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User`s Manual

1. 17 Dock Leveler 36 ENG LOAGING Meer 17 AYANG cists 39 DENVICE TOOIS axzvzc2edeuiceceseevarieieeaeenctacies 18 Hydraulic Power Unit 41 Preventative Maintenance 19 43 Troubleshooting Guide 21 Distributor Information 46 INTRODUCTION Welcome and thank you for choosing this dock leveler This User s Manual contains information that you need to safely install operate and maintain the dock leveler 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 April 2007 6001762B Vertical Hydraulic Dock Leveler 3 2007 4Front Engineered Solutions Inc OWNER S RESPONSIBILITIES The owner s responsibilities include the following The owner should recognize the inherent danger of the interface between dock and transport vehicle The owner should therefore train and instruct operators in the safe use of dock leveling devices When a transport vehicle is positioned at the dock there shall be at least 4 of overlap between the front edge of the lip of the dock leveler 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
2. Important Installer Responsibility Vertical levelers ship partially disassembled and require field assembly Prior to complete electrical and hydraulic installation levelers must be stored safely If leveler is mounted on hinges and stored vertically maintenance post must be secured with lock out pin and padlock until the leveler is completely wired tested and fully operational Padlock must not be removed until leveler is completely wired tested and fully operational Failure to follow safety practices could result in death or serious injury GENERAL INFORMATION The successful installation of a vertical leveler requires good coordination with other trades involved on the site You must have a clear access to the dock area inside and out Ideally the leveler should not be installed until the control panel is installed has live power connected to the control panel and field wiring to the power unit is complete This will allow the complete installation at one time as opposed to making several trips The bumper assemblies must not be installed until the leveler is functional as pit construction errors may not be evident until that time The installed location of the control panel and hydraulic power unit must be specified on a job specific Approval Drawing Check with the general contractor or sales person for this information PIT CHECK Check the entire dock leveler pit for proper construction according to the job specif
3. Green pilot light turns on when leveler reaches working range 14 6001762B Vertical Hydraulic Dock Leveler 2007 4Front Engineered Solutions Inc RAISE Pump starts and shuttle valve shifts Main solenoid valves SV2 amp SV3 open to extend main cylinder Lip solenoid valve SV4 closes to prevent lip from retracting Green pilot light turns off when leveler raises above working range Fully Raised Leveler stored sensor closes Pressure increases e Sequence valve shifts Lip cylinder extends LIP RETRACT Pump starts and shuttle valve shifts Main solenoid valves SV2 amp SV3 open allowing leveler to raise and lip to retract Green pilot light turns off when leveler raises above the working range LIP EXTEND e Pump starts and shuttle valve shifts Main cylinder solenoid valve 1s closed Lip solenoid valve opens allowing lip to extend April 2007 Before operating the dock leveler read and follow the Safety practices on page 6 Restrict use of dock leveler to trained operators Follow safe operating procedures described in this manual and in the operation placard which was shipped with the leveler The placard should be posted near the leveler If either labels or placard is lost call 1 800 525 2010 or 972 466 0707 for a free replacement DO NOT USE DOCK LEVELER IF IT LOOKS DAMAGED OR DOES NOT SEEM TO WORK PROPERLY Inform your supervisor immediately Always be certain that
4. Vertical Hydraulic Dock Leveler 9 2007 4Front Engineered Solutions Inc INSTALLATION continued 13 14 Remove shipping plug from the hydraulic reservoir and replace with the breather cap Pull out the Emergency Stop button The amber power light should be on Press and hold the Raise push button for only 5 seconds while looking into the hydraulic reservoir fill hole If the motor is turning in the correct direction you will immediately see the fluid level drop If after 5 seconds you see no drop in fluid level stop the pump and switch wires to reverse the rotation See troubleshooting guide and electrical schematics in this manual to correct 15 Press and hold the Raise push button The main cylinder 16 17 will begin to extend in an abrupt motion Hold the cylinder away from the leveler while extending so that it will extend freely The cylinder rod or adjusting end may be damaged by contact with the deck while extending If the sound of the pump changes before the cylinder reaches its full stroke 16 stop the pump and add 8 ounces of hydraulic fluid see page 14 under Components amp Specifications for hydraulic fluid specifications Continue to run the pump until the main cylinder is fully extended Add more fluid if required Press the Lower button and hold until the main cylinder is fully retracted This will eliminate excess air from the main cylinder Then press the Lip Retract button and hold
5. 11 24V Xe N TERMINAL CONNECTIONS FUR SINGLE PHASE INCHMING SERVICE DISCONNECT AND FUSING SUPPLIED BY OTHERS DOCK LEVELER MOTOR Sv4 N D LIP SOLENOID VALVE SV4 SOLENOID 2 amp 3 MAIN MAIN SOLENOID VALVES SVe amp SV3 POWER DOWN SOLENOID VALVE SVI NEUTRAL CREMOVE JUMPER IF USED RESTRAINT INTERLDCK REMOVE JUMPER IF USED DOOR OPENED INTERLOCK SWITCH SWITCH COMMON LSI M LEVELER STORED SWITCH 9e 9 MAINTAINED FLOAT SWITCH ma x Ho Z 32 6001762B Vertical Hydraulic Dock Leveler April 2007 2007 4Front Engineered Solutions Inc SINGLE PHASE MOTOR AMP CHART ELECTRICAL SCHEMATIC VOLTAGE AMPERAGE 208V to 240V SINGLE PHASE 208 6 4 Fig 21 220 6 2 230 6 1 240 6 0 1 HP SEE CHART FOR MOTOR AMPERAGE NOTE Power to control box must be psc Ll DL INCOMING SERVICE 10 AMP NN DM DISCONNECT AND FUSING Fuses T2 2 DICK LEVELER SUPPLIED BY OTHERS L3 L3 13 oe peto oes G F1 E xl 120VAC N Q4V AC F3 10 AMP F4 1 2 AMP IL1 120VAC gt 24VAC NEUTRAL 11 24V N TERMINAL CONNECTIONS FOR SINGLE PHASE NOTE INCOMING SERVICE DISCONNECT AND FUSING SUPPLIED BY OTHERS SV4 N D ha a ge a e SVI Q7 o o NEUTRAL CREMOVE
6. 7 float range Amber lamp flashes if both LS1 amp 152 the LOWER button when Green light on leveler are on or an overload condition exists control panel indicates leveler has reached the operating range See Fig 8 16 6001762B Vertical Hydraulic Dock Leveler April 2007 2007 4Front Engineered Solutions Inc April 2007 OPERATING INSTRU CTIONS continued Storing Leveler 3 To return the leveler to its vertical stored position press and hold the RAISE button Green light will turn off Audible Alarm will sound if the button is released before the leveler is fully raised When the leveler is fully raised and the lip is extended release the RAISE button Push the EMERGENCY STOP button to turn off power amber light off See Fig 9 End Loading Operation 1 Pull the EMERGENCY STOP button to switch on power Amber indicates power on Press and hold LOWER button until the leveler is partially lowered Press and hold LIP RETRACT button until the lip is fully retracted Press and hold LOWER button until Green light on leveler control panel indicates the leveler has reached the operating range Leveler will float down to the pit floor See Fig 10 To reposition the leveler for normal loading unloading press the RAISE button until lip is clear of the truck The Green light will go off and the Audible Alarm will sound if the leveler is stopped above the operating range Press the LIP EXTEND button until lip is ful
7. PW RU ER ST Leveler Stored No push buttons pressed Emergency Stop pulled out April 2007 PW RU ER A ST Leveler Stored Lower button pressed 6001762B Vertical Hydraulic Dock Leveler 25 2007 4Front Engineered Solutions Inc LC D IAG N OSTICS continued Leveler between float and stored Raise button pressed Alarm condition LS1 amp LS2 both on or overload tripped No buttons pressed 26 6001762B Vertical Hydraulic Dock Leveler April 2007 2007 4Front Engineered Solutions Inc HYDRAULIC POWER UNIT ADJUSTMENT Fig 14 Motor Lip Solenoid Valve SV4 Main Solenoid Valve SV2 To Main amp Lip Cylinder Retract Tee To Lip Cylinder Extend Manifold Block Reservoir Power down solenoid SV1 Power Down Relief Valve To Main Cylinder Extend POWER UNIT FULL ASSEMBLY Port SV3 ix Port SV1 Port A Port MANIFOLD BLOCK DETAIL April 2007 6001762B Vertical Hydraulic Dock Leveler 2 2007 4Front Engineered Solutions Inc HYDRAULIC POWER UNIT ADJUSTMENT continuea Description Purpose Adjustment Primary Relief Valve Controls maximum pressure in the Remove threaded cap Turn screw clock hydraulic system and protects the wise to increase relief pressure Relief other components from excessive pressure is factory set at 2 000 PSI an
