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User`s Manual - Curlin, Inc.

1. Fig 28 MAI CYLINDER E SIDE SHIFT CYLINDER LIP P d CYLINDER APT z SV5 C2 1 6 SAE 6 SAE 6 SAE E l SV4 SV3 2 i 5 2 Y x EEG NG ADJUST E NEEDLE CVS EM PC2 5 2 2 1 aig e e pc 9 7 POWER DOW gens NEEDLE VALVE x 1 0 lt gt rU L1 1 2 July 2012 6003936K Hydraulic Rail Leveler 33 2012 4Front Engineered Solutions Inc PARTS LIST DOCK LEVELER A WARNING 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 could result in product malfunction breakdown premature wear death or serious injury Fig 29 Note 1 Items 2 36 and 48 not shown 2 Assemble 65 grease zerk for vertical rollers with ball port towa
2. Fig 20 Pins E i s ain Hoses weekly quarterly ____ 1 ul 00000 udi Hinge pins 4 places Rollers T Maintenance strut 6 places 1 place 18 6003936K Hydraulic Rail Leveler July 2012 92012 Engineered Solutions Inc Fig 21 6004112 PLANNED MAINTENANCE continued CRUSH HAZARD DO NOT WALK s FRONT OF DOCK LEVELER until you Restore the dock leveler to its safe stored vertical position with lip fully extended Press the Leveler Stop button to stop leveler from moving Unsupported dock levelers can lower unexpectedly Ensure dock leveler is properly supported by lip or U
3. 13A Block Contact 632 228 4 13B Block Contact NO 632 228 2 Contactor 6000467 Contactor 6000457 3 Overload 12 18 AMPS 6000478 6000477 6000476 Overload 4 6 AMPS 6000475 Overload 1 6 2 5 AMPS 6000473 2 5A 600V time delay F1 2 600V time delay E 0 25A 1 4 Block Contact 632 229 832 109 oe E a Non hydraulic side shift Hydraulic side shift only July 2012 6003936K Hydraulic Rail Leveler 47 92012 4Front Engineered Solutions Inc PARTS LIST CONTROL PANEL continued Where Used QTY Kelley Standard 6004100V1 6004100V2 3 6004100 4 5 6004100V6 6004100V7 6004100V8 Serco Standard 6004090V1 6004090 2 3 6004090 4 5 6004090 6 6004090 7 6004090 8 6004809V1 6004809V2 3 6004809V4 5 6004809 6 6004809V7 6004809 8 6004810V1 6004810 2 3 6004810V4 5 6004810v6 6004810 7 6004810 8 End Stop Screwless NS 2 A Control Panel Label Serco 6004114 1 1 1 1 1 1 28B Control Panel Label 6004782 1 1 1 1 1 1 Complete Control Panel Assy No amber Piot Light Module 6006842 Green Piot Light Module 600684 NOTE See electrical schematics located at the end of this manual 48 6003936K Hydraulic Rail Leveler July 2012 2012 4Front Engineered Solutions Inc NOTES July 2012 6003936K Hydraulic Rail Leveler 49 92012 4Fron
4. completed always Ensure that no equipment material people dock Restore dock leveler to its safe stored vertical position with lip fully extended Press the Leveler Stop button to stop leveler from moving SAFETY INSTRUCTIONS OPERATION Read and follow all instructions and warnings in user s manual Use of dock leveler restricted to trained operators Always restrain rail car from moving before operating dock leveler or beginning to load or unload Never use hands or equipment to move ramp or lip Before activating dock leveler Check rail car alignment If misaligned side shift leveler as required before lowering Ensure rail car supports extended lip or arm assemblies and green light is on before driving on ramp Stay clear of hinges and front and sides of moving dock leveler Never use damaged or malfunctioning dock leveler Report problems immediately to supervisor o MAINTENANCE SERVICE Read and follow all instructions warnings and maintenance schedules in user s manual Maintenance Service of dock leveler restricted to trained personnel Place barriers in front of leveler and on dock floor to show service work is being performed 4 DO NOT SERVICE LEVELER unless dock leveler is securely supported by maintenance lock out pin 5 Turn off power and use OSHA lockout tagout procedures 6 Secure the lock out
5. 1161 1 2 1 GR 120 20 NE from 324 e rom 3251 LEGEND PANEL WIRING FIELD WIRING BY OTHERS Epp Mn fs KELLEY AFRONT ENGINEERED SOLUTIONS SERCO wy 1612 HUTTON DR CARROLLTON TX 75006 TEL 972 466 0707 800 525 2010 FAX 972 523 2665 HYDRAULIC RAIL LEVELER HRL 07 24 12 ADD BUCHER MOTOR DETAIL BAR IS ONE INCH LONG ON SINGLE PHASE POWER DISTRIBUTION 120 240V 1PH 60HZ THIS DRAWING IS INTENDED FOR USE ON THE PROJECT ONE INCH ON THIS SHEET 05 24 07 INITIAL RELEASE LISTED HEREIN REPRODUCTION IS AUTHORIZED BY ADJUST SCALE ACCORDINGLY DWG No SCALE FILE SHT OF REV PREV ENGINEERED SOLUTIONS FORE USE THIS 6004100 NONE 6004100C1 1 5 200 THREE PHASE PANEL REFERENCE SESH 21 208 575V 3PH 60HZ 380V 3PH 50HZ FUSES 0 PRIMARY FUSING AND DISCONNECT BY OTHERS 6004090V5 6004810V5 202 PANEL FLA SEE CHART LEVELER can NOTE LEVELER MOTOR WIRED T T 1 DIRECTLY TO OVERLOAD 011 wo ZENTREN PE x USE CLASS CC TIME DELAY FUSES L2 2041 X MOT204 EEEE ns 204 32 47 42 TS DECAL REFERENCE 2 2042 ido EELE EEEE cae a DECAL P N n 91 6004115 7 pee 6004114 MOTOR DETAIL 6004782 6004781 600V THREE P
6. This procedure is to be performed ONLY when the leveler is working properly but when properly stored vertically with the lip extended the lock out pin will not fit into the hole in the maintenance strut This procedure requires a 1 1 2 and 2 open end wrenches It will describe how to change the length of the main cylinder without disconnecting the upper or lower pins A DANGER Before starting this procedure read and follow the Safety Practices on page 3 and the Operation section in this manual and be certain that 1 THE LEVELER IS STORED IN A VERTICAL POSITION WITH THE LIP EXTENDED 2 The LEVELER STOP button is pressed 3 Barriers are in place There must not be more than 1 1 2 of thread showing on the adjustable rod end below the jam nut If more than 1 1 2 of thread shows do not proceed Failure to do so could result in death or serious injury 1 Pull the LEVELER STOP button out 2 Press and hold the LOWER button until the leveler deck is vertical instead of leaning back away from the rail tracks 3 Press the LEVELER STOP button in There must not be more than 1 1 2 of thread showing on the adjustable rod end below the jam nut If more than 1 1 2 of thread shows do not proceed 4 Loosen the jam nut on the rod end adjuster at the bottom end of the main lifting cylinder with the 1 1 2 wrench and using the 2 wrench rotate the cylinder rod by the flats machined in the end of the rod to make the cylin
7. NO COIL 1 2 SOLENOID 24VAC TYPE DELTA POWER 313564 5 RETAINING NUT 1 2 SOLENOID 6011725 HOSE ASSY 3 8ID X 15 8 LOA 90 EL 6 JIC F SW X STR 6 JIC F SW 6013004 NI N co N WO WT O 2 6003936K Hydraulic Rail Leveler July 2012 92012 Engineered Solutions Inc PARTS LIST SIDE SHIFT HYDRAULIC ASSEMBLY continued Fig 33 29 lt A SAAS gt AS ASS SAN July 2012 6003936K Hydraulic Rail Leveler 43 2012 4Front Engineered Solutions Inc PARTS LIST SIDE SHIFT HYDRAULIC ASSEMBLY continued Nr HOSE ASSY 1 21D X 72 5 LOA 90 EL 8 JIC F SW X STR 8 JIC F SW 6008056 HOSE ASSY 1 4 ID X 26 5 LOA STR 6 JIC F SW X STR 6 JIC F SW 31961 HOSE ASSY 1 4 ID X 51 LOA STR 6 JIC F SW X STR 6 JIC F SW 6002304 FTG 90 EL 6 JIC M X 1 2 NPT M 206074 NO PW 1 BOLT SIZE 1 1 16 HOLE 234161 HYD SS CYLINDER 3 BORE X LG CONTACT FACTORY 3 4 DIA X 5 WEDGE ANCHOR 6001187 3 4 10 UNC LOCK NUT 214558 NO NO MT NO HEX BOLT 5 16 18 X 1 LG 212064 1 oO 4 35 4 6003936K Hydraulic Rail Leveler July 2012 92012 Engineered Solutions Inc
8. pages 30 31 a Adjust Needle Valve FNV Turn counter clockwise to increase lowering speed or clockwise to decrease speed The speed of the deck while lowering in the float range should be equal to the speed in the powered range See pages 30 31 a Confirm SV1 solenoid coil is de engergized Inspect SV1 for contamination and then replace solenoid valve July 2012 PROBLEM 9 Lip plate will not extend or extends too slowly 10 Lip plate extends too soon 11 Lip plate will not stay out falls as leveler is lowering 12 Lock out pin can not be freely inserted through the maintenance strut and the bracket on the deck when the leveler is fully raised 13 Audible alarm sounds when leveler is in the stored position 14 Leveler will not enter Float range when lowered no green light on control panel alarm continues to sound and leveler stops when in working range July 2012 TROUBLESHOOTING GUIDE continued POSSIBLE CAUSE a Low fluid level in reservoir b Sequence valve pressure set too high 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 solenoid not closing c Lip cylinder is damaged a Main cylinder adjustable rod end needs adjustment a Main cylinder rod end adjuster not adjusted correctly b Leveler stored proximity sensor damaged or connection to sensor los
9. 10 Hydraulic Schematic 32 Hydraulic System Operation 11 Pans Ciste nee 34 SF AO INS T2 51 ges 16 Distributor Information 52 INTRODUCTION Welcome and thank you for choosing this hydraulic rail leveler for your material handling applications This User s Manual contains information that you need to safely install and identify parts for the hydraulic rail leveler Please read and follow this User s Manual when installing the hydraulic rail leveler 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 A DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury NOTICE Indicates a potentially hazardous situation which if Notice is used to address practices not related to not avoided could result in death or serious injury 2 6003
10. PARTS LIST CONTROL PANEL Without Optional Side Shift Fig 34 DANGER 2690 59 P ror PER Los hl NC ONE Ai a DO NOT DRIVE ON DOCK LEVELER UNLESS GREEN LIGHT IS ON Gees egt e 32 GREEN LIGHT 34 DOCK LEVELER Use by untrained personnel could result in death or serious injury Do not operate with anyone standing on or in front of the dock leveler Never drive on leveler unless the green and amber lights on the controls are lit and the leveler is supported by the rail car bed Read the Owner s manual before operating making adjustments or repairs 1570 MS Anat ve siga 3 i amp Fa tine NAG tgo s TP Tes 22524 URRI a NEL udi Power On LEVELER STOP Pushintostop Pulltorelease AMBER LIGHT um July 2012 6003936K Hydraulic Rail Leveler 45 2012 4Front Engineered Solutions Inc PARTS LIST CONTROL PANEL continued With optional hydraulic side shift Fig 35 DANGER MEE Pon N ito aires 27 DO DRIVE ON DOCK om LEVELER
11. Practices on page 3 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 control panel If either labels or placard is lost contact your local authorized distributor for replacement DO NOT USE DOCK LEVELER IF IT LOOKS DAMAGED OR DOES NOT SEEM TO WORK PROPERLY Inform your supervisor immediately Always secure the rail car to make sure it cannot move before operating the dock leveler Always keep hands and feet clear of all moving parts Never drive on dock leveler unless GREEN LIGHT is lit on the dock leveler control panel AND rail car supports either the extended lip or both arm assemblies with at least 4 of overlap A DANGER Do not operate the dock leveler with anyone standing on or in front of it DO NOT walk in front of dock leveler until you Restore the leveler to its safe stored vertical position with lip extended Press the LEVELER STOP button to stop the leveler from moving Always return the dock leveler to its safe stored vertical position with lip extended with the LEVELER STOP button pressed and the GREEN and AMBER LIGHTS OFF after servicing rail car Failure to observe these warnings could result in death or serious injury If the dock leveler will not raise with the RAISE pushbutton and it must be raised by external mechanical means
12. et Nen jJ UNLESSGHEEN ASA in LIGHT LIGHT IS ON SUED TELE DOCK LEVELER Cae tain SIDE SHIFT RESET xa E geriet P Aes y s bsp on Lip Extend ON Big cde T 1 SNAP gr Came GEA ash pn bss Power ON Do not use leveler if light is flashing stop Pulltorelease AMBER LIGHT 46 6003936K Hydraulic Rail Leveler 92012 4Front Engineered Solutions Inc July 2012 PARTS LIST CONTROL PANEL continued Where Used QTY Kelley Standard 6004100V1 6004100 2 3 6004100 4 5 6004100V6 6004100V7 6004100V8 1 WM F au uu Complete Control Panel Assy No Saco Senda Transformer 120V 24 6001045 Transformer 480 240 120 24 6001046 Transformer 575 120 24 6001047 Overload 9 13 AMPS Overload 5 5 8 AMPS m 4A 600V time delay FNQ R 4 FNQ R 2 1 2 1 FNQ R 2 F1 1A 600V time delay FNQ R 1 F1 0 8A 600V time delay 8 10 pjmswmwweme we 2
13. light is flashing replace PLC e Both leveler float and stored inputs e Inspect repair or replace proximity ON sensors 2 Leveler does not raise or lower a Loose wiring connection a Check all wiring connections from line motor starts then stops motor to motor starter relay overload and to starter relay chatters motor b Voltage drop due to long wiring b Check voltage when motor is started distance from power source Voltage drop is more often a problem on single phase motors Verify wire gage is adequate for length of wire 3 Overload relay tripping check a Overload relay set too low a Set overload to full load current full load amperage and relay specified for voltage on motor setting nameplate Loss of 1 phase Three phase only b Check for voltage at all three motor connections T1 T2 T3 at output of overload in control panel 4 Leveler does not raise or lower a Voltage drop a See solution 2 b Motor hums Loss of 1 phase Three phase only b Check for voltage at all three motor connections T1 T2 T3 at output of overload in control panel July 2012 6003936K Hydraulic Rail Leveler 21 2012 4Front Engineered Solutions Inc TROUBLESHOOTING GUIDE continued PROBLEM 5 Leveler does not raise or lower Motor runs 6 Leveler will not lower Motor runs and leveler raises 7 Leveler floats down too fast or too slowly in float range 8 Leveler will not
14. lip or both arm assemblies with at least 4 of overlap July 2012 6003936K Hydraulic Rail Leveler 13 2012 4Front Engineered Solutions Inc OPERATIONS continued 3 Toreturn the leveler to its vertical stored position press and hold the RAISE button GREEN light will turn off Audible horn 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 LEVELER STOP button to turn off power AMBER light off See Fig 14 END LOADING OPERATION 1 If the leveler lip will interfere with adding or removing a pallet an end load must be performed Pull the LEVELER STOP button to switch on power AMBER light indicates power on Press LOWER button until the leveler is partially lowered Press LIP RETRACT button until lip is fully retracted Press LOWER button until leveler is just above working range Push in LEVELER STOP button to halt leveler movement Extend both arm assemblies so that arms will land on the floor of rail car with at least 4 of overlap Make sure the T bolts are tightened Pull out LEVELER STOP button and press LOWER button until GREEN light on leveler control panel indicates leveler has reached the operating range Leveler will float down to the rail car floor See Fig 15 2 To reposition the leveler for normal loading unloading press the RAISE button and hold until lip is clear of the rail car Press the L
15. 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 6003936K 100 101 102 105 104 105 106 107 108 109 110 111 112 115 114 115 116 117 118 119 120 121 122 SINGLE PHASE PANEL REFERENCE 120V 1PH 60HZ UU CL sme DISCONNECT BY OTHERS 120 amp s2ri 5004090 1 600410071 eo04810vi PANEL FLA SEE CHART LEVELER 208 25 j 96FlA 10 56 6004090 2 6004810 2 24 soa essa 60040903 600410073 60048105 6004809V3 MOT103 L 1031 M1 OL1 1032 USE CLASS TIME DELAY FUSES 2 450 12 1055 l DECAL REFERENCE EE Lo 1041 n 6004115 e 6004114 Er S MOTOR DETAIL F1 110 115V SINGLE PHASE 3251 350VA 3261 X 24VAC from 326 g 3261 NE NOTE VISUALLY CONFIRM MOTOR TAG 120VAC from 324 from 325 N 208 230V SINGLE PHASE 50 60HZ 3251 208 240 1 PH 60HZ NOTE VISUALLY CONFIRM MOTOR TAG PRIMARY FUSING AND DISCONNECT BY OTHERS PANEL FLA SEE CHART CONTACTOR MOT114 L1 1141 M1 1142 _ ___ LEVELER MOTOR 1 a RPM ge 1152 1 A Ul
16. pin with a padlock if the hydraulic system is disabled ES Failure to follow posted instructions could result in death or serious injury 6004112 824 001 H o rm 6007867 A DANGER CRUSH HAZARD Before doing any maintenance repair or adjustments on the dock leveler store the leveler in a vertical position with lip extended and engage the lock out pin in the maintenance strut Do not remove the lock out pin from the maintenance strut 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 strut If the pin does not slide freely support the leveler securely using other means and determine the cause of the interference Failure to follow these instructions will result in death or serious injury Refer to user s manual for proper procedure 6007867A 6000873 DANGER Do not remove the lock out pin from the maintenance post unless authorized personnel 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 Refer to user s manual for proper procedure 6000873D KEEP CLEAR 6004101 OPERATI
17. raise Motor runs 22 2012 4Front Engineered Solutions Inc POSSIBLE CAUSE a Low fluid in reservoir b Main solenoid valve SV2 and or SV3 does not open c Pump running in reverse d Pump damaged or broken internally e Insufficient pressure Primary relief valve RV1 setting too low a Lower solenoid valve SV1 does not open b NV1 needle valve set too tight a Needle Valve FNV requires adjustment a Solenoid valve SV1 not closed 6003936K Hydraulic Rail Leveler SOLUTION 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 Check for magnetism at solenoid coil If magnetism present remove and inspect valve for contamination and then replace solenoid valve c Check motor rotation and reverse electrical connections T1 and T2 if necessary d With the leveler safely secured by the lock out pin inserted in the maintenance strut 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 RV1 to 2500 PSI See page 30 and 31 a Check for magnetism at solenoid coil If magnetism present remove and inspect valve for contamination and then replace solenoid valve b Adjust NV1 needle valve CCW See hydraulic power unit adjustment on
18. 409 410 p 411 412 120 gem gt 413 ANCHOR WIRE BUNDLES TO THIS FLAT ANCHOR WIRE BUNDLES TO THIS FLAT ANCHOR AGAIN AT WALL ENTRY 414 ANCHOR AGAIN AT WALL ENTRY BIND WITH SPIRAL TAPE BIND WITH SPIRAL TAPE A E 415 SIDE SHIFT 416 417 Y SEE 418 way DETAIL 419 LIP 420 MAIN POWER DOWN 421 MAIN TAG LEGEND DETAIL A 6XX XXX P N PExx TAG 422 LINE REFERENCE 2xx ARBITRARI ee me DESCRIPTIONS DWN YOUNGBLOOD DATE 2 22 2007 mU CDM DRE ose ____ CK fome ____ SERCO AP WE _____ 612 HUTTON DR CARROLLTON TX 75006 TEL 972 466 0707 800 525 2010 FAX 972 323 2663 KELLEY ENGINEERED SOLUTIONS C 07 24 12 ADD BUCHER ELEVATION DETAIL B 06 10 10 MDY REMOVE J BOX ELEVATION DETAL _ A 05 24 07 MY INTIAL RELEASE PREV DATE REVISION AP THIS DRAWING IS INTENDED FOR USE ON THE PROJECT LISTED HEREIN REPRODUCTION IS AUTHORIZED BY 4FRONT ENGINEERED SOLUTIONS FOR USE ON THIS PROJECT ONLY 0 1 BAR 15 ONE LONG ON ORIGINAL DRAWING IF ONE INCH ON THIS SHEET ADJUST SCALE ACCORDINGLY HYDRAULIC RAIL LEVELER HRL ELEVATION DETAIL STANDARD and POWERED SIDESHIFT DWG No SCALE FILE SHT OF REV 6004100 NONE 6004100C5 5 5 C
19. 48YZ 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 2500 PSI sequence valve factory set at 2000 PSI Cycle Times Lower 16 sec 3 sec Raise 30 sec 5 Sec Reservoir Capacity 1 0 5 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 ZZFI 5606 Low Temp HYDRAULIC SYSTEM OPERATION AUDIBLE HORN Sounds when leveler stops between float and fully stored position Will silence when leveler is raised to stored position or LEVELER STOP is pressed LEVELER STOP BUTTON Push in Control circuit disabled AMBER pilot light turns off Solenoid valves SV2 and 5 3 deenergize preventing leveler movement Pull out Control circuit disabled AMBER pilot light turns on Main solenoid valves SV2 and SV3 remain closed except when pump is running or leveler is lowered to working range LOWER BUTTON Pump starts Power down solenoid valve SV1 opens to retract main cylinder When leveler lowers to working range the pumps stops the power down solenoid valve SV1 closes and Main solenoid valves SV2 and SV3 open to allow leveler to float down to rail car floor GREEN pilot light turns on when leveler reaches working range RAISE BUTTON Pump starts
20. 7 26 PROTECTIVE HOSE WRAP POLY SPIRAL 6013570 101 NI 1 1 2 20 2 2 23 2 5 4 1 1 1 1 1 1 2 1 1 2 1 2 2 1 1 4 4 2 2 2 2 2 1 1 1 0 6003936K Hydraulic Rail Leveler July 2012 92012 Engineered Solutions Inc PARTS LIST SIDE SHIFT POWER UNIT continuea Fig 32 July 2012 6003936K Hydraulic Rail Leveler 41 2012 4Front Engineered Solutions Inc PARTS LIST SIDE SHIFT POWER UNIT continued Dem mae 1 1 BUCHER 120V 1 PH 50 60 HZ PUMP UNIT 6012602 BUCHER 220V 1 PH 50 60 HZ PUMP UNIT 6012602 BUCHER 240V 3 PH 50 60 HZ PUMP UNIT 6012603 BUCHER 480V 3 PH 50 60 HZ PUMP UNIT 6012603 BUCHER 575V 3 PH 50 60 HZ PUMP UNIT 6012604 SOLENOID VALVE 2W2P 8 NC POPPET SV3 amp SV4 DSV 080 2NCP BNC 3 HOME RUN CABLE QD 8 LEAD VOLTAGE LABEL EXT ON PUMP 120 VOLT 921051 VOLTAGE LABEL EXT ON PUMP 208 VOLT 921050 lt gt VOLTAGE LABEL EXT ON PUMP 240 VOLT 921052 VOLTAGE LABEL EXT ON PUMP 480 VOLT 921053 VOLTAGE LABEL EXT ON PUMP 575 VOLT 921054 PHASE LABEL EXT ON PUMP SINGLE PHASE PHASE LABEL EXT ON PUMP THREE PHASE 921027 POWER CABLE SO 14 4 X 60 LG POWER CABLE SO 14 3 X 60 LG 172607 7 NI N wj N NI N NI NI
21. 936K Hydraulic Rail Leveler 92012 4Front Engineered Solutions Inc personal injury July 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 contact your local authorized distributor 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 contact your local authorized distributor for a replacement Do not use the dock leveler to service rail cars outside of its intended working range See page 5 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 Stay 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 no
22. EVELER STOP button Retract both arm assemblies Press the LIP EXTEND button until the lip is fully extended Press and hold the LOWER button until GREEN light on leveler control panel indicates the leveler has reached the operating range Leveler will float down to the rail car floor See Fig 16 3 Toreturn the leveler to its vertical stored position press and hold the RAISE button GREEN light will turn off Audible horn 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 LEVELER STOP button to turn off power AMBER light off See Fig 14 Fig 14 Press Raise button 9 Push for power off Fig 15 Press to retract lip Press Lower button eL Pull for power on Fig 16 Press to raise Press to extend lip 14 6003936K Hydraulic Rail Leveler July 2012 92012 4Front Engineered Solutions Inc OPERATION S continued HYDRAULIC SIDE SHIFT OPERATION Fig 17 If equipped The optional hydraulic side shift feature on the hydraulic rail Side shift selector switch Left Right is viewed levelers is operated by a hydraulic cylinder that positions the from the building side of the leveler entire dock leveler left or right along the rail connected to the embed channel Ensure the leveler is stored in the upright vertical position Turn selector switch left or right to position the leve
23. F CONNECTOR 90 DEG 1 2 5 8 145084 22 POWER CABLE SO 14 4 X 60 LG 172603 POWER CABLE SO 14 3 X 60 LG 172607 8 6003936K Hydraulic Rail Leveler July 2012 92012 Engineered Solutions Inc PARTS LIST STANDARD HYDRAULIC ASSEMBLY Fig 31 209 23 13 9 Ses p July 2012 6003936K Hydraulic Rail Leveler 39 2012 4Front Engineered Solutions Inc PARTS LIST STANDARD HYDRAULIC ASSEMBLY continuea HOSE ASSY 1 21D X 72 5 LOA 90 EL 8 JIC F SW X STR 8 JIC F SW 6008056 FTG 45 EL 6 JIC M X 1 4 18 NPT 313219 SWIVEL NUT RUN TEE 6 JIC F X 6 JIC M X 6 JIC M 313105 FLOAT STD SENSOR ASSY V2 6000749 ADJUSTMENT ASSY ROD END VSL 6001315 NM L7 M NE NE IL Lus EK M NEN EE 8 E NN 7 10 1 12 13 PW 1 BOLT SIZE 1 1 16 HOLE 234161 PIN 1IN DIA X 2 3 16 LG 5861063 HEX BOLT 1 4 20 X 1 LG 000369 NYLOCK NUT 1 4 20 UNC 214502 HEX BOLT 5 16 18 X 1 LG 212064 NYLOCK NUT 5 16 18 UNC 214522 FTG ELBOW 90 SWIVEL 6 x 6 JIC F STL 313595 25 1 BREATHER CAP DIPSTICK 601263
24. HASE 60HZ 206 L 207 208 A 120 D 200VA NOTE VISUALLY CONFIRM MOTOR TAG 380 480V THREE PHASE 50 60HZ 210 211 120 from 325 212 3251 NOTE VISUALLY CONFIRM MOTOR TAG 213 200 240V THREE PHASE 50 60HZ 214 215 216 NOTE VISUALLY CONFIRM MOTOR TAG 217 218 219 220 221 LEGEND PANEL WIRING 222 FIELD WIRING BY OTHERS DWN YOUNGBLOOD DATE ose 1612 HUTTON DR CARROLLTON TX 75006 TEL 972 466 0707 800 525 2010 FAX 972 323 2663 Jl fs 4FRONT ENCINEERED SOLUTIONS SERCO HYDRAULIC RAIL LEVELER HRL THREE PHASE POWER DISTRIBUTION C 07 24 12 ADD BUCHER MOTOR DETAIL BAR IS ONE INCH LONG ON ORIGINAL DRAWING IF NOT 208 575V 3PH 60HZ 380V 3PH 50HZ AS 2 ee DNE NCH ON THIS SHEET PREV DATE REVISION THIS DRAWING IS INTENDED FOR USE ON THE PROJECT LISTED HEREIN REPRODUCTION IS AUTHORIZED BY 4FRONT ENGINEERED SOLUTIONS FOR USE ON THIS PROJECT ONLY ADJUST SCALE ACCORDINGLY DWG No SCALE FILE SHT OF REV 6004100 NONE 6004100C2 2 5 C 300 323 TELEMECANIQUE TELEMECANIQUE TWDLCAA24DRF TWOLCAA24DRF N BASE CONTROLLER BASE CONTROLLER 109 120 211 301 14 INPUTS 24000 524 10 OUTPUTS AC DC NEUTRAL PLC1 PLC1 3251 302 PROGRAM NOTES RVSOO1 3021 1921 3022 325 to 110 1212128 5291 3 p 222 INSIDE GREEN LAMP IS
25. HIS DRAWING IS INTENDED FOR USE ON THE PROJECT ONE INCH ON THIS SHEET 05 11 06 INITIAL RELEASE LISTED HEREIN REPRODUCTION IS AUTHORIZED BY ADJUST SCALE ACCORDINGLY DWG No SCALE FILE SHT OF REV REV DAE REVSION APP AFRONT ENGINEERED SOLUTIONS FOR USE ON THIS PROJECT ONLY 6004100 NONE 6004100C5 3 5 NOTES pow te DWN YOUNGBLOOD DATE 2 22 2007 ______ ____ KELLEY 4FRONT ENGINEERED SOLUTIONS ____ SERCO wy 1812 HUTTON DR CARROLLTON TX 75006 Me c rap 972 466 525 972 523 Lyc 0 Un HRL _ CREME BAR IS ONE INCH LONG ON INTERCONNECTION DETAIL DWG No SCALE FILE SHT REV 6004100 NONE 6004100C4 4 5 C ORIGINAL DRAWING IF NOT B 06 10 10 MDY REMOVE INTERCONNECTION DETAIL mus DRAWING IS INTENDED FOR USE ON THE PROJECT ONE INCHEON THS SHEET 05 24 07 INITIAL RELEASE pn LISTED HEREIN REPRODUCTION IS AUTHORIZED BY ADJUST SCALE ACCORDINGLY REV DAE REMSON APP 4FRONT ENGINEERED SOLUTIONS FOR USE ON THIS PROJECT ONLY 400 401 HYDRAULIC RAIL LEVELER with MANUAL SIDESHIFT HYDRAULIC RAIL LEVELER with POWERED SIDESHIFT 402 403 404 405 406 PM 407 408
26. Hydraulic Rail Leveler This manual applies to Hydraulic Rail Levelers manufactured beginning April 2012 with the serial numbers 61043720 and higher pepe User s M Do not install operate or service this product unless Se r S n have read understand the Safety Practices Warnings and Installation and Operating Instructions Installation Operations contained in this User s Manual Failure to do so could Maintenance and Parts result in death or serious injury Part No 6003936K TABLE OF CONTENTS TON T 2 Planned 17 Safety Signal Words 2 Troubleshooting Guide 20 Safety Practices 3 Cylinder Adjustment to Align Lock Out Pin 24 Owners Responsibilities 4 Hydraulic System Bleed Procedure 25 Working Estas 5 DISOnosll6S 28 RETE 6 Hydraulic Power Unit Adjustment 30 Components and Specifications
27. Hydraulic Rail Leveler July 2012 92012 Engineered Solutions Inc PARTS LIST STANDARD POWER UNIT continuea Fig 30 July 2012 6003936K Hydraulic Rail Leveler 37 2012 4Front Engineered Solutions Inc PARTS LIST STANDARD POWER UNIT continuea Dem 1 1 BUCHER 120V 1PH 50 60 HZ PUMP UNIT 6012602 BUCHER 220V 1 PH 50 60 HZ PUMP UNIT 6012602 BUCHER 240V 3 PH 50 60 HZ PUMP UNIT 6012603 BUCHER 480V 3 PH 50 60 HZ PUMP UNIT 6012603 BUCHER 575V 3 PH 50 60 HZ PUMP UNIT 6012604 J BOX 4 PORT QD 6008051 FTG STR THD CONN 8 JIC M X 6 SAE ORB M STL 6006640 FTG ELBOW 90 SWIVEL NUT 8 JIC M X 8 JIC F SW STL 6011446 FTG STR THD ELBOW 90 6 JIC M X 6 SAE ORB M STL 313214 HOME RUN CABLE QD 8 LEAD 6008848 VOLTAGE LABEL EXT ON PUMP 120 VOLT 921051 VOLTAGE LABEL EXT ON PUMP 208 VOLT 921050 VOLTAGE LABEL EXT ON PUMP 240 VOLT 921052 VOLTAGE LABEL EXT ON PUMP 480 VOLT 921053 VOLTAGE LABEL EXT ON PUMP 575 VOLT 921054 4 RETAINING NUT 1 2 SOLENOID 6011725 PHASE LABEL EