise leveler See Fig 41 4 Continue to press the RAISE button The lip will automatically extend when the leveler is fully raised NOTE To extend the lip earlier press and hold the lip extend pushbutton The deck will hold in positi
49. ead Cap Screw 1 4 20 x 1 3 4 long 131300 17 DU Bearing 1 I D 6005495 Deck Support Leg Keeper Assy 18 Lip 8 ft units 6008339 Deck Support Leg Keeper Assy 20 Lip 8 ft units 6008887 Deck Support Leg Keeper Assy 18 Lip 10 and 12 ft units 6008346 Deck Support Leg Keeper Assy 20 Lip 10 and 12 ft units 6008392 1 1 1 1 Label Danger Maintenance Strut 921074 Label Danger Entering Pit 921070 May 2012 6009080C Dock Leveler and Lift Combo 73 2012 4Front Engineered Solutions Inc PARTS LIST continued Scissor assembly Fig 73 Part Description Part Number Scissor Assembly 8 ft long 6008380 Scissor Assembly 10 ft long 6008401 Scissor Assembly 12 ft long 6008388 DU Bearing 1 1 4 I D 6005147 Pin Rear Scissor 1 1 4 Dia Cam Follower 2 1 2 Roller Dia 8 ft units 6005190 Cam Follower 3 Roller Dia 10 and 12 ft units 6005493 Hex Nut 1 14 Thread 8 ft units 6008378 Hex Nut 1 1 4 12 Thread 10 and 12 ft units 6008384 e Scissor Frame Assembly 8 ft long Remote Mount 6005401 74 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc PARTS LIST continued Scissor assembly Item Qty Part Description Part Number 6 1 Scissor Frame Assembly 8 ft long Remote Mount 6005401 1 Scissor Frame Assembly 10 ft long Remote Mount 6005591 1 Scissor Frame Assembly 12 ft long Remote Mount 6005588 1 Scissor Frame Assemb
50. ed when the leveler is resting on the maintenance strut with the lip pendant Add fluid if required and check for leaks See page 54 Fig 58 b Remove the hose from main lift cylinder and point free end into reservoir opening If no oil is pumped replace pump c Check motor rotation and change electrical connections if necessary See motor name plate d Set primary relief valve setting to 2000 PSI See page 54 Note Requires use of pressure gauge or pump will be severely damaged 6009080C Dock Leveler and Lift Combo 51 2012 4Front Engineered Solutions Inc TROUBLESHOOTING continued Before servicing the dock leveler read and follow the Safety Practices on Pages 3 4 and the Operation section in 5 6 7 Leveler floats down too slowly 8 this manual PROBLEM Overload relay tripping Leveler will not lower Lip plate will not extend or extends too slowly 9 Lip plate extends too soon 10 Lip plate will not stay out falls 52 as leveler is lowering 2012 4Front Engineered Solutions Inc POSSIBLE CAUSE a Overload relay set too low b Loss of one phase a Automatic safety stop velocity fuse is locked a Flow control requires adjustment a Low fluid level in reservoir b Sequence valve set too high c Lip hinge binding d Primary relief valve set too low a Sequence valve set too low a Pilot operated check valve valve not closing
51. el stored position with the lip supported by both lip keepers and ensure no equipment material or people are on the dock leveler See Fig 44 Failure to do so may leave the dock leveler in a position below the level of the dock floor This condition may result in unexpected drop of personnel or material handling equipment and could result in death or serious injury Press to raise release to lower 2 Reapply the rear chains or close the swing gate or any other device blocking traffic access See Fig 46 3 After the dock leveler is stored rotate the MLS switch Press to raise to DO NOT SERVICE VEHICLE This will change the inside light to red and the outside light to flashing green Press to extend BELOW DOCK END LOADING lip 1 Press and hold the leveler RAISE button until the leveler is fully raised and the lip starts to extend When the lip has extended 2 to 3 to clear the front of the keepers release the button Leveler will float down for end loading See Fig 45 Make sure END LOADING is done with the MLS switch in the ENTER VEHICLE position May 2012 6009080C Dock Leveler and Lift Combo 39 2012 4Front Engineered Solutions Inc OPERATING INSTRUCTIONS LIFT MODE AWARNING Fig 46 Always secure the vehicle wit
52. ended and the leveler is on the maintenance struts a Push and hold the LIP EXTEND pushbutton b Rotate the lip maintenance bar up to the lock position c Release the lip and ensure the lip is supported by the l lip maintenance bar 3 Before lowering the maintenance struts disengage the Lowered position lip maintenance bar a Pushand hold the LIP EXTEND pushbutton and rotate the lip maintenance bar down to release b Carefully lower the lip NOTE Avoid pressing the RAISE pushbutton with the lip maintenance bar in the raised position as this can damage the maintenance bar l 28 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc SERVIC E TOO LS continued 4 To disengage the maintenance struts from its locked upright position two people are needed a Push and hold the RAISE button on the control panel b Second person shall lift each maintenance strut up from its locked position c Rotate the maintenance struts toward the rear of the unit to lower them d Release the RAISE button AADANGER It is important to always engage the lip maintenance bar mechanism whenever working under the leveler with the lip extended Any upward force on the lip could release the lip latch bar allowing the lip to fall May 2012 6009080C Dock Leveler and Lift Combo 29 2012 4Front Engineered Solutions Inc COMPONE
53. ered Solutions Inc Please direct questions about your dock leveler and lift combo to your local distributor or to 4Front Engineered Solutions Inc Corporate Head Office Your local 4Front Engineered Solutions Inc distributor is 1612 Hutton Dr Suite 140 Carrollton TX 75006 Tel 972 466 0707 Fax 972 323 2661 2012 4Front Engineered Solutions Inc Part No 6009080C
54. ets the leveler whenever a Fig 50 vehicle pulls away from the loading dock with the lip resting on the vehicle This function performs in this manner 1 If the vehicle pulls away the leveler will float down to the lowest position and the lip will fall When the light communication switch is in the DO NOT SERVICE VEHICLE position the leveler will automatically raise retract the lip and then float down to the stored position See Fig 50 42 6009080C Dock Leveler and Lift Combo 2012 4Front Engineered Solutions Inc May 2012 To ensure proper operation of your dock leveler and lift combo perform the following planned maintenance procedures ADANGER Be certain before entering the dock leveler and lift combo pit or doing any maintenance or repair under the dock leveler and lift combo that 1 The safety blocks are in place on the scissor frame 2 The maintenance struts are securely supporting the leveler portion 3 The power is disconnected and properly tagged or locked out Before servicing the dock leveler and lift combo read and follow the Safety Practices on pages 3 4 and the Operation section of this manual Place barricades on the dock floor around the dock leveler and lift combo pit and in the driveway in front of the pit while installing maintaining or repairing the unit WEEKLY 1 Clean the upper portion of the lip plate
55. h a vehicle restraint or wheel chocks before operating the dock leveler Do not operate the dock leveler and lift combo with anyone standing on or in front of the unit Do not drive on the lip until it is fully extended and supported by the vehicle bed or by the drive surface at grade level Always keep hands and feet clear of all moving parts Always restore the dock leveler and lift combo to its safe dock level position after servicing the vehicle NOTE Strobe light will flash when the unit is away from dock level The strobe light will stop flashing when the unit returns to dock level An alarm will sound if the unit stays below dock level for more than ten minutes Return the unit to dock level or press the silence alarm button to silence alarm if desired LOWERING LIFT Before operating the lift onto a truck bed ensure a vehicle restraining device is engaged or wheel chocks in place Before lowering the lift onto the driveway ensure that there are no obstructions impeding the downward travel of the lift Ensure the dock leveler and lift combo is in Lift Mode Verify the lock pins are retracted and deck is supported by both deck support legs When the unit is in Lift Mode the Lift Mode lighted pushbutton will be lit If the unit is not in Lift Mode rotate the Light Communication MLS switch to DO NOT ENTER TRUCK and press the LIFT pushbutton The leveler will rise then the lock pins disengage and the deck support legs
56. hazardous situation which if not avoided could result in death or serious injury 2 6009080C Dock Leveler and Lift Combo 2012 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 May 2012 Read these safety practices before installing operating or servicing the dock leveler Failure to follow the safety practices could result in death or serious injury If you do not understand the instructions ask your supervisor to explain them to you or call your authorized 4Front Engineered Solutions Inc distributor OPERATION Use restricted to trained operators Follow procedures on placard posted near the dock leveler and lift combo Do not use this unit to service vehicles outside its intended working range 8 long dock leveler and lift combo is 12 above dock 10 long dock leveler and lift combo is 15 above dock 12 long dock leveler and lift combo is 18 above dock All units service 12 below dock While in Leveler Mode do not operate leveler portion with equipment material or people on the ramp or lip Do not operate the dock leveler and lift combo when anyone is in front of it unless they are securing the maintenance strut Stay clear of the dock leveler and lift combo when it is moving Ensure there are no obstructions which may
57. he dock leveler and lift combo matches the facility s power supply Mount the control panel on the wall near the front of the dock leveler and lift combo and connect the power supply The recommended mounting height of the control panel is approximately 60 inches from the floor to the pushbuttons See Fig 19 for detail review approval drawings for specific details if applicable Inadequate lifting equipment or practices can cause a lifted load to fall unexpectedly Make sure lifting chain or other lifting devices are in good condition and have a rated capacity exceeding the lifting load for the angle used See Fig 20 for expected weight Never allow anyone to stand on or near the dock leveler and lift combo when it is being lifted or placed in the pit Failure to follow this warning can allow the dock leveler and lift combo to fall tip or swing into people resulting in death or serious injury 3 The dock leveler and lift combo weight is shown on Fig 20 Ensure that the crane has sufficient lift capacity to safely carry this load The entire weight of the dock leveler and lift combo shall be lifted from the four lifting rings mounted on the deck surface Lifting under the side or end frame angles will damage the dock leveler and lift combo The preferred lifting method is with a 4 way chain sling hooked to the four lifting lugs on the deck If short chains are used a spreader bar is recommended to reduce side loading Adjust the s
58. hinge with a brush and blow away all dirt and debris 2 Inspect for debris in rear hinge area of the dock leveler and lift combo Also check for debris between the unit and the side pit walls to ensure smooth operation Clean as required 3 Check the full operation of the dock leveler and lift combo to ensure there is no hesitation in the hydraulic system Any loss of fluid will affect the safety valve operation 4 Inspect the operation of the telescopic toe guards to ensure they are not distorted or binding when the leveler is operating 5 Clean the area that accesses the drain located at the bottom of the pit to remove any build up of debris PLANNED MAINTENANCE QUARTERLY 1 Inspect all warning labels and placards See page 44 Replace as necessary 2 Clean out the inside of the pit area Take care not to spray any electrical parts 3 Inspect and lubricate all mechanical pivot points on the dock leveler and lift combo with S A E 30 oil Cycle the unit when lubricating See page 44 4 Inspect the hydraulic cylinders and hoses for any fluid loss Check the hoses for signs of excessive wear 5 Inspect the reservoir level of the leveler power unit Check the reservoir level with the leveler fully extended Add fluid as required See page 44 6 Inspect the reservoir level of the scissor lift power unit Check the reservoir level with the unit fully extended Add fluid as required See page 44 7 Inspect all welds u
59. hold the Lift Mode pushbutton Verify both lock pins retract and the lip keepers rotate downward and the support legs are positioned to support the deck After the cycle has completed release the Lift Mode pushbutton e Press the Leveler Raise button to raise the leveler to full height Press the Stop button and store both maintenance struts e Pull the Stop button out and allow the leveler to float down to stored position The deck should rest on the deck support legs 24 6009080C Dock Leveler and Lift Combo 2012 4Front Engineered Solutions Inc May 2012 INSTALLATION wm PIT MOUNT continued 25 While in Service Mode position the dock leveler and lift combo using the raise and lower pushbuttons so that the back edge of the deck is precisely level with the floor Use a straight edge to accomplish this a board or equivalent will make a satisfactory marker when laid across the gap of the lift AADANGER Do not enter the pit area under the dock leveler and lift combo unless the scissor motor is off and both safety stop blocks are placed in front of the scissor arm rollers 26 Check and adjust the position of the floor level sensor located under the front right side of the platform See Fig 26 for location and details 27 Loosen the two socket head cap screws that are fixed in the slot of the sensor back plate This will allow correct positioning of the floor level sensor If needed adjust the height of the a
60. hown above FU409 HIL H3 8H2 4H4 015 480 Am PRI xF 411 120V 8 24V 2 SEC Ge D50VA X3 x1 LIFT AND LEVELER MOTOR DETAILS 11 x2 380 480V THREE PHASE 50 60HZ CH RD WH BK NOTE VISUALLY CONFIRM MOTOR TAG LEGEND PANEL WIRING FIELD WIRING BY OTHERS PC BOARD TRACES WIRE COLOR GAUGE unless otherwise specified 208 600VOLT BLACK 14GA 24VAC 120VAC RED 16GA from 600 24VAC RED BLK 16GA 120 24VAC NEUTRAL WHT 16GA 24VDC BLUE 18GA 120VAC NEUTRAL 24VDC OVDC BLU WHT 18GA from 601 from 602 12VOLT AC OR DC PURPLE 18GA 12VOLT PUR WHT 18GA May 2012 6009080C Dock Leveler and Lift Combo 67 2012 4Front Engineered Solutions Inc ELECTRICAL SCHEMATIC continued Fig 70 600V 3 PHASE 50 HZ INCOMING SERVICE TO BE TERMINATED AT DISCONNEC MAIN MOTOR PANEL BULKHEAD PANEL FLA 9 6AMPS DS50 CONTACTOR SCCR 5KA SE FU501 M618 OL1 oi t t f TL Aea Sik l MOT502 1 oT t stat FC ag WAT Can HP VER S i o Sof 7 oX o RED d 1 2FLA 575V 60HZ 7 TT SLS SEN RH 3450RPM UT Z G MOTOR S Ku CONTACTOR M621 OL2 TET EH l l MOT505 7 5 ZEZ Fo Sege SI Hlor i l 9FLA 600V 60HZ s3 e013 WA 9A Sg NOTE Power to control panel must be from fused disconnect supplied
61. ical to the application INSPECTION AND MAINTENANCE The dock leveler and lift combo shall be inspected and maintained in proper working order in accordance with the manufacturer s operating maintenance manual and safe operating practices Only trained and authorized personnel shall be permitted to perform maintenance on the dock leveler and lift combo MAINTENANCE PERSONNEL SHALL Read and understand the manufacturer s operating maintenance manual and all safety rules and labels prior to performing any maintenance or service on the equipment Full time unlimited access to the manufacturer s operating maintenance manual REMOVAL FROM SERVICE Any dock leveler and lift combo not in safe operating condition such as but not limited to excessive leakage missing rollers pins or fasteners any bent or cracked structural members cut or frayed electrical wiring or hydraulic lines damaged or malfunctioning controls or safety devices etc shall be removed from service until it is repaired to the original manufacturer s standards All repairs shall be made by qualified personnel in conformance with the manufacturer s instructions REPAIRS Allrepairs shall be made by qualified personnel in conformance with the manufacturer s instructions OPERATORS Only trained and authorized personnel shall be permitted to operate the dock leveler and lift combo BEFORE OPERATION Before using the dock leveler and lift combo Read and o
62. ice May 2012 6009080C Dock Leveler and Lift Combo 3 2012 4Front Engineered Solutions Inc SAF ETY PRACTICES continued INSTALLATION MAINTENANCE AND SERVICE Place barricades on the dock floor around the dock leveler pit and in the driveway in front of the pit while installing maintaining or repairing the dock leveler and lift combo Be certain before entering the dock leveler and lift combo pit or doing any maintenance or repair under the dock leveler and lift combo that 1 The both safety stop blocks are in place on the scissor frame See Fig 1 2 The both both maintenance struts are securely supporting the leveler portion See Fig 1 3 The power is disconnected and properly tagged or locked out If it is necessary to troubleshoot inside the control box with the 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 may cause electrical shock serious injury or death All electrical troubleshooting or repair must be done by a qualified technician and must meet applicable codes 4 6009080C Dock Leveler and Lift Combo 2012 4Front Engineered Solutions Inc Fig 1 Maintenance struts Lip plate Roller blocks Safety stop positions May 2012 OWNER S RESPONSIBILITIES LIFT It is the responsibility of the user purchaser to advise the manufacturer where deflection may be crit
63. id Control Valve Controls the lower speed of the unit and Factory Set No adjustment required directs fluid to the cylinders when the pump is running Solenoid Valve Raise Stops the unit from rising once the lift RAISE No adjustment required button is released Solenoid Valve Lower Stops the unit from lowering when the lift No adjustment required LOWER button is released HYDRAULIC FLUID LEVEL REMOTE MOUNTED The hydraulic fluid level for the remote mounted lift power unit should be checked when the dock leveler and lift combo is in the fully lowered position at grade level See Fig 61 Check the fluid level sight gauge on the lift power unit Ensure the fluid level is 2 above the bottom of the sight glass If the fluid level is low fill to the appropriate level using approved oil from the list on page 32 HYDRAULIC FLUID LEVEL PIT MOUNTED The hydraulic fluid level for the pit mounted lift power unit should be checked when the dock leveler and lift combo is in the fully lowered position at grade level See Fig 61 Check the fluid level sight gauge on the lift power unit Ensure the fluid level is 1 above the bottom of the sight glass If the fluid level is low fill to the appropriate levelt using approved oil from the list on page 32 58 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc ADJUSTEMENTS PROXIMITY SWITCHES There are a total of 9 proximity switches used o
64. itch Quck disconnect cable There are 9 proximity switches used on the Dock Leveler and Lift Combo See Fig 64 These switches need to be checked quarterly to ensure proper separation proper connection to the electrical cable and proper fitting to the mounting bracket PROXIMITY SWITCH SEPARATION The separation range should be 1 16 to 1 8 between the target and switch PROXIMITY SWITCH CONNECTION TO CABLE The proximity switches are connected to an electrical cable This is a threaded connection and needs to be checked quarterly to ensure proper connection There should be a solid connection between the switch and cable tighten if needed by hand PROXIMITY FITTING TO MOUNTING BRACKET There are two nuts attaching the proximity switch to the mounting bracket Ensure this is a tight connection use two 15 16 open end wrenches to tighten if needed 62 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc Fig 65 May 2012 Lift cylinder HYDRAULIC SCHEMATIC LIFT Lift cylinder wegder eee Velocity fuse Velocity fuse SV7 raise solenoid A O AN y i SV6 lower solenoid A RE Y Q CECR 7 5GPM MHA Primary Relief valve l t LLU 6009080C Dock Leveler and Lift C
65. le used See Fig 4 for expected weight Never allow anyone to stand on or near the dock leveler and lift combo when it is being lifted or placed in the pit Failure to follow this warning can allow the dock leveler and lift combo to fall tip or swing into people resulting in death or serious injury May 2012 Fig 4 Dock leveler and lift combo weight chart remote mounted lift power unit Size width x Weight in Ibs length kg 6x8 7000 3175 6 5x 8 7200 3265 7x8 7400 3356 6 x 10 8000 3629 6 5 x 10 8200 3720 7x10 8400 3810 6x12 9000 4082 6 5 x 12 9200 4173 7x12 9400 4264 NOTE The lip end of the dock leveler and lift combo is slightly heavier than the rear hinge end 6009080C Dock Leveler and Lift Combo 2012 4Front Engineered Solutions Inc INSTALLATION REMOTE MOUNT continued 6 10 The dock leveler and lift combo weight is shown on Fig 4 Ensure that the crane has sufficient lift capacity to safely carry this load The entire weight of the dock leveler and lift combo shall be lifted from the four lifting rings mounted on the deck surface Lifting under the side or end frame angles will damage the dock leveler and lift combo The preferred lifting method is with a 4 way chain sling hooked to the four lifting lugs on the deck If short chains are used a spreader bar is recommended to reduce side loading Adjust the sling chain
66. ling chains so that the lip end is slightly higher than the rear hinge end to prevent damage to the front curtain brackets The recommended lift point is 6 away from center closer to the front lip end of the dock leveler and lift combo If the dock leveler and lift combo cannot be set into the pit it must always rest on a flat surface NOTE The lip end of the dock leveler and lift combo is slightly heavier than the rear hinge end 4 Pick up the dock leveler and lift combo with a 4 way chain sling hooked to the four lifting lugs on the deck May 2012 Fig 20 Dock Leveler and Lift Combo Weight Chart Pit Mounted Lift Power Unit Size width x length Weight in Ibs kg 6x8 7200 3265 6 5 x8 7400 3356 7x8 7600 3447 6 x 10 8200 3720 6 5 x 10 8400 3810 7x10 8600 3900 6x 12 9200 4173 6 5x 12 9400 4264 7x12 9600 4354 6009080C Dock Leveler and Lift Combo 2012 4Front Engineered Solutions Inc INSTALLATION PIT MOUNT continued Inspect the hoses and fittings to ensure that they have not loosened during shipment Set the dock leveler and lift combo in the pit while taking care to prevent damage to the sides of the platform and the front curtain brackets Position the dock leveler and lift combo so that there is an equal space along each side of the platform and a 3 4 space at the rear 5 The four lifting lugs are attached by shipping bolts
67. ly 8 ft long Pit Mount 6008877 1 Scissor Frame Assembly 10 ft long Pit Mount 6008878 1 Scissor Frame Assembly 12 ft long Pit Mount 6008879 Safety Stop Block Assembly 8 ft units 6008419 2 Safety Stop Block Assembly 10 ft units 6008790 2 Safety Stop Block Assembly 12 ft units 6008443 EJEA Label Maintenance Device 921234 CS Label Danger Use of Maintenance Device 6007074 Label Danger Lift 6003451 Label Pinch Point 6007121 Retaining Ring Main Scissor Pin 6008377 Deck Support Leg Keeper Assy 20 Lip 10 and 12 ft units 6008392 Label Danger Maintenance Strut 921074 Label Danger Entering Pit 921070 Shipping Rod Rear 5 8 11 x 21 long 6008445 Lifting Nut Assembly 6008368 Pin Lifting 1 Dia 6008415 19 6 Hex Head Machine Bolt 3 4 10 x 4 Long 212321 Shipping Rod Front 5 8 11 x 25 long 6008446 Note Item 6 is referenced by the location of the scissor power unit remote mounted or pit mounted Note Items 16 20 are used for shipping and installing purposes only May 2012 6009080C Dock Leveler and Lift Combo 75 2012 4Front Engineered Solutions Inc PARTS LIST continued Roller curtain and push rod Fig 74 Part Description Part Number Roller Curtain 6 ft wide 6008408 Roller Curtain 6 5 ft wide 6008409 Roller Curtain 7 ft wide 6008410 Curtain Rod 6 ft wide 6008335 Curtain Rod 6 5 ft wide 6008411 Curtain Rod 7 ft wide 6008412 Pushrod 6 ft wide 18 lip 600
68. mic errors flash only one pilot lamp the lamp associated with the current transition mode and indicate a logging of the last attempted step in a given transition mode prior to failure Example if the error occurs while the Lift acquisition mode was executing the Lift pilot lamp will flash the trouble code The number in parentheses represents the number of lamp flashes These dynamic trouble codes store information that is lost once the motor run time has elapsed Before servicing the dock leveler and lift combo read and follow the Safety Practices on pages 3 4 and the Operation section of this manual LIFT pilot lamp flashing lift acquisition timeout 20 seconds LEVELER pilot lamp flashing Leveler acquisition timeout 30 seconds Flash F robiem Possible Cause Solution Count Category a Load on Leveler 2 Deck Raise Press RESET push button b Leveler Power Unit malfunction a Sensors incorrectly positioned or malfunctioning 3 Pins In Legs Up Press RESET push button b Leveler Power Unit malfunction Flash Problem Count Condition Possible Cause Solution a Scissor stop blocks are preventing the unit from lowering 2 Lift Lower Press RESET push button b Lift Power Unit malfunction 3 Lift Raise a Lift Power Unit malfunction Press RESET push button a Load on Leveler 4 DeckRaise Press RESET push button b Leveler Power Unit malfunction a Pins not aligned with la
69. n Verify both lock pins extend and the lip keepers rotate into position After the cycle has completed release the Leveler Mode pushbutton D Press and hold the Lift Mode pushbutton Verify both lock pins retract and the lip keepers rotate downward and the support legs are positioned to support the deck After the cycle has completed release the Lift Mode pushbutton Fig 10 Scissor hydraulic hose Hydraulic tee 14 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc INSTALLATION REMOTE MOUNT continued Press the Leveler Raise button to raise the leveler to full height Press the Stop button and store both maintenance struts e Pull the Stop button out and allow the leveler to float down to stored position The deck should rest on the deck support legs 25 While in Service Mode position the dock leveler and lift combo using the raise and lower pushbuttons so that the back edge of the deck is precisely level with the floor Use a straight edge to accomplish this a board or equivalent will make a satisfactory marker when laid across the gap of the lift ADANGER Do not enter the pit area under the dock leveler and lift combo unless the scissor motor is off and both safety stop blocks are placed in front of the scissor arm rollers 26 Check and adjust the position of the floor level sensor located under the front right side of the platform See Fig 11 fo
70. n the Dock Leveler and Lift Combo See Fig 62 for location of these proximity switches on the unit Check the separation of the proximity switch and the respective target Also ensure the electrical cable connector is seated firmly on the switch This should be done quarterly and included with other scheduled maintenance See Fig 64 on page 62 for separation detail Fig 62 l N K K i wee g Lock pins extended GE N proximity swtiches S Lock pins extended proximity swtiches Lip pendant proximity switch Deck level proximity swtiches Keeper leg proximity swtiches May 2012 6009080C Dock Leveler and Lift Combo 59 2012 4Front Engineered Solutions Inc ADJUSTEMENTS PROXIMITY SWITCHES continue The following table shows which maintenance devices need to be in place while adjusting the proximity switches This chart also shows what mode the unit needs to be positioned in for servicing a certain proximity switch NOTE Certain positions can only be achieved in Service Mode ADANGER Do not enter the pit area under the Dock Leveler and Lift Combo to make switch adjustments unless the scissor motor is off and safety devices are in place per the table below Safety Devices In Place 2 Q O SS a Serviced in Serviced 8 g Proximity Switch Leveler in Lift A S Mode Mode 2 S o S i D 2 D
71. nd transport vehicle The owner should therefore train and instruct operators in the safe use of dock leveling devices When atransport vehicle is positioned as closely as practicable to a dock leveling device there shall be at least 4 of overlap between the front edge of the lip and the edge of the floor or sill of the transport vehicle Nameplates cautions instructions and posted warnings shall not be obscured from the view of operating or maintenance personnel for whom such warnings are intended Manufacturer s recommended periodic maintenance and inspection procedures in effect at date of shipment shall be followed and written records of the performance of these procedures should be kept Dock leveling devices that are structurally damaged or have experienced a sudden loss of support while under load such as might occur when a transport vehicle is pulled out from under the dock leveling device shall be removed from service inspected by the manufacturer s authorized representative and repaired as needed before being placed back in service The owner shall see that all nameplates caution and instruction markings or labels are in place and legible and that the appropriate operating and maintenance manuals are provided to users Modifications or alterations of dock leveling devices shall be made only with written permission of the original manufacturer When industrial vehicles are driven on and off transport vehicles d
72. nder the dock leveler and lift combo for fatigue or failure particularly the lip plate hinge top plate beams front hinge bar and the scissor cylinder support weldments 8 Check the full operation of the dock leveler and lift combo Make any adjustments as required 9 Lubricate the lip plate tubes and the main scissor bearings with a Molydenum Disulfide NLGI 2 grease Do not over grease For the lip hinge tubes stop when grease starts to ooze from the hinge tube ends Wipe off excess grease See page 44 10 Inspect dock bumpers 4 of bumper protection is required Worn torn loose or missing bumpers must be replaced Hydraulic Fluid An all weather hydraulic fluid with a viscosity of 15 CSt at 40 C 100 F such as Shell Tellus T 15 Mobil Aero HFA 49011 Exxon Univis HV13 N15 J13 Texaco Aircraft Oil 1554 U S Oil Co Inc ZFI 5606 Low Temp May 2012 6009080C Dock Leveler and Lift Combo 43 2012 4Front Engineered Solutions Inc PLANNED MAINTENANCE continued Fig 51 Legend Symbol Lubricate Oil Light oil SAE 30 Lubricate Grease Molybdenum disulfide NLGI 2 Rear hinge pins 4 places Cleaning Location frequency Visually Inspect Replace damaged or worn
73. ng grade level e Release of the LOWER button at any point of travel shifts the solenoid and stops the unit Lip extend Solenoid valve shifts allowing the lip to extend e Lip will stay extended while the lift LOWER button is pressed STOP Solenoid valve shifts locking main cylinder and lip cylinder e Power cut off from motor control circuit NOTE Strobe light will flash when the unit is away from dock level Alarm will sound if the unit is below dock for more than ten minutes Press the silence alarm button to silence alarm if desired 34 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc HYDRAULIC SYSTEM OPERATION PENDANT Fig 39 UP e Raise solenoid shifts and lift motor starts allowing the lift to rise e Lift will continue to rise while holding the UP button until reaching dock height or the UP button is released e At dock height the raise solenoid valve will shift e The unit will then stop cree AAA DOWN e Lower solenoid shifts allowing lift to lower e Hydraulic fluid is displaced from the lift cylinders to the reservoir as the unit has a controlled descent e Lift will continue to lower while holding the LOWER button until reaching grade level e Release of the LOWER button at any point of travel shifts the solenoid and stops the unit LIP EXTEND ON LOWER e Rapidly press the DOWN button twice and hold e The lip solenoid valve shift
74. not cover any failure caused by improper installation abuse improper operation negligence or failure to maintain and adjust the DOCK LEVELER AND LIFT COMBO properly Parts requiring replacement due to damage resulting from vehicle impact abuse or improper operation are not covered by this warranty 4FRONT DISCLAIMS ANY RESPONSIBILITY OR LIABILITY FOR ANY LOSS OR DAMAGE OF ANY KIND INCLUDING WITHOUT LIMITATION DIRECT INDIRECT CONSEQUENTIAL OR PUNITIVE DAMAGES OR LOST PROFITS OR LOST PRODUCTION arising out of or related to the use installation or maintenance of the DOCK LEVELER AND LIFT COMBO including premature product wear product failure property damage or bodily injury resulting from use of unauthorized replacement parts or modification of the DOCK LEVELER AND LIFT COMBO 4FRONT s sole obligation with regard toa DOCK LEVELER AND LIFT COMBO that is claimed to be deficient in material or workmanship shall be as set forth in this Limited Warranty This Limited Warranty will be null and void if the original purchaser does not notify 4FRONT s warranty department within ninety 90 days after the product deficiency is discovered THERE ARE NO WARRANTIES EXPRESS OR IMPLIED WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF INCLUDING BUT NOT LIMITED TO A WARRANTY OF MERCHANTABILITY OR OF FITNESS FORA PARTICULAR PURPOSE ALL OF WHICH 4FRONT HEREBY DISCLAIMS May 2012 6009080C Dock Leveler and Lift Combo 91 2012 4Front Engine
75. om the panel and route the solenoid cable back through the auxiliary port Reattach the auxiliary port cover plate to the deck assembly The two countersunk screws should not protrude above the deck surface ADANGER Before doing any electrical work make certain the power is disconnected and properly tagged or locked out All electrical work must done by qualified technician and must meet all applicable codes If it is necessary to make troubleshooting checks inside the control panel with the 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 cause electrical shock death or serious injury 22 With the temporary power removed permanent power must be provided from the control panel to the junction box located on the pit mounted lift power unit 23 While in the pit route the bundle of electrical cables through the 3 conduit Leave excess cable length in the pit area for travel above finished floor These cables will connect to the proper receptacle on the bottom surface of the control panel The yellow cable cable 617 with a 19 pin connector contains 24V signal wiring for the proximity switches The gray cable cable 615 with an 8 pin connector contains the 24V signal wiring for the solenoids The black cable cable 302 with a 4 pin connector contains the power wiring for the leveler power unit Review electrical schematics for wi
76. ombo 63 2012 4Front Engineered Solutions Inc ELECTRICAL SCHEMATIC Fig 66 208V 3 PHASE 60 HZ INCOMING SERVICE TO BE TERMINATED AT DISCONNEC LEVELER MAIN MOTOR PANEL BULKHEAD PANEL FLA 23 2AMPS DS10 CONTACTOR SCCR 5KA S0 RORI FU101 M618 OL1 L Toot Lear BLK 1 i MOT102 dek T d siz e a HT cairo ue LEVELER i f Delen 5 53 E f 3r AS208V 60HZ LIFT G MOTOR L BP CONTACTOR M621 OL2 TL1 271 l MOT105 EE eeng HET OR G a BTS H 22FLA 208V 60HZ NOTE L Power to control panel must be from fused LIFT AND LEVELES MOTOR DETAILS disconnect supplied by others Max Type 200 240V THREE PHASE 50 60HZ CC fuse size shown above 13 Wel RD S ef m WH z WE CR SE FU109 BI S HALDEX NOTE VISUALLY CONFIRM MOTOR TAG Hie H2 0H3 H4 GROUP J 460 230 208V PRI XF111 ec 24 83 V SEC e 250VA X3 x1 DW X2 l LEGEND PANEL WIRING FIELD WIRING BY OTHERS PC BOARD TRACES WIRE COLOR GAUGE unless otherwise specified 208 600VOLT BLACK 14GA 120VAC RED 166GA 24VAC 24VAC RED BLK 16GA from 600 120 24VAC NEUTRAL WHT 16GA 24VDC BLUE 18GA 24VDC OVDC BLU WHT 18GA 120VAC NEUTRAL 12VOLT AC OR DC PURPLE 18GA from 601 from 602 12VOLT PUR WHT 18G
77. ombo 81 2012 4Front Engineered Solutions Inc PARTS LIST continued Hydraulic and electrical 20 Hose Assy Keeper Retract to Manifold 8 ft units Hose Assy Keeper Retract to Manifold 10 ft units Hose Assy Keeper Retract to Manifold 12 ft units N Hose Assy Keeper Extend to Manifold 8 ft units Hose Assy Keeper Extend to Manifold 10 ft units Hose Assy Keeper Extend to Manifold 12 ft units Hose Assy Manifold to Lock Pin Tee Hose Assy Lock Pin to Tee Manifold to Power Unit Hose Assy Lip Retract 8 ft units Hose Assy Lip Retract 10 ft units Hose Assy Lip Retract 12 ft units N Wu Hose Assy Lip Extend 8 ft units Hose Assy Lip Extend 10 ft units Hose Assy Lip Extend 12 ft units Hose Assy Main Cylinder 8 ft units Hose Assy Main Cylinder 10 and 12 ft units Hose Assy Main Cylinder to Manifold 8 ft units Hose Assy Main Cylinder to Manifold 10 ft units Hose Assy Main Cylinder to Manifold 12 ft units Velocity Fuse 10 G P M Fitting Street Elbow Fitting Run Tee hm D Fitting Elbow Fitting Male 45 Elbow Fitting Tee Male Fitting Swivel Nut Branch Tee Solenoid Valve Assy SV2 Pin Lip Cylinder 82 6009080C Dock Leveler and Lift Combo 2012 4Front Engineered Solutions Inc Kr 1 Pid 1 1 1 1 we 1 1 1 1 1 EJES Item Qty Part Description Part Number 1 31961 31955 313544 313545 6000724 6000724 336
78. ombo is properly positioned remove the safety stop blocks from the lift frame Operate the unit through the entire range from fully lowered to fully raised Watch for any interference with the pit walls If any interference is found either remove the obstruction or shift the dock leveler and lift combo in the pit When the clearances are acceptable raise the dock leveler and lift combo to floor level Remove power panel off and place both safety stop blocks in front of the lower scissor arm rollers Fig 6 Scissor assembly Leveling 4 x 10 bolt Scissor shim frame Fig 7 Roller 6 wide shim 12 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc INSTALLATION REMOTE MOUNT continued ADANGER Do not enter the pit area under the dock leveler and lift combo unless the scissor motor is off and both safety stop blocks are placed in front of the scissor arm rollers 20 When the dock leveler and lift combo has been correctly positioned and leveled Weld the scissor frame to the shims Then weld the shims to the pit floor embeds See Fig 8 and Fig 9 for details regarding welding NOTE Attach the welder ground cable only to the frame not to the platform or scissor arms ADANGER Do not enter the pit area under the dock leveler and lift combo unless the scissor motor is off and both safety stop blocks are placed in front of the scissor arm rollers 21
79. on and the lip will extend fully Do not drive on dock leveler or lip until it is fully extended and supported by the vehicle bed Never use a fork truck or other material handling equipment to lower the ramp and lip section 5 When lip is fully extended release the button The leveler will slowly float down to the vehicle bed See Fig 43 NOTE If an obstruction prevents the lip from deploying properly press and hold the leveler RAISE button to raise and retract the lip Restore the leveler to safe dock level position with the lip in both lip keepers for end loading 38 6009080C Dock Leveler and Lift Combo 2012 4Front Engineered Solutions Inc Fig 41 Press to raise Raise Release to lower Float May 2012 OPERATING INSTRUCTIONS LEVELER MODE continued STORING LEVELER Fig 44 1 To return the leveler to the stored position press and hold the leveler RAISE button As the leveler rises the lip will retract When the lip is fully retracted release the button The leveler will float down to the stored position with the lip supported by both lip keepers Before allowing vehicle to leave always return the dock leveler to its dock lev
80. p ABOVE e PORT PIN COLOR TA 15 WHT 1B 7 GRY PNK PORT PIN COLOR 1 0S E 2A 5 GRN 7 s f WHT 1 2B 4 RED BLU SCH 2 2 BRN 3A 16 Yw oy 3 3 GRN g 2 3B 8 WHT GRN 2 4 4 YW 4A 3 GRY GND 5 GRY S Ap 14 BRN GRN GND 6 PNK 5 ee 5A 17 PNK NEU 7 BLU 19 8 5B o WHT YLW NEU 8 RED 4 6A 2 RED S ty 6B 13 YLW BRN 7A 11 BLK 2 10 7B 10 WHT GRY n 17 BA 1 vo 118 WW 12 88 18 _GRY BRN GND 12 GRN YLW 24v 19 ov 6 Bw t53 NOT SHOWN LS7A LS7B LEFT AND RIGHT SIDE NOT SHOWN LS6A LS6B LEFT AND RIGHT SIDE NOT SHOWN 4 PORT HUB SOLENOIDS 1 5 HYDRAULIC POWER UNIT LEVELER AND SECONDARY HYDRAULIC CIRCUITS ONLY MOTOR LEADS FLOW CONTROL PRIMARY RELIEF LIFT POWER UNIT REMOTE MOUNT 46 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc TROUBLESHOOTING continued Use the Troubleshooting Guide if ever the dock leveler and lift A WARNING combo fails to perform properly Find the condition that most closely matches your situation and make the recommended adjustments Observe all safety warnings before attempting any maintenance procedure The PLC will display real time diagnostics using the Lift Leveler pilot lamps located on the front face of the control panel Static errors flash both pilot lamps simultaneously indicating a specific failure condition Dyna
81. proximately equal to the height difference recorded for each corner If one side is more that 3 8 lower than the other side insert shims under the low side approximately 3 4 of the difference and repeat the measurement May 2012 6009080C Dock Leveler and Lift Combo 21 2012 4Front Engineered Solutions Inc INSTALLATION PIT MOUNT continued NOTE Leveling adjustments are easier to check if the highest corner of the platform is even with the floor Shims will be used to raise the low corners so that all four corners on the platform are level ADANGER Do not enter the pit area under the dock leveler and lift combo unless the scissor motor is off and both safety stop blocks are placed in front of the scissor arm rollers 15 16 17 Use the three front and three rear leveling bolts to lift the frame until the shims can be inserted A jack and a short piece of 4 x 4 extending to the upper scissor frame can be used to support the weight and make the front leveling screw easier to adjust The rear 4 x 10 shims must extend under the rear scissor arm pivot on each side These 4 x 10 shims will be placed 1 2 from the back edge and 1 2 from the outside edge See Fig 25 for more detail on the rear shim locations The front roller track shims must be placed under the entire length of the front roller track This shim length will vary depending on dock leveler and lift combo length The roller track shims
82. r have explained and understood the manufacturer s operating instructions and safety rules Inspect the dock leveler and lift combo for proper operation and condition Any suspect item shall be carefully examined and a determination made by a qualified person as to whether it constitutes a hazard All items not in conformance with the manufacturer s specification shall be corrected before further use of the dock leveler and lift combo DURING OPERATION The dock leveler and lift combo shall only be used in accordance with the manufacturer s operating maintenance manual Do not overload the dock leveler and lift combo Ensure that all safety devices are operational and in place MODIFICATIONS OR ALTERATIONS Modifications or alterations of the dock leveler and lift combo shall be made only with written permission from the original manufacturer These changes shall be in conformance with all applicable provisions of this standard and shall be as safe as the equipment was before modification These changes shall also satisfy all safety recommendations of the original equipment manufacturer for the particular application of the dock leveler and lift combo May 2012 6009080C Dock Leveler and Lift Combo 5 2012 4Front Engineered Solutions Inc OWNER S RESPONSIBILITIES DOCK LEVELER The owner s responsibilities include the following The owner should recognize the inherent danger of the interface between dock a
83. r location and details 27 Loosen the two socket head cap screws that are fixed in the slot of the sensor back plate This will allow correct positioning of the floor level sensor If needed adjust the height of the arm by loosening the screw in the middle of the sensor As shown in Fig 12 position the arm of the sensor at 25 to the contact tube When rotating the sensor a snap can be felt when rotated past 25 Adjust the sensor arm and sensor to the correct position and retighten 28 Remove the safety stop blocks from the frame and store the blocks to the side Lower the dock leveler and lift combo approximately 12 below floor level Now raise the dock leveler and lift combo The unit should automatically stop close to floor height Reposition the floor level sensor if necessary 29 Raise the dock leveler and lift combo approximately 4 to 6 above floor level Extend the lock pins using the method described previously Place a PVC shim bushing over each lock pin Now place the latch block over each extended lock pin Orient each latch block as shown in Fig 13 Fig 11 Floor level sensor Contact target NOTE The floor level sensor assembly is easily accessed if the leveler platform is raised and placed on the maintenance struts Raising the leveler deck will not affect the floor level adjustment Fig 12 Sensor back plate Socket head cap screws Scissor leg Con
84. r unexpectedly Before chocking wheels or engaging vehicle restraint dump air from air ride suspensions and set parking brakes Always be certain that the vehicle wheels are chocked or that the vehicle is locked in place by a vehicle restraining device and the brakes are set before loading or unloading Vehicles pulling away from the dock unexpectedly can cause uncontrolled drop of the dock leveler which can result in death or serious injury Visually check that the lip is supported by the vehicle platform or the ramp is supported by both front lip keepers or deck support leg before driving or walking on the ramp The maximum uncontrolled drop of a dock leveler under load is 4 from the vehicle platform height from which the dock leveler was positioned Always return the dock leveler to its dock level stored position before allowing the vehicle to leave the dock If the vehicle pulls away from the dock before the dock leveler is stored the lip will fall to its pendant position and the ramp will drop In addition failure to properly store the leveler may leave the leveler in a position below the level of the dock floor This condition may result in unexpected drop of personnel or material handling equipment and result in death or serious injury Failure to follow these instructions could result in death or serious injury to operators and or bystanders INTRODUCTION The dock leveler and lift combo is a combination dock leveler an
85. range from fully lowered to fully raised Watch for any interference with the pit walls If any interference is found either remove the obstruction or shift the dock leveler and lift combo in the pit When the clearances are acceptable raise the dock leveler and lift combo to floor level Remove power panel off and place both safety stop blocks in front of the lower scissor arm rollers AADANGER Do not enter the pit area under the dock leveler and lift combo unless the scissor motor is off and both safety stop blocks are placed in front of the scissor arm rollers 19 When the dock leveler and lift combo has been correctly positioned and leveled Weld the scissor frame to the shims Then weld the shims to the pit floor embeds See Fig 24 and Fig 25 for details regarding welding NOTE Attach the welder ground cable only to the frame not to the platform or scissor arms ADANGER Do not enter the pit area under the dock leveler and lift combo unless the scissor motor is off and both safety stop blocks are placed in front of the scissor arm rollers Fig 24 Scissor frame Track support embed Front Shim Detail Scissor frame Rear frame 4 x 10 embed shim Rear Shim Detail May 2012 6009080C Dock Leveler and Lift Combo 23 2012 4Front Engineered Solutions Inc INSTALLATION PIT MOUNT continued 20 Disconnect the wiring to the temporary power cord and disconnect the lift solenoid cable fr
86. ring details if the control panels is not fitted with electrical connectors 24 Once all electrical connections have been made Place unit in Service Mode and verify all mode functions are available as follows e Press Lift Lower and verify the lift lowers e Press Lift Raise and verify the lift raises Continue to raise the dock leveler and lift combo above floor level to the highest point of travel Ensure the remote hydraulic hose and all electrical cables have sufficient slack in the line If needed put the safety stop blocks in place and pull extra hose cable length through the conduit e Press Leveler Raise and verify the deck portion leveler raises There may be a slight delay but the leveler deck should start to rise If the deck does not rise the motor may be running in reverse Review the electrical schematics to reverse the motor connections within the control panel and try again Raise the leveler deck to its full height and before it can float back down press the Stop button This will hold the deck in the raised position Extend both maintenance struts and lower the leveler deck by pulling the Stop button out e Press Lip Extend and verify the lip extends e With the deck raised and positioned on the maintenance struts press and hold the Leveler Mode pushbutton Verify both lock pins extend and the lip keepers rotate into position After the cycle has completed release the Leveler Mode pushbutton e Press and
87. rm by loosening the screw in the middle of the sensor As shown in Fig 27 position the arm of the sensor at 25 to the contact tube When rotating the sensor a snap can be felt when rotated past 25 Adjust the sensor arm and sensor to the correct position and retighten 28 Remove the safety stop blocks from the frame and store the blocks to the side Lower the dock leveler and lift combo approximately 12 below floor level Now raise the dock leveler and lift combo The unit should automatically stop close to floor height Reposition the floor level sensor if necessary 29 Raise the dock leveler and lift combo approximately 4 to 6 above floor level Extend the lock pins using the method described previously Place a PVC shim bushing over each lock pin Now place the latch block over each extended lock pin Orient each latch block as shown in Fig 28 30 Lower the platform until it is level with the floor Remove power panel off and slide the latch block to fit snug with the embed pit steel Make a heavy tack weld to the top and both sides of the latch block attaching it to the pit steel NOTE Attach the welder ground cable only to the curb angle not to the platform scissor arms Fig 26 Floor level sens r Contact target NOTE The floor level sensor assembly is easily accessed if the leveler platform is raised and placed on the maintenance struts Raising the leveler deck will not affect the floor
88. s allowing the lip to fully extend e The unit will then lower while the lip stays extended e Release of the LOWER button at any point of travel shifts the solenoid and stops the unit The lip solenoid shifts and the lip rotates to the pendant position e Label 6009318 is located on the side of the pendant This label explains operation of the lip extend on lower function NOTE The pendant duplicates the LIFT RAISE and LOWER functions May 2012 6009080C Dock Leveler and Lift Combo 35 2012 4Front Engineered Solutions Inc OPERATION LA WARNING Before operating the dock leveler and lift combo read and follow the Safety Practices on pages 3 4 Use of dock leveler restricted to trained operators Follow procedures on placard posted near dock leveler DO NOT USE THE DOCK LEVELER IF IT LOOKS BROKEN OR DOES NOT SEEM TO WORK RIGHT Tell your supervisor it needs repair right away or contact your local Serco distributor Before pressing button ensure lip avoids contact with vehicle platform sides and cargo If lip does not lower to vehicle platform reposition vehicle platform Stay clear of leveler unless lip is supported by vehicle platform or the leveler is stored at dock level Visually check that the lip is supported by the vehicle platform or the ramp is supported by both lip keepers or safety legs before driving or walking on the ramp Unsupported dock levelers can lowe
89. s so that the lip end is slightly higher than the rear hinge end to prevent damage to the front curtain brackets The recommended lift point is 6 away from center closer to the front lip end of the dock leveler and lift combo If the dock leveler and lift combo cannot be set into the pit it must always rest on a flat surface Pick up the dock leveler and lift combo with a 4 way chain sling hooked to the four lifting lugs on the deck Inspect the hoses and fittings to ensure that they have not loosened during shipment Set the dock leveler and lift combo in the pit while taking care to prevent damage to the sides of the platform and the front curtain brackets Position the dock leveler and lift combo so that there is an equal space along each side of the platform and a 3 4 space at the rear The four lifting lugs are attached by shipping bolts which extend down to the lift frame Loosen the nuts which secure the lifting lugs and then remove the threaded rods Keep all lifting hardware in case the dock leveler and lift combo must be removed in the future Locate the hydraulic hose that shipped loose with the dock leveler and lift combo Connect one end to the remote mounted power unit above the Solenoid valves The other end will connect to the dock leveler and lift combo through the auxiliary port See Fig 5 for location Loosen the two countersunk screws from the auxiliary port Remove the auxiliary port cover plate from the deck
90. side edge See Fig 9 for more detail on the rear shim locations The front roller track shims must be placed under the entire length of the front roller track This shim length will vary depending on dock leveler and lift combo length The roller track shims shall be placed 1 2 from the front of the scissor frame and 1 2 from the outside edge After the shims are in place loosen the leveling bolts so that the weight is resting only on the shim plates See Fig 8 for more detail on shim locations NOTE Carefully stack the shims in all four locations so that the pit floor embeds are visible for welding 18 19 Repeat the measurements and adjust the shimming until the platform is level The platform does not need to be at the same height as the floor but all four corners must be the same distance above or below the floor The front of the dock leveler and lift combo may be up to 1 8 higher than the rear but should not be lower Check that there is a space of 3 4 between the rear of the platform and the pit wall Ensure that there is an equal space on both sides of the platform If the spaces are not correct the frame can be shifted using a pry bar or small hydraulic jack between the pit wall and the ends of the frame Do not use the jack near the middle of the frame side angles If the dock leveler and lift combo has been repositioned re check the platform for level and shim as required When the dock leveler and lift c
91. sion Remove threaded cap If the lip extends before the ramp is fully raised the valve should be turned clockwise Tightening the valve too far will cause very slow lip extension or no extension at all Solenoid Valve Stops the fall of the top plate when either the No adjustment required LIP EXTEND or LEVELER STOP button is pushed Secondary Relief Valve Controls the force and speed of lip retraction Remove threaded cap If the lip is closing too when the power unit is running Does not forcefully turn the adjusting screw clockwise affect speed of lip closing when power unit If the lip is not closing fully when the lip is is not running above the keepers turn the adjusting screw counterclockwise HYDRAULIC FLUID LEVEL Fig 58 The hydraulic fluid level should be checked when the leveler is resting on the maintenance strut with the lip pendant The fluid level in reservoir should be approximately 1 2 full 3 1 4 plus or minus 1 2 down from breather cap when measured on the dipstick See Fig 58 If the level is low fill to the halfway point using an approved oil from the list on page 32 3 1 4 1 2 u 3 1 4 1 2 54 6009080C Dock Leveler and Lift Combo May 2012 2012 4Front Engineered Solutions Inc HYDRAULIC SCHEMATIC LEVELER
92. surface of the dock leveler and lift combo Keep all hardware the cover plate will be reattached after this phase of installation Fig 5 Countersunk Screws Hydraulic hose Auxiliary port Rear of dock leveler and lift combo 10 6009080C Dock Leveler and Lift Combo 2012 4Front Engineered Solutions Inc May 2012 INSTALLATION REMOTE MOUNT continued 11 Pull the hydraulic hose from the auxiliary port a sufficient distance to gain access to the fitting approximately 12 Connect the auxiliary hose with the hydraulic hose attached to the remote mounted power unit Ensure the routing of this hose avoids any pinch points or other hazards 12 Ensure all electrical and hydraulic connections are made and power is supplied to the control panel 13 Enter Service Mode by pressing and holding the reset pushbutton located on the righthand side of the control panel for 5 seconds Within the panel verify the PLC has booted and the PLC run light is solidly illuminated Ensure the input 19 door interlock is illuminated if it is not jumper wires must be correctly installed to satisfy this condition 14 Verify Service Mode is active The red and green lights located on the panel should be flashing Press and hold the LIFT RAISE pushbutton and note that the scissor lift motor is running The lift should start to rise If within 10 seconds the lift does not rise the motor polarity may need to be re
93. tact target Sensor arm May 2012 6009080C Dock Leveler and Lift Combo 15 2012 4Front Engineered Solutions Inc INSTALLATION REMOTE MOUNT continued 30 Lower the platform until it is level with the floor Remove power panel off and slide the latch block to fit snug with the embed pit steel Make a heavy tack weld to the top and both sides of the latch block attaching it to the pit steel NOTE Attach the welder ground cable only to the curb angle not to the platform scissor arms 31 After the latch blocks have been tack welded supply power back to the panel Place the unit in Service Mode and retract the lock pins Lower the dock leveler and lift combo several feet below floor level and remove the installation shim bushing from each latch block Now raise the platform to floor level It will stop automatically Extend the lock pins Carefully inspect the lock pin for proper engagement into the latch blocks If a pin does not engage properly note the area of interference If necescary remove the latch blocks and repeat the block installation procedure 32 When the blocks have been properly positioned lower the dock leveler and lift combo and fully weld the latch blocks in place See Fig 14 for weld details NOTE Fine adjustments can be made to floor level sensing using the PLC s potentiometer see Fig 14 Using a jewelers screwdriver or equivalent rotate the potentiometer clockwise to incre
94. tch blocks Pins Out de dag 5 b Sensors incorrectly positioned or malfunctioning Press RESET push button Legs Down c Leveler PowerUnit malfunction May 2012 6009080C Dock Leveler and Lift Combo 47 2012 4Front Engineered Solutions Inc TROUBLESHOOTING continued A WARNING Before servicing the dock leveler and lift combo read and follow the Safety Practices on pages 3 4 and the Operation section of this manual LIFT LEVELER pilot lamps flashing both simultaneously The dock leveler and lift combo is supplied with connectivity products to ease installatio n and troubleshooting The 8 port junction box located where shown below has signal LED display Page 49 and 50 will detail the standard LED display when the unit is stored in LIFT and LEVELER mode Fig 54 4 port solenoid junction box Flash Problem f 8 Courit Condition Possible Cause Solution 2 Lock Pin Sensors Lock Pins Engaged and Disengaged sensors are ON at the same time investigate Seet EFSER malfunction 3 Leg Keeper Assy Lip Keepers and Deck Support Leg sensors are ON at the same time een SES 4 Deck Level Deck not level while in LIFT mode unless lowering with lip retracted gt check for any interference 0 degrees 5 Flooded Flood condition power to motors and solenoid valves is removed check for flooding in pit 6 Lift motor Lift motor timeout 1 minute possible power unit malfunction Press RESET p
95. uring the loading and unloading operation the brakes on the transport vehicle shall be applied and wheel chocks or positive restraints that provide the equivalent protection of wheel chocks engaged The dock leveler should never be used outside its vertical working range or vertical lifting range or outside the manufacturer s labeled rated capacity It must also be compatible with the loading equipment and other conditions relating to the dock 6 6009080C Dock Leveler and Lift Combo 2012 4Front Engineered Solutions Inc May 2012 RAMP AND LIP GRADES Fig 2 Ramp grade Lip grade G A gt Ramp and lip grades for each dock leveler and lift combo length Vehicle bed 8 dock 10 dock 12 dock leveler and leveler and leveler and lift combo lift combo lift combo position from dock in x O O Q D gt O E st Ke x O O Q z D aa Ramp and lip grade 4 lip bend 18 lip May 2012 6009080C Dock Leveler and Lift Combo H 2012 4Front Engineered Solutions Inc INSTALLATION REMOTE MOUNT REMOTE MOUNT INSTALLATION Fig 3 Before installing the dock leveler and lift combo read i and follow the Safety Practices on pagse 3 4 and the Operating Instructions on pages 33 42 Failure to follow KC WN Control panel the Safety Practices could result in death or serious injury a 60
96. ush button 7 Leveler motor Leveler motor timeout 1 minute possible power unit malfu nction Press RESET push button 8 port sensor junction box 48 6009080C Dock Leveler and Lift Combo 2012 4Front Engineered Solutions Inc May 2012 Before servicing the dock leveler and lift combo read and follow the Safety Practices on pages 3 4 and the Operation section of this manual LEVELER MODE LED DISPLAY The LED display below represents the standard LEVELER MODE condition with the deck raised and resting on the maintenance struts and the lip pendant This can be used as a troubleshooting starting point to help diagnose the area of concern Fig 55 LS3 lip pendant amber light illuminated May 2012 TROUBLESHOOTING continued LS8 lip keepers up amber light illuminated LS6 lock pins extended amber light illuminated LS4 dock height indicator amber light illuminated Power indicator green light illuminated LS1 and LS2 deck level indicator if the leveler is not raised and resting on the maintenance struts both LS1 and LS2 will have the amber light illuminated 6009080C Dock Leveler and Lift Combo 49 2012 4Front Engineered Solutions Inc TROUBLESHOOTING continued
97. versed 15 With the platform raised to floor level the frame must be shimmed so that all four corners of the platform are level with the floor Measure and record the height from each corner of the dock leveler and lift combo to the floor Then select shims approximately equal to the height difference recorded for each corner If one side is more that 3 8 lower than the other side insert shims under the low side approximately 3 4 of the difference and repeat the measurement NOTE Leveling adjustments are easier to check if the highest corner of the platform is even with the floor Shims will be used to raise the low corners so that all four corners on the platform are level ADANGER Do not enter the pit area under the dock leveler and lift combo unless the scissor motor is off and both safety stop blocks are placed in front of the scissor arm rollers May 2012 6009080C Dock Leveler and Lift Combo 11 2012 4Front Engineered Solutions Inc INSTALLATION REMOTE MOUNT continued 16 17 Use the three front and three rear leveling bolts to lift the frame until the shims can be inserted A jack and a short piece of 4 x 4 extending to the upper scissor frame can be used to support the weight and make the front leveling screw easier to adjust The rear 4 x 10 shims must extend under the rear scissor arm pivot on each side These 4 x 10 shims will be placed 1 2 from the back edge and 1 2 from the out
98. y 2012 ADJUSTMENTS LIFT HYDRAULIC POWER UNIT ADANGER Be certain before entering the dock leveler and lift combo pit or doing any maintenance or repair under the dock leveler and lift combo that 1 The safety blocks are in place on the scissor frame 2 The maintenance struts are securely supporting the leveler portion 3 The power is disconnected and properly tagged or locked out Before servicing the dock leveler and lift combo read and follow the Safety Practices on pages 3 4 and the Operation section of this manual Place barricades on the dock floor around the dock leveler and lift combo pit and in the driveway in front of the pit while installing maintaining or repairing the unit Fig 61 Detail view from opposite side To lifting cylinder hose Junction box Solenoid valve lower Solenoid valve raise Check valve Cap Reservoir tank Gauge port Fluid control valve Fluid level sight gauge set at factory Drain plug Relief valve set at factory May 2012 6009080C Dock Leveler and Lift Combo 57 2012 4Front Engineered Solutions Inc ADJUSTEMENTS LIFT HYDRAULIC POWER UNIT continued Relief Valve Controls maximum pressure in the hydraulic Factory Set No adjustment required lift system and prevents other components from excessive force Relief Valve pressure is set at the factory contact your local distributor if there is belief adjustment is required Flu

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