8. JUMPER IF USED RESTRAINT INTERLDCK CREMOVE JUMPER IF USED DOOR OPENED INTERLOCK SWITCH SWITCH COMMON LS2 from fused disconnect supplied by others Fuse size can be no greater than the size shown in the above schematic or chart for dual element time delay DETD fuses All electrical work must be done by qualified technician and must meet all applicable codes All devices shown in de energized state ee LLL o LIP SOLENOID VALVE SV4 m SVe MAIN SOLENOID VALVES SV2 amp SV3 eee POWER DOWN SOLENOID VALVE SV1 1 uec o LEVELER STORED SWITCH o AE MAINTAINED FLOAT SWITCH April 2007 6001762B Vertical Hydraulic Dock Leveler 33 2007 4Front Engineered Solutions Inc ELECTRICAL SCHEMATIC 208V to 575V THREE PHASE otee anrerace voice ruse SIZE F1 P2 208 220 3 3 208 240 1 5 230 240 3 2 480 1 0 460 480 1 6 575 0 5 575 1 3 DISCONNECT CHART 9 VOLTAGE FUSE SIZE 208 240 6 AMP DETD a 2 ET 460 480 3 AMP DETD a INCOMING SERVICE 1 575 3 AMP DETD DISCONNECT AND FUSING SUPPLIED BY OTHERS pou iE een DUCK LEVELER Mn B m AMPERAGE 0 e _ bo Cot 4 lc e e SEE DISCONNECT CHART FOR MAX FUSE SIZE NOTE SEE FUSE CHART Power to control box must be from fused disconnect supplied ae by others Fuse size can be no 120VAC gre
9. NOTE 7 1 1 LEVELER STORED SWITCH 24VDC N O SWITCH CLOSED WHEN LEVELER IS STORED MOUNTED ON NOTE 4 SV2 MAIN SOLENOID 24VAC VALVE OPEN WHEN DECK ACTIVATED COIL IS MOUNTED ON MOTOR AND WIRED INTO JUNCTION BOX NOTE 8 152 MAINTAINED FLOAT SWITCH 24VDC N O SWITCH CLOSED WHEN LEVELER IS LOWERED TO 37 DEGREES FROM DOCK HEIGHT MOUNTED ON DECK WIRE COLOR LEGEND LEGEND 120VAC RED XXX WIRE NUMBER 120VOLT NEUTRAL WHITE 4 XXX34 L1NE REFERENCE NUMBER DRY CONTACTS YELLOW 24VDC BLUE 24VDC BLUE W WHITE STRIPE PANEL TERMINALS Tat VG PURPLE ARA 12VDC PURPLE W WHITE STRIPE FEILD WIRING April 2007 6001762B Vertical Hydraulic Dock Leveler 31 2007 4Front Engineered Solutions Inc ELECTRICAL SCHEMATIC 120 VOLT SINGLE PHASE Fig 20 DUCK LEVELER MOTOR INCOMING SERVICE DISCONNECT AND FUSING 12 8 A SUPPLIED BY UTHERS _ NOTE Power to control box must be FI asa Fe from fused disconnect supplied OY by others Fuse size can be no XF 106 greater than the size shown in the above schematic or chart X1 X 24VACD for dual element time delay DETD fuses All electrical F4 AMP F3 10 AMP work must be done by qualified technician and must meet all 1L1 24V applicable codes All devices shown in de 120VAC gt 24V AC x2 NEUTRAL N 1 energized state D
10. States Dallas TX 972 466 0707 Canada London Ont 519 457 7155 Failure to follow these instructions could result in death or serious injury i 6000849 6000873 20 6001762B Vertical Hydraulic Dock Leveler 2007 4Front Engineered Solutions Inc CD IP Do not remove the lock out pin from the maintenance post unless authorized personal have confirmed that the hydraulic cylinders valve and hoses have been properly installed and filled with fluid Failure to do so could result in death or serious injury 6000873A DO NOT REMOVE THE LOCK OUT PIN from the maintenance post until you are sure the hydraulic system is in proper working condition Do not stand in front of the dock leveler while removing the lock out pin Reach from the side of the leveler Do not force the lock out pin out of the maintenance post If the pin does not slide freely support the leveler securely using other means and determine the cause of 6004101 i i Sli OPERATIONS the interference Failure to follow these instructions could result in death or serious injury 6000849A WARNING AND OPERATION PLACARD MOUNTED NEAR CONTROLS April 2007 TROUBLESHOOTING GUIDE 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
11. leveler until you Restore the leveler to its safe stored vertical position with lip extended Press the Emergency Stop button to stop the leveler from moving Failure to do so could result in death or serious injury Normal Operation 1 To lower the dock leveler pull the EMERGENCY STOP button on control panel to switch on power Amber light indicates power on Press and hold LOWER button The pump will start and the leveler will start to lower Release the LOWER button when the Green light on the control panel turns on Green light on leveler control panel indicates leveler has reached operating range The leveler will float down to the truck bed See Fig 7 Green light on Green light Press to lower Push to stop Pull for power on 2 To stop the leveler release the LOWER button Audible Alarm will sound if the button is released before the leveler is in its operating range Push the EMERGENCY STOP button at any time to stop all operation and silence the Audible Alarm If this condition persists a short duration tone will sound periodically to remind the operator of the illegal leveler condition Amber and green lights will turn off To resume operation of the leveler pull the EMERGENCY STOP button amber light Note Audible alarm pulses and green lamp goes off if on and press and hold the LOWER button and the EMERGENCY STOP button is pressed while leveler leveler will float down to the truck bed Release 5
12. not extend until the leveler is fully raised See page 28 a Inspect and clean pilot check valve b Replace cylinder a Adjust as required See page 35 April 2007 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 INPUTS Leveler Stored Sensor Float Sensor Raise Push Button Lip Extend Push Button Lip Retract Push Button Lower Push Button Leveler STOP Overload Tripped Restraint Engaged Interlock Door Opened Interlock Spare Spare Spare 0 1 2 3 4 5 6 T 8 CO PWR RUN ERR STAT PLC DIAGNOSTICS The Vertical Leveler is controlled by a Programmable Logic Controller PLC which reads input signals from push buttons and proximity sensors and closes the appropriate output relays to the motor solenoid valves audible alarm and warning lights OUTPUTS Lower Valve SV1 Main Valves SV2 amp SV3 Lip Valve SV4 Motor Amber Lamp Green Lamp Audible Alarm Loading Light Relay VSL Fault Leveler Stored No Alarm Condition Pilot INPUTS OUTPUTS The charts below show all of the valid conditions for the PLC Unit 0 12 34 eLLLILITISSLLLI INPUTS ele lej fe ovrrurs xy zl o 1 2 3 4 5 6 7 8 9 lt
13. of three but using the forks to separate the levelers is not recommended as damage to the hydraulic components may occur The levelers should be lifted individually by installing a 3 4 UNC load centering eyebolt through the hole supplied in the lip plate See Fig 2 TO INSTALL 1 Mount and wire the control panel in the location as shown on the job specific approval drawing Ensure that the voltage and phase of the incoming power agrees with the control panel and the decals on the pump and motor Power to the control must come from a user supplied fused disconnect with correct fuse sizes for the voltage and phase of the motor See electrical diagram for correct fuse size 2 Pick up the leveler using the load centering eyebolt and suspend the leveler vertically as shown in Fig 2 3 Align the leveler rear hinges with the fixed hinge section and insert the two outer hinge pins from the side without standing in front of or underneath the suspended leveler Do not install the center pin until the maintenance post has been installed and secured Fig 3 shows placement of the pins 4 Insert the maintenance post bar through the guide bracket on the leveler and secure the lower end to the frame with the pin Note Strut is not symmetric Larger hole in strut pins to deck Insert the pin from the side without standing in front of or underneath the suspended leveler See Fig 3 5 Allow the leveler to lean away from the dock door until th
14. remove and inspect valve for contamination and then replace solenoid valve c Check motor rotation amp reverse electrical connections 1 amp T2 if necessary d With the leveler safely secured by the lock out pin inserted in the maintenance post and bracket on deck remove the hose from the upper port of the main lift cylinder and point free end into the reservoir opening If no fluid is pumped replace hydraulic power unit e Set primary relief valve to 2000 PSI See instructions on page 28 a Check for magnetism at solenoid coil If magnetism present remove and inspect valve for contamination and then replace solenoid valve b If load was on the leveler remove the load and jog the RAISE or LOWER buttons to unlock the leveler April 2007 6001762B Vertical Hydraulic Dock Leveler 23 2007 4Front Engineered Solutions Inc TROUBLESHOOTING GUIDE continued Do not disconnect hoses or any hydraulic components unless the leveler is fully raised with lip extended the lockout pin is inserted through the maintenance post Emergency Stop button is pressed and barriers are in place If you do disconnect any hydraulic components remove the pin from the main cylinder rod end and perform steps 17 through 24 of the Installation Instructions on pages 10 and 11 before removing the lockout pin from the maintenance post and bracket on deck Failure to do so could result in death or serious injury Problem 7 Le
15. to do so could result in death or serious injury Problem 1 Leveler does not raise or lower Motor not running 2 Leveler does not raise or lower motor starts then stops motor starter relay chatters 3 Overload relay tripping check full load amperage and relay setting 4 Leveler does not raise or lower Motor hums 22 2007 4Front Engineered Solutions Inc Possible Cause a No electrical power to control panel b Electrical connections incorrect or broken c No electrical power to PLC d PLC not running a Loose wiring connection b Voltage drop due to long wiring distance from power source a Overload relay set too low b Loss of 1 phase Three phase only a Voltage drop b Loss of 1 phase Three phase only 6001762B Vertical Hydraulic Dock Leveler Solution a Check that voltage is present at terminal connections to the control panel b Check that wiring matches the wiring diagram c No electrical wiring to the PLC d If the fault light is flashing replace PLC a Check all wiring connections from line to motor starter relay overload and to motor b Check voltage when motor is started Voltage drop is more often a problem on single phase motors Verify wire gage 15 adequate for length of wire a Set overload to full load current specified for voltage on motor nameplate b Check for voltage at all three motor connections T1 T2 T3 at outpu
16. 0 Volt Label Ext on Pump 921 051 208 Volt Label Ext on Pump 921 050 240 Volt Label Ext on Pump 921 052 480 Volt Label Ext on Pump 921 053 5 5 Volt Label Ext on Pump 921 054 Plug 3 8 Pipe discarded at installation 42 6001762B Vertical Hydraulic Dock Leveler April 2007 2007 4Front Engineered Solutions Inc PARTS LIST CONTROL PANEL Fig 28 HAZARDOUS VOLTAGE Turn off power supplying the equipment before working on or inside Electric shock could cause death or severe injury May contain more than one power supply DO NOT DRIVE ON DOCK LEVELER UNLESS GREEN LIGHT IS ON DOCK LEVELER GREEN LIGHT Use by untrained people could cause death or serious injury Do not operate with anyone standing on or in front of the dock leveler Do not enter the truck until it has been secured by a vehicle restraint or wheel chocks Read the Owner s manual before operating making adjustments or repairs Push and hold to raise dock leveler Lip plate will extend when leveler is fully raised When fully raised push the Emergency Stop 4 Lip Extend Push to extend lip plate Release at desired lip extension 3 J Lip Retract Push to retract lip plate Release at desired lip retraction Release Emergency Stop Push and hold Lower button until green light indicates leveler has reached operating range Power On Do not use leveler if light is flashing AMBER LI
17. GHT ART 162A April 2007 6001762B Vertical Hydraulic Dock Leveler 43 2007 4Front Engineered Solutions Inc PARTS LIST CONTROL PANEL continuea Where Used QTY Complete Control Panel Assy No gt Kelley _ 6000863 _ 6000854 856 8581 6000855 857 859 6000860 6000861 6000828 6000829 831 833 6000830 832 834 6000835 6000836 Part Description 110 120 1 60 208 240 1 60 208 240 3 60 480360 575 600 3 60 1 Transformer 120V 24 6001045 1 1 1 1 1 Transformer 480 240 120 24 6001046 Transformer 575 120 24 6001047 2 Contactor 6000467 1 1 1 1 1 Contactor 6000457 Overload 12 18 AMPS 6000478 1 1 1 1 1 Overload 5 5 8 AMPS 6000476 Overload 2 5 4 AMPS 6000474 Overload 1 1 6 AMPS 6000472 2 5 AMP Fuse 600Volt F4 F2 6001048 2 2 2 2 2 Pee ea EE C t 7t t 17 2 AMP Fuse 120Volt F5 F7 2 3 AMP Fuse 120Volt F6 Push Button Universal Push Button 40mm Red Body Mounting Collar Block Contact NO Block Contact NC Pilot Light Head Green LED Sj 3 3 4 5 T 0 1 4 a wf Oo O17 B NM 1 X NIO Pilot Light Head Amber LED 633 002 uppressor apacitor not shown Operating Sticker not shown erminal Fused not shown erminal Endplate lain Marker umper Terminal 2 way Terminal 2 conductor nd Stop Screwless not shown ontrol Panel Label Serco ontrol Panel La
18. R SWITCH SUPPLIED BY OTHERS MOTOR ON MOUNTING BRACKET AND WIRED INTO JUNCTION BOX NOTE 2 VEHICLE RESTRAINT INTERLOCK 13 14 LEVELER WILL NOT TO LIGHTS ONLY OVERRIDE ACTIVATED COIL IS MOUNTED ON MOTOR AND WIRED INTO JUNCTION BOX WHEN ENERGIZED THIS VALVE NOTE 3 SV1t SOLENOID 24VAC gt N O VALVE CLOSED WHEN IS DIRECTIONAL FLUID WILL NOT FLOW OUT OF THE ACTIVATED COIL IS MOUNTED WITH VALVE BENEATH RETRACT PORT MOTOR ON MOUNTING BRACKET AND WIRED INTO JUNCTION BOX NOTE 7 1 1 LEVELER STORED SWITCH 24VDC N O SWITCH CLOSED WHEN LEVELER IS STORED MOUNTED ON NOTE 4 SV2 MAIN SOLENOID 24 N C VALVE OPEN WHEN DECK ACTIVATED COIL IS MOUNTED ON MOTOR AND WIRED INTO JUNCTION BOX NOTE 8 LS2 MAINTAINED FLOAT SWITCH 24VDC N O SWITCH CLOSED WHEN LEVELER IS LOWERED TO 37 DEGREES FROM DOCK HEIGHT MOUNTED ON DECK WIRE COLOR LEGEND LEGEND 120VAC RED XXX WIRE NUMBER 120VOLT NEUTRAL WHITE 4 XXXL INE REFERENCE NUMBER DRY CONTACTS YELLOW 24VDC BLUE 24VDC BLUE W WHITE STRIPE PANEL TERMINALS 12VDC PURPLE BM 12VDC PURPLE W WHITE STRIPE FEILD WIRING 30 6001762B Vertical Hydraulic Dock Leveler April 2007 2007 4Front Engineered Solutions Inc ELECTRICAL SCHEMATIC PLC DIAGRAM 208V 575V Fig 19 NOTE BEFORE INSTALLING A VEHICLE RESTRAINT amp CONTROL PANEL THAT WILL BE USED WITH A VERTICAL LEVELER AND ITS CONT
19. ROL PANEL CONSULT FACTORY bl NEUTRAL NOTE REMOVE JUMPERS WHEN CONNECTING EXTERNAL DEVICES gt JUMPER vci DOOR OPENED INTERLOCK LEVELER ENABLE INTERLOCK AUDIBLE ALARM I I z OVERLOAD TRIPPED ae og lt lt A Ul N Zo Zo wS i5 206 EMERGENCY STOP a 6 INSIDE GREEN LIGHT 204 D LT2 L baad N INSIDE AMBER LIGHT LOWER RY DUT COM 1 LIP RETRACT LEVELER MOTOR STARTER LIP EXTEND RAISE LIP SOLENUID SV4 MAINTAINED FLOAT R LEVELER STORED U o Q lt MAIN SOLENOID SV8 AND SV3 PLC120 TWIDU PLC TWDLCAA24DRF POWER DOWN SOLENOID SV1 DC OUT 100 240VAC 120 NOTE 1 DOOR INTERLOCK 415 16 LEVELER WILL NOT NOTE 5 SV3 SOLENOID 24VAC N O VALVE CLOSED WHEN LOWER UNLESS DOOR IS OPENED ACTIVATED COIL IS MOUNTED WITH VALVE BENAETH e4VDC DOOR SWITCH SUPPLIED BY OTHERS MOTOR ON MOUNTING BRACKET AND WIRED INTO JUNCTION NOTE 2 VEHICLE RESTRAINT INTERLOCK 13 14 LEVELER WILL NOT LOWER UNLESS RESTRAINT IS ENGAGED OR HAS BEEN SWITCHED NOTE 6 SV4 SOLENOID 24VAC N O VALVE CLOSED WHEN TO LIGHTS ONLY OVERRIDE ACTIVATED COIL IS MOUNTED ON MOTOR AND WIRED INTO JUNCTION BOX WHEN ENERGIZED THIS VALVE NOTE SVt SOLENOID 24VAC N O VALVE CLOSED WHEN IS DIRECTIONAL FLUID WILL NOT FLOW OUT OF THE ACTIVATED COIL IS MOUNTED WITH VALVE BENEATH RETRACT PORT MOTOR ON MOUNTING BRACKET AND WIRED INTO JUNCTION BOX
20. Vertical Hydraulic Dock Leveler 25 50K Capacity This manual applies to vertical Dock Levelers manufactured beginning November 24 2003 with the serial numbers 63251 and higher User s Manual Do not install operate or service this product unless you sta lati on 7 rati ons 7 have read and understand the Safety Practices Warnings i and Installation and Operating Instructions contained in M an te nance an d Pa rts this User s Manual Failure to do so could result in death Part No 6001762B or serious injury LIMITED WARRANTY 4Front Engineered Solutions warrants to and for the sole benefit of the original purchaser of dock levelers and vehicle restraints manufactured by 4Front Engineered Solutions the Products that the Products shall be free from defects in material and workmanship subject to the following expressed provisions Base Limited Warranty All Products are warranted for one year base period Base Warranty Period commencing on the earlier of the date of 4Front Engineered Solutions approved installation or the sixtieth 60th day after the date of shipment This limited warranty covers the repair or replacement of the defective Product units or components at 4Front Engineered Solutions sole election and expense including reasonable labor travel and freight If the Product is sold to the original purchaser through a 4Front Engineered Solutions dealer or distributor appli
21. al dock leveler uses push button controls to position the ramp Pressing and holding the Lower button operates a hydraulic pump and retracts a hydraulic cylinder to lower the ramp When the ramp is lowered to the working range it floats down to rest on the bed of a trailer forming a bridge After loading pressing and holding the Raise button extends the hydraulic cylinder to raise the ramp to the stored position When the dock leveler reaches its full raised position a second hydraulic cylinder extends the dock leveler lip Push the Emergency Stop when the leveler is stored to prevent operation With the dock leveler in its fully stored position a maintenance post may be secured with a lock out pin to prevent inadvertent operation 6001762B Vertical Hydraulic Dock Leveler 15 2007 4Front Engineered Solutions Inc OPERATING INSTRUCTIONS Safety First 1 Always secure the truck with a vehicle restraint or wheel chocks and set brakes before operating the dock leveler 2 Do not operate dock leveler with anyone standing on or in front of it Press lower button 3 Always keep hands and feet clear of all moving d Pull for power on parts 4 Always restore the leveler to its safe stored vertical position with the lip extended and the Emergency Amber light on Powered Stop button pressed after servicing truck Float down 5 Press EMERGENCY STOP button to stop leveler amp lip from moving 6 DO NOT walk in front of dock
22. all safety warnings before attempting any maintenance procedure Before servicing the dock leveler read and follow the Safety Practices on page 6 and the Operation section in this manual Be certain before doing any maintenance or repair on the dock leveler that 1 THE LEVELER IS STORED IN A VERTICAL POSITION WITH THE LIP EXTENDED AND THE LOCK OUT PIN INSERTED THROUGH THE MAINTENANCE POST AND BRACKET ON DECK and 2 The power is disconnected and properly tagged or locked out Do not enter the area in front of or under the leveler unless the leveler is fully raised and lip extended lock out pin is inserted through the maintenance post and bracket on deck the Emergency Stop button is pressed and barriers are in place If the dock leveler will not raise and it must be raised by external mechanical means to close the dock door use extreme caution and do not allow anyone to stand in front of the leveler Ensure that the lock out pin is inserted through the maintenance post and bracket on deck before the mechanical lifting means is removed If the dock leveler has been raised to the stored position by external means or if the motor pump unit or any hydraulic component or cylinder has been replaced the lock out pin must not be removed from the maintenance post until the hydraulic system has been bled of air and all hydraulic functions have been tested Remove the pin from the main cylinder rod end and perform steps 17 through 24 of
23. ater than the size shown in 24VAC the above schematic or chart for dual element time delay DETD fuses All electrical work must be done by qualified F4 172 AMP 10 AMP 111 Sou technician and must meet all applicable codes All devices shown in de 1L1 24V N energized state NEUTRAL 24VACD TERMINAL CUNNECTIONS FUR PHASE NOTE INCOMING SERVICE DISCONNECT AND FUSING SUPPLIED BY BIBHENS 77777 SV4 N D BUS LIP SOLENOID VALVE SV4 ne er ae ee er eee _4 a i MAIN SOLENOID VALVES SV2 amp SV3 SV1 N C lm m cC e 4 POWER DOWN SOLENOID VALVE SVI es ge a ee NEUTRAL CREMOVE JUMPER IF USED RESTRAINT INTERLLICK CREMOVE JUMPER IF USED DOOR OPENED INTERLOCK SWITCH SWITCH COMMON LSI Eu Sa Mu9 7244 LEVELER STORED SWITCH ee MAINTAINED FLOAT SWITCH 34 6001762B Vertical Hydraulic Dock Leveler April 2007 2007 4Front Engineered Solutions Inc MAIN CYLINDER ADJUSTMENT Before servicing the dock leveler read and follow the Safety Practices on page 6 and the Operation section in this manual Before doing any maintenance or repair on the dock leveler be certain that 1 THE LEVELER IS STORED IN A VERTICAL POSITION WITH THE LIP EXTENDED AND THE LOCK OUT PIN INSERTED THROUGH THE MAINTENANCE POST AND BRACKET ON DECK 2 The Emergency Sto
24. bel Kelley 1 1 1 1 1 3 1 1 1 1 4 20 1 2 NO 5 NO 2 TU 2 2 2 1 1 1 NO NO N 5 26 27 28 29 Brand Specific 4 6001762B Vertical Hydraulic Dock Leveler April 2007 2007 4Front Engineered Solutions Inc U v E gt 5 O 6001056 NOTES April 2007 6001762B Vertical Hydraulic Dock Leveler 45 2007 4Front Engineered Solutions Inc NOTES 46 6001762B Vertical Hydraulic Dock Leveler April 2007 2007 4Front Engineered Solutions Inc NOTES April 2007 6001762B Vertical Hydraulic Dock Leveler 47 2007 4Front Engineered Solutions Inc Please direct questions about your vehicle restraint to your local distributor or to 4Front Engineered Solutions Inc Corporate Head Office Your local distributor is 1612 Hutton Dr Suite 140 Carrollton TX 75006 Tel 972 466 0707 Fax 972 323 2661 2007 4Front Engineered Solutions Inc Part No 6001762B
25. ble Sequence Valve huttle Valve Primary Relief Valve 2 000 PSI ELECTRICAL SCHEMATIC PLC DIAGRAM 120V Fig 18 NOTE BEFORE INSTALLING A VEHICLE RESTRAINT amp CONTROL PANEL THAT WILL BE USED WITH A VERTICAL LEVELER AND ITS CONTROL PANEL CONSULT FACTORY 24V Xe NEUTRAL Em C2 NOTE REMOVE JUMPERS WHEN CONNECTING EXTERNAL DEVICES 15 c ne o lt o Ww JUMPER DOOR OPENED INTERLOCK 182 m LEVELER ENABLE INTERLOCK i AUDIBLE ALARM OVERLOAD TRIPPED 206 sla ES 9 I I 4 ke D EMERGENCY STOP G INSIDE GREEN LIGHT 4 P4 N D 20 LT2 x2 AMBER LIGHT LOWER e INSIDE BE 1 LIP RETRACT LEVELER MOTOR STARTER LIP EXTEND RAISE Og LIP SOLENOID lt SV4 8 F7 MAINTAINED FLOAT LI 203 84 SV N C NOTE 4 4 0 LEVELER STORED RY OU T MAIN SOLENOID SV2 AND SV3 MOV i 3 PLC120 N POWER DOWN SOLENOID SVD oO m na A CJ A Ul EE lt z 100 240VAC O gt za m w 2 HP SV1 N D al I WLDO PLC i o ro NOTE 3 TWDLCAA2ADRF 180v AC D NOTE 1 DOOR INTERLOCK 15 16 LEVELER WILL NOT NOTE 5 SV3 SOLENOID 24VAC gt N O VALVE CLOSED WHEN LOWER UNLESS DOOR IS OPENED ACTIVATED COIL IS MOUNTED WITH VALVE BENAETH 24VDC DOO
26. cable charges for labor travel and freight shall not exceed those set forth in 4Front Engineered Solutions s dealer reimbursement policy Hydraulic Limited Warranty All cylinders and hydraulic power units of the Products described by 4Front Engineered Solutions as VSL products are warranted to cover the cost of replacement parts only of an extended period of four 4 years after the Base Warranty Period Parts amp Assembly Limited Warranty All spare or replacement parts are warranted to cover the cost of replacement parts and freight only for 90 days from the date of shipment THE ABOVE LIMITED WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES EITHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE In no event shall 4Front Engineered Solutions or any of its subsidiaries be responsible for or liable to anyone including any third parties for special indirect collateral punitive incidental or consequential damages Such excluded damages include but are not limited to loss of goodwill loss of profits loss of use interruption of business or other similar indirect financial loss This limited Warranty shall be void and of no effect i if a Product is altered or modified from its original condition as installed or as delivered at or from the factory ii to the extent that the Product defect is the direct result of improper installation operation beyond capa
27. city or other than in accordance with 4Front Engineered Solutions instructions abuse careless or negligent use or failure to maintain the Product as recommended by 4Front Engineered Solutions or iii if the original purchaser does not notify 4Front Engineered Solutions s Warranty Department of the defect within 90 days after the Product defect is discovered 2 6001762B Vertical Hydraulic Dock Leveler April 2007 2007 4Front Engineered Solutions Inc TABLE OF CONTENTS Warranty e r n tuts 2 PLC DIagnoSllCS oce 20 INEFOQUCHON sonreir 3 Hydraulic Power Unit Adjustment 27 Owners Responsibilities 4 Hydraulic Schematic 29 Deck amp Lip 5 Hydraulic Valve Cross Section 29 Salei M 5 Electrical Schematics Safety Practices 6 PEG Diagram 120V 2 22 22 30 MStalallO Merienne US PLC Diagram 208V 575V 31 Components amp Specifications 13 120V Single Phase 32 Hydraulic System Operation 14 208V 230V Single Phase 33 Operating Instructions 208V 57 5V Three Phase 34 IMFO GUCTION eM CERNERET 15 Main Cylinder Adjustment 35 Normal Operation 16 Parts List Storing Leveler
28. cking truck Chocktruck wheels or lock truck into place with truck restraining device and set brakes before loading or unloading Never drive on dock leveler unless Green Light is lit on the dock leveler control panel and the truck bed supports extended lip or ramp is supported by the concrete below Always restore leveler to its safe stored vertical position with lip extended and Emergency Stop button pressed after servicing truck 6 6001762B Vertical Hydraulic Dock Leveler 2007 4Front Engineered Solutions Inc DO NOT walk in front of dock leveler until you Restore the leveler to its safe stored vertical position with lip extended Press Emergency Stop button to stop the leveler and lip from moving Move all equipment material or people off the dock leveler and store the dock leveler after use Do not use a fork truck or other material handling equipment to lower the leveler Many trailers have air ride suspension that may cause the trailer to move away from the dock during loading and unloading operations commonly referred to as trailer walk The potential for trailer walk caused by air ride suspension may be reduced by exhausting or dumping the air from the suspension system before servicing the trailer INSTALLATION MAINTENANCE AND SERVICE Place barricades on the dock floor around the dock leveler and in the driveway in front of the dock leveler while installing maintaining or repairing the dock I
29. cy Stop button is pressed 3 The power is disconnected and properly tagged or locked out 4 Barriers are in place Failure to do so could result in death or serious injury Weekly 1 Check that the lock out pin can be freely inserted through the maintenance post and the bracket on the deck when the leveler is fully raised 2 Check the full operation of the leveler to ensure there is no hesitation in the hydraulic system Any loss of fluid will affect the safety valve operation 3 Inspect that both control panel lights are working and replace bulbs if necessary 4 Clean away any debris from the pit area If washing out take care not to direct spray at any electrical parts 5 Clean away any dirt and debris from the lip hinge April 2007 Quarterly 1 Inspect and lubricate all mechanical pivot points on the leveler with S A E 30 oil Cycle the leveler when lubricating 2 Inspect the hydraulic cylinders valves and hoses for any fluid loss and check the reservoir level with the leveler fully lowered with the lip pendant Add fluid as required fluid level should be 1 2 from top of reservoir 3 Inspect all welds under leveler for fatigue or failure particularly the lip plate hinge and under the top plate 4 Inspect all warning labels and placard Replace as required See page 20 for part numbers and label location 6001762B Vertical Hydraulic Dock Leveler 19 2007 4Front Engineered Solutions I
30. d force should not require adjustment Do not adjust without a pressure gauge or pump may be damaged Shuttle Valve Controls the lowering speed of Remove threaded cap Turn the screw the leveler and directs fluid to clockwise to decrease lowering speed the cylinders when the pump is running Sequence Valve Controls lip plate retraction and Remove threaded cap If the lip extends extension before the deck 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 28 6001762B Vertical Hydraulic Dock Leveler April 2007 2007 4Front Engineered Solutions Inc HYDRAULIC SCHEMATIC Fig 16 MAIN CYLINDER MA mE VELOCITY FUSE 7GPM i m B _ MANIFOLD ASSEMBLY RVI A p meal 1 5 1 ei une LIP CYLINDER PARI by 1 1 PRIMARY RELIEF VALVE 2000 PSI T SV1 POWER DOWN SOLENOID SV2 MAIN SOLENOID A SV3 MAIN SOLENOID B SV4 LIP SOLENOID RVI RELIEF VALVE POWER DOWN 7 22 7 77 on Rossum DU SE HYDRAULIC VALVE CROSS SECTION Fig 17 Lip Extend Port to Main Solenoid Valve A Lip Solenoid SV4 Lip and main cylinders Retract Port OE TUBES Vu ANC URS CH rn N WE Nu EFE Return Po zie S C April 2007 6001762B Vertical Hydraulic Dock Leveler 29 2007 4Front Engineered Solutions Inc Port to Manifold Port A Adjusta
31. e lock out pin can be inserted through the upper end of the maintenance post and the bracket on the deck See Fig 12 page 18 Place a padlock through the hole provided in the lock out pin This will prevent any unauthorized activation of the leveler and is essential to the personal safety of anyone near this leveler 8 6001762B Vertical Hydraulic Dock Leveler 2007 4Front Engineered Solutions Inc Fig 3 Ensure that the leveler is leaning away from the dock door If the leveler is standing vertical or leaning towards the dock door do not proceed with installation The lock out pin must be inserted through the maintenance post and the bracket on the deck The pin must be secured with a padlock before the lifting device is removed Failure to do so could result in death or serious injury See Fig 12 on page 18 for lock out pin location April 2007 INSTALLATION continued 6 Install the center hinge pin Do not force pins through with a hammer as this may damage ring grooves Secure all three leveler hinge pins and the lower pin of the maintenance post with the retaining clips provided See Fig 3 for reference 7 Remove the lifting device from the leveler lip Leave the lip fully extended 8 The hydraulic power unit is pre assembled on a mounting bracket with all valves attached This mounting bracket is designed to suit many different applications The mounting position is specified on the job specific appr
32. eler 6000722 Hose Assy 1 2 x 48 6ft Leveler 3 1959 Hose Assy 1 2 x 72 8ft Leveler 6000724 e o wea _ Oa 0 Wemesmao 9 2 etw ww NPTeao _ 16 1 Remote Mount Hydraulic Power Unit Assy 120 1 60 6000706 Remote Mount Hydraulic Power Unit Assy 208 1 60 6000707 Remote Mount Hydraulic Power Unit Assy 240 1 60 6000864 Remote Mount Hydraulic Power Unit Assy 208 3 60 6000865 Remote Mount Hydraulic Power Unit Assy 240 3 60 6001382 Remote Mount Hydraulic Power Unit Assy 480 3 60 6000867 Remote Mount Hydraulic Power Unit Assy 575 3 60 6000868 Rod End Adjustment Assembly 6001315 40 6001762B Vertical Hydraulic Dock Leveler April 2007 2007 4Front Engineered Solutions Inc PARTS LIST REMOTE MOUNT POWER UNIT ASSEMBLY N LL 6001762B Vertical Hydraulic Dock Leveler 41 April 2007 Inc d Solutions 2007 4Front Engineere PARTS LIST REMOTE MOUNT PUMP ASSEMBLY continued Ps Quantity Part Description Part Number 1 1 Hydraulic Power Unit 115 230V 1 60 313 548 Hydraulic Power Unit 208 460V 3 60 313 549 Hydraulic Power Unit 575V 3 60 313 550 6 2 2Way 2 Port NC Spool Valve PB S2G 00 HC25 2 Way 2 Port NC Poppet Valve PB S2B 00 HC25 8 a Relief Valve 0 800 PSI PB RVA 00 0800 L3 ewo rowo pesonas mans 18 2 single Phase Label Ext on Pump 921 026 Three Phase Label Ext on Pump 921 027 19 2 12
33. ement 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 a way alter the product from its normal working condition at the time of purchase from 4Front Engineered Solutions could result in product malfunction breakdown premature wear 20 death or serious injury d i am Nes l a tHe C S gt C A 4 Z 7 E LX og A 2 Z 7n f 2 N 36 6001762B Vertical Hydraulic Dock Leveler April 2007 2007 4Front Engineered Solutions Inc PARTS LIST DOCKLEVELER continuea Part Description Capacity amp Part Number 25 000 30 000 35 000 40 000 45 000 50 000 1 Hinge Pin 6 ft 586 0017 586 0017 586 0017 586 0287 586 0287 586 0287 Hinge Pin 6 5 ft 586 1494 586 1494 586 1494 586 1495 586 1495 586 1495 1 Hinge Pin 7 ft 586 0201 586 0201 586 0201 586 0392 586 0392 586 0392 Part Number 417 113 6000307 986 1066 236 114 986 1063 231 123 231 126 6000749 6000847 6000873 6000848 6000849 921 017 921 142 341 034 6000295 986 1466 236 110 6001761 6001315 6001762 Quantity Part Description Drive Fit Grease Fitting Lock Out Pin Assy Pin Rear Hinge Hyd Cyl Klipring 1 5304 100 TRUARC Pin 1 Dia
34. es 24VAC Motor NEMA Standard T E N V 56C frame 1 h p 15 mi duty cycle single or three phase Pump Fixed displacement gear pump 1 gpm primary relief valve factory set at 2000 psi Reservoir Capacity 1 U S gal 3 8 lit level measured by dipstick Hydraulic Fluid Acceptable Hydraulic fluids Shell Tellus T 15 Mobil Aero HFA 49011 Exxon Univis Grade J13 Texaco Aircraft Oil 1554 U S Oil Co Inc ZFI 5606 Low Temp HYDRAULIC SYSTEM OPERATION The following describes the operation of the hydraulic and electrical system when the controls are AUDIBLE ALARM e Sounds when leveler stops between working range and fully stored position Will silence when Raise Lower or EMERGENCY STOP is pressed EMERGENCY STOP Push in Power cut off to motor circuit Amber pilot light turns off e Solenoid valves SV2 and SV3 deenergized preventive leveler movement Pull out Power connected to motor circuit Amber pilot light turns on Main solenoid valves SV2 and SV3 remains closed except when pump is running or leveler 1s lowered to working range LOWER Pump starts and shuttle valve shifts Lower solenoid valve SV opens to retract main cylinder When leveler lowers to working range the pump stops the Lower solenoid valve SV1 closes and Main solenoid valves SV2 and SV3 open to allow leveler to float down to the truck bed Lip solenoid valve SV4 closes to prevent lip from retracting
35. f the leveler is left in a disabled condition the lock out pin must be padlocked in position Do not operate the dock leveler when anyone is standing in front of the dock leveler Before doing any maintenance or repair under the leveler be certain that the leveler is stored with the lock out pin inserted through the maintenance post and bracket on the deck the Emergency Stop button is pressed the power is disconnected and properly tagged or locked out and barriers are in place Disconnect the power and properly tag or lock out before entering the pit or doing any maintenance or repair under the leveler All electrical troubleshooting or repair must be done by qualified technician and must meet applicable codes If it is necessary to make troubleshooting checks inside the control box with power on USE EXTREME CAUTION Do not place fingers or uninsulated tools inside the control box Touching wires or other parts inside the control box could result in electrical shock serious injury or death Vertical levelers ship partially disassembled and require field assembly Priorto complete electrical and hydraulic installation levelers should be stored safely If leveleris mounted on hinges and stored vertically the lock out pin must be inserted through the maintenance post and the bracket on deck and secured with a padlock until the leveler is completely wired tested and fully operational April 2007 INSTALLATION OF DOCK LEVELER
36. ic approval drawings Check electrical service running to the control panel to ensure it agrees with the phase and voltage of the motor and control box supplied with the dock leveler See the wiring diagram located inside the control panel Schematics for standard control panels are provided in this manual April 2007 INSTALLATION Make sure lifting devices are in good condition and have a rated capacity of at least 3000 Ib at the lifting angle they are being used Stand clear of the dock leveler when it is being placed into the pit Never allow anyone to stand on or near the dock leveler when it is being lifted or placed into the pit The dock leveler can tip or swing into bystanders which could result in death or serious injury Fig 2 3 4 UNC load centering eyebolt Take care when moving the dock leveler to ensure that the electrical and hydraulic components are not damaged 6001762B Vertical Hydraulic Dock Leveler 2007 4Front Engineered Solutions Inc INSTALLATION continued HANDLING AND UNLOADING The rear fixed hinge channels will be installed first by the concrete contractor In most cases these components will have arrived at the site much earlier than the levelers The levelers will arrive on a truck laid flat with the hydraulic cylinders facing upward Spacers will be inserted between the levelers to prevent damage to the leveler components The levelers can be lifted off the truck in stacks
37. ineered Solutions Inc April 2007 RAMP amp LIP GRADES TRUCK BED DECK and LIP grades for Dock leveler length Leveler 7 from DOCK ee 6 Leveler 8 Leveler a ing DECK LIP GRADE A B C K NENNEN B E L Ww D C K Deck and lip grade 16 lip SAFETY You may find safety signal words such as DANGER WARNING or CAUTION 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 injury or death ACAUTION Indicates an imminently hazardous situation which if Indicates a potentially hazardous situation which if not not avoided will result in death or serious injury avoided may result in minor or moderate injury Indicates a potentially hazardous situation which if not Caution used without the safety alert symbol indicates avoided could result in death or serious injury a potentially hazardous situation which if not avoided may result in property damage April 2007 6001762B Vertical Hydraulic Dock Leveler 5 2007 4Front Engineered Solutions Inc SAFETY PRACTICES 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 understa
38. ly extended If above the operating range press and hold the LOWER button until the Green light on the control panel indicates leveler has reached the operating range Leveler will float down to the truck bed See Fig 11 Amber light off Green light off Press raise button Push for power off Green light on Press to retract lip Press lower button dO Pull for power on Float down Fig 10 Green light Press to raise Press to extend lip Press to lower Lip out Raise Push to stop Pull for Amber light Float down Fig 11 6001762B Vertical Hydraulic Dock Leveler 2007 4Front Engineered Solutions Inc 17 SERVICE TOOLS Before servicing the dock leveler read and follow the Safety Practices on page 6 and the Operation section in this manual Before doing any maintenance or repair on the dock leveler be certain that 1 THE LEVELER IS STORED IN A VERTICAL POSITION WITH THE LIP EXTENDED AND THE LOCK OUT PIN INSERTED THROUGH THE MAINTENANCE POST AND BRACKET ON DECK 2 The Emergency Stop button is pressed 3 Barriers are in place Failure to do so could result in death or serious injury Maintenance Post The vertical dock leveler is equipped with a maintenance post to hold the leveler in the stored position during maintenance Always follow the procedure below when performing maintenance or adjustments of any kind to
39. maintenance personnel for whom such warnings are intended Manufacturer s recommended periodic maintenance and inspection procedures in effect at time of shipment shall be followed and written records of the performance of these procedures should be kept Adock levelerthatis structurally damaged or has experienced a sudden loss of support while under load such as might occur when a transport vehicle is pulled out from under the dock leveler 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 Whenindustrialtrucks are driven on and offtransport vehicles during the loading and unloading operation the brakes on the transport vehicle shall be applied and wheel chocks or positive restraints that provide the equivalent of wheel chocks engaged The dock leveler should never be used outside its vertical working 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 4 6001762B Vertical Hydraulic Dock Leveler 2007 4Front Eng
40. nc PREVENTATIVE MAINTENANCE continues WARNING LABELS AND OPERATION PLACARD LOCATION Call 1 800 525 2010 or 972 466 0707 for free replacements Fig 13 6000847 gi en 6000848 Improperly using dock levelers endangers workers Read and follow the owner s manual and warning and operation placards before operating or performing maintenance on this dock leveler nm DO NOT WALK IN FRONT OF DOCK LEVELER until you Restore the leveler to its safe stored vertical position with the lip extended e Press the Emergency Stop button to stop leveler from moving afa Unsupported docklevelers can lower unexpectedly Before allowing vehicle to leave the dock always Ensure that no equipment material or people are on the dock leveler Restore leveler to its safe stored vertical position with the lip extended Press the Emergency Stop button to stop leveler from moving Failure to follow these instructions could result in death or serious injury 6000847A Before doing any maintenance repair or adjustment on the dock leveler store the lever in a vertical position with lip extended engage the lock out pin in the maintenance post and press the Emergency Stop pushbutton Secure the lock out pin with a padlock if the hydraulic system is disabled Refer to the User s Manual for proper maintenance and adjustment procedures United
41. nd the instructions ask your supervisor to explain them to you or call 4Front Engineered Solutions at 972 466 0707 USA or 519 457 7155 CAN OPERATION Restrict use of dock leveler to trained operators Follow safe operating procedures described in this manual and in the operation placard which was shipped with the leveler The placard should be posted near the leveler If either labels or placard is lost call 1 800 525 2010 or 972 466 0707 for a free replacement Do not use the dock leveler to service trailers outside of its intended working range which is 6 above dock and 6 below the building floor Do not operate the dock leveler when anyone is in front of it Do not operate the dock leveler with equipment material or people on the ramp or lip otay clear of the dock leveler when it is moving KEEP HANDS CLEAR OF HINGES AT ALL TIMES Do not use hands to position dock leveler ramp or lip or to store dock leveler Do not use the dock leveler if it appears damaged or does not operate properly Inform your supervisor immediately Do not attempt to manually lift the dock leveler ramp or lip If the dock leveler does not operate correctly using the operational procedures contained in this manual do not use the leveler Refer to the troubleshooting guide in this manual If Leveler still does not operate properly call an authorized service representative Do not stand in the driveway between the dock leveler and the ba
42. ored position and the lip is fully extended The Green light on the control panel should remain off and the alarm should not sound Insert the lock out pin through the maintenance post and bracket on the deck The pin must insert freely If there is any resistance adjust the hydraulic cylinder as described in steps 17 amp 18 on page 10 April 2007 INSTALLATION continued Fig 4 Typical Bumper Installation using VB420 11F bumpers LJ ANCHOR OPTIONAL ACCORDING TO WALL y e VB420 11F N DOCK BUMPERS 3 4 DIA x 5 WEDGE ANCHOR lt BUMPER MUST HAVE GOOD CONTACT WITH CONCRETE DOCK FACE BUMPER MOUNTING AREA TO BE FLAT UNIFORM amp SMOOTH 6001762B Vertical Hydraulic Dock Leveler 11 2007 4Front Engineered Solutions Inc INSTALLATION continued 25 Remove the lock out pin and lower the leveler as instructed in step 21 Observe the lowering speed of the leveler after it reaches the working range The leveler lowering speed should match the leveler power down portion of the lowering Adjust shuttle valve as necessary see page 28 26 With the leveler in the fully lowered position place each 27 12 bumper assembly on the floor between the leveler and the door jamb A 1 space must be present between the side of the leveler and the nearest face of the bumper assembly This space is important fo
43. oval drawing for the project Fasten the power unit mounting bracket as required 9 Lay cardboard or other absorbent material under the hydraulic power unit This prevents staining the floor in the event of an overflow Place a pan directly under the reservoir to catch any spilled fluid 10 The electrician can now connect the wiring from the control panel to the motor and solenoid valves 11 Mark the 3 hydraulic hoses and the leveler stored and maintained float sensor cables located on the deck with colored tape or numbers for identification Do not remove the plugs from the hydraulic hoses at this time Feed the hose assemblies and the sensor cables through the conduit if equipped 12 Remove the plugs and make the connections to the correct hose fittings Refer to Fig 14 on page 27 and page 3 for the hydraulic hoses connections These fittings are all JIC type and require no thread sealant If the hoses are too long coil the hoses neatly at the bottom of the power unit and secure with plastic ties Do not leave excess hose under the leveler but leave a loop so hoses are not pulled tight see Fig 25 on page 36 Connect the leveler stored and maintain float sensor cables to the control panel Do not remove the lock out pin from the maintenance post until the following steps have been completed to ensure that the leveler is functioning property Failure to do so could result in death or serious injury April 2007 6001762B
44. p button is pressed 3 Barriers are in place Failure to do so could result in death or serious injury This requires a 1 1 2 and 2 open end wrenches Loosen the jam nut on the threaded rod end of the main cylinder NO Using the 2 wrench to hold the chrome cylinder rod tighten the jam nut using the 1 1 2 wrench Turn the chrome cylinder rod clockwise to pull the leveler forward or counter clockwise to push the leveler back until the lockout pin in the maintenance post move freely See Page 18 for maintenance post operation There must not be more than 1 1 2 inches of thread showing on the adjustable rod end If more than 1 1 2 inches of thread shows do not proceed Ensure that the leveler is leaning away from the dock door If the leveler is standing vertical or leaning towards the dock door than the leveler is not in a safe stored position Correct immediately using the steps above Failure to do so could result in death or serious VERTICAL LEVELER IN STORED POSITION Vertical line __p Fig 23 Maintain Float Sensor eveler Stored injury Sensor Nut Adjustable Rod End April 2007 6001762B Vertical Hydraulic Dock Leveler 35 2007 4Front Engineered Solutions Inc PARTS LIST DOCKLEVELER Fig 25 To ensure proper function durability and safety of the product only replac
45. r rod tighten the jam nut using the 1 1 2 wrench Turn the chrome cylinder rod clockwise to pull the leveler forward until the pins in the maintenance post move freely There must not be more than 1 1 2 inches of thread showing on the adjustable rod end below the jam nut If more than 1 1 2 inches of thread shows do not proceed 21 Ensure that the pit area is clear Remove the padlock from the lock out pin Stand at the side of the leveler reach in and remove the lock out pin from the maintenance post 22 Press and hold the Lower button The pump will run and the leveler will move forward and start to lower The alarm will sound if the leveler is stopped between the lowered working range and the stored position Continue to press the Lower button until the pump stops The leveler will hesitate momentarily when it reaches the working range then continue to float down The Green light on the control panel should be on Visually check that the ramp stops are resting on the front curb steel Press the Lip Retract button on the control panel until the lip is pendant 23 Press and hold the Raise button until the leveler is raised above the working range and the Green light goes off Release the pushbutton The leveler should remain position and the alarm should sound Release the pushbutton The leveler should remain in position and the alarm should sound 24 Press and hold the Raise button until the leveler reaches the st
46. r the bottom seal to work properly The bumper assemblies must be welded to the front curb steel using proper weld techniques Vertical down weld passes are not acceptable All applicable anchors must be 3 4 x 6 min depth Refer to Fig 4 Permanently mount the laminated WARNING and OPERATION instruction placard near the dock leveler control panel Command TogegleDesktop 6001762B Vertical Hydraulic Dock Leveler 2007 4Front Engineered Solutions Inc April 2007 COMPONENTS amp SPECIFICATIONS The main components of the leveler are shown below See the Parts List for specific part numbers Fig 5 Velocity Fuse Lip Plate Lip Cylinder Lip Hinge User Warning Label on both sides aiia c RN FE m Warning Deck E P 2d Labels Assembly 15 Lock Out Pin with Warning Tag Maintenance Post Main Lift Cylinder sontro Pane stable Rod End Raise Blue Push button Lip Extend Green Push button Lip Retract Black Push button Lower Yellow Push button Emergency Stop Red Push Pull Mushroom Style Push button DOCK LEVELER April 2007 6001762B Vertical Hydraulic Dock Leveler 13 2007 4Front Engineered Solutions Inc COMPONENTS amp SPECIFICATIONS continued Control Panel Standard NEMA 12 automatic motor starter thermal overload resettable control circuit breaker U L approved Pilot Light LED Solenoid Valv
47. t of overload in control panel a See solution 2 b b Check for voltage at all three motor connections T1 T2 T3 at output of overload in control panel April 2007 TROUBLESHOOTING GUIDE continued Do not disconnect hoses or any hydraulic components unless the leveler is fully raised with lip extended the lockout pin is inserted through the maintenance post Emergency Stop button is pressed and barriers are in place If you do disconnect any hydraulic components remove the pin from the main cylinder rod end and perform steps 17 through 24 of the Installation Instructions on pages 10 and 11 before removing the lockout pin from the maintenance post and bracket on deck Failure to do so could result in death or serious injury Problem Possible Cause 5 Leveler does not raise or lower Motor Low fluid in reservoir runs b Main solenoid valves SV2 amp SV3 do not open c Pump running in reverse three phase only d Pump damaged or broken internally 6 Leveler will not lower Motor runs and leveler raises e Insufficient pressure Primary relief valve setting too low a Lower solenoid valve SV1 does not open b Automatic safety stop velocity fuse is locked Solution a Check fluid level with leveler fully lowered Oil level should be 1 2 3 4 bwlow top of reservoir with lip pendant Add oil if required b Check for magnetism at solenoid coil If magnetism present
48. the dock leveler 1 Raise the leveler to its fully stored position with the lip extended 2 Press the EMERGENCY Stop Button on the control panel 3 Insert the Lock Out Pin through the maintenance post and the bracket on the deck Reach from the side of the leveler while inserting Lock Out Pin The Lock Out Pin should insert freely 4 Place a padlock through the hole in the Lock Out Pin to prevent accidental activation of the dock leveler 5 Place barricades around the dock leveler to show leveler is out of service 18 6001762B Vertical Hydraulic Dock Leveler 2007 4Front Engineered Solutions Inc Fig 12 be Padlock Guide Bracket Lock Out Pin Warning Tag er AK C n quini D 57 2 Te XS 09 S Af fo C Y J Qi a Ji QOH M Ke J TAN 5 PASS April 2007 PREVENTATIVE MAINTENANCE To ensure the continued good operation of your dock leveler perform the following preventative maintenance procedures Before servicing the dock leveler read and follow the Safety Practices on page 6 and the Operation section in this manual Before doing any maintenance or repair on the dock leveler be certain that 1 THE LEVELER IS STORED IN A VERTICAL POSITION WITH THE LIP EXTENDED AND THE LOCK OUT PIN INSERTED THROUGH THE MAINTENANCE POST AND BRACKET ON DECK 2 The Emergen
49. the Installation Instructions on pages 10 and 11 If the dock leveler has been raised to the stored position by external means there may be a vacuum exerting a strong retracting force on the cylinder rod Loosen the hydraulic hose fitting on the top port of the main cylinder and allow air to fill the vacuum before attempting to remove the pin from the cylinder rod end Failure to do so could result in death or serious injury April 2007 Do not disconnect hoses unless the leveler is fully raised with lip extended the lockout pin is inserted through the maintenance post Emergency Stop button is pressed and barriers are in place After replacing hoses and or motor pump cycle the leveler at least 4 times to remove air from the cylinder Check oil and add if required Failure to do so could result in death or serious injury 6001762B Vertical Hydraulic Dock Leveler 21 2007 4Front Engineered Solutions Inc TROUBLESHOOTING GUIDE continued Do not disconnect hoses or any hydraulic components unless the leveler is fully raised with lip extended the lockout pin is inserted through the maintenance post Emergency Stop button is pressed and barriers are in place If you do disconnect any hydraulic components remove the pin from the main cylinder rod end and perform steps 17 through 24 of the Installation Instructions on pages 10 and 11 before removing the lockout pin from the maintenance post and bracket on deck Failure
50. the truck wheels are chocked or that the truck is locked in place by a truck restraining device and the brakes are set before loading or unloading Trucks pulling away unexpectedly can cause uncontrolled drop of the dock leveler which can result in death or serious injury Never drive on dock leveler unless Green Light is lit on the dock leveler control panel and truck bed supports the extended lip or the ramp is supported by the concrete below Always return the dock leveler to its safe stored vertical position with lip extended with the Emergency Stop button pressed after servicing truck If the truck pulls away before the dock leveler is stored the lip will fall to its pendant position and will not be supported In addition failure to properly store the dock leveler may leave the leveler in a position below dock level These conditions may result in unexpected drop of personnel or material handling equipment and result in death or serious injury DO NOT walk in front of dock leveler until you Restore the leveler to its safe stored vertical position with lip extended Press Emergency Stop button to stop the leveler from moving April 2007 OPERATING INSTRUCTIONS INTRODUCTION The 4Front Engineered Solutions vertical dock leveler is designed to span and compensate for space and height differences between a loading dock and freight carrier to allow safe efficient freight transfers The 4Front Engineered Solutions vertic
51. until the lip is fully retracted Then press the Lip Extend button and hold until the lip is fully extended Then press the Lip Retract button again and hold until the lip is fully retracted This will eliminate air from the lip cylinder Run both cylinders in out a minimum of 4 times until any abrupt motion is eliminated 18 With both the main cylinder and the lip cylinder retracted 19 10 check the oil level in the reservoir Oil should be clear and within 1 2 of the top with the lip plate fully retracted Add oil if necessary See page 14 under Components amp opecifications for hydraulic fluid specifications If the oil is foamy leave for approximately 15 minutes to let the oil settle before checking oil level This step requires 1 1 2 and 2 open end wrenches Loosen the jam nut on the threaded rod end of the main cylinder Press the Raise button and hold until the main cylinder is fully extended With the main cylinder rod fully extended rotate the rod end so that the pivot pin can be inserted freely through the cylinder pivot on the embedded channel frame Secure the pivot pin with the clips provided See page 35 Ensure the grease fitting 6001762B Vertical Hydraulic Dock Leveler 2007 4Front Engineered Solutions Inc April 2007 Incorrect hydraulic power unit adjustment that allows the leveler to descend rapidly could result in death or serious injury 20 Using the 2 wrench to hold the chrome cylinde
52. veler floats down too fast or too slowly in Float range 8 Lip plate will not extend or extends too slowly 9 Lip plate extends too soon 10 Lip plate will not stay out falls as leveler is lowering 11 Lock out pin can not be freely inserted through the maintenance post and the bracket on the deck when the leveler is fully raised 24 6001762B Vertical Hydraulic Dock Leveler 2007 4Front Engineered Solutions Inc Possible Cause a Shuttle valve requires adjustment a Low fluid level in reservoir b Sequence valve pressure set too high c Lip hinge binding d Primary relief valve pressure set too low a Sequence valve pressure set too low a Pilot check valve is leaking b Lip cylinder is damaged a Main cylinder adjustable rod end needs adjustment Solution a Adjust shuttle valve Turn counter clockwise to increase lowering speed or clockwise to decrease speed Lowering speed in Float range should equal lowering speed when powered See page 28 a Check fluid level with leveler fully lowered Oil level should be 1 2 3 4 below top of reservoir with lip pendant Add oil if required b Decrease sequence valve setting See page 28 c Inspect hinge area for damage or trapped debris d Set primary relief valve to 2000 PSI See page 28 Do not adjust relief valve without a pressure gauge a Turn sequence valve clockwise to increase pressure so the lip plate does
53. x 2 3 16 GR RNG SK Pins 215 250 1500 or equal 25 35K SLK Pins 218 250 2250 or equal 40 50K Float Stored Sensor Assy User Warning Label Lock Out Tag Warning Maintenance Label Warning Lockout Label DP Serial Label Leveler Information Tag PadLock Toggle Lockout Maintenance Post Vertical Lock Pin Klipring 3 4 5304 75 TRUARC Wall Mounted Placard Safety and Operations Rod End Adj Assy User s Manual NO NI April 2007 6001762B Vertical Hydraulic Dock Leveler 3 2007 4Front Engineered Solutions Inc PARTS LIST DOCKLEVELER continuea Qty Part Description Capacity amp Part Number T 50 000 3 3382 3 3383 Lip Assy 7 ft x 16 in 3 Taper 3 3807 Lip Assy 7 ft x 18 in 3 Taper 3 3808 Lip Assy 7 ft x 20 in 6 Taper 3 3388 38 6001762 Vertical Hydraulic Dock Leveler April 2007 2007 4Front Engineered Solutions Inc PARTS LIST HYDRAULIC Fig 26 DETAILA LL JH To Lip Cylinder Extend To Main amp Lip Cylinder Retract Tee To Main Cylinder Extend April 2007 6001762B Vertical Hydraulic Dock Leveler 39 2007 4Front Engineered Solutions Inc PARTS LIST HYDRAULIC continued Mem Quantity Part Description Part Number Lock Nut 1 4 20 UNC NYLOCK 214 502 Hose Assy 1 2 x 24 ft 3 1650 Hose Assy 1 2 x 24 3 1961 Hose Assy 1 2 x 37 5ft Lev

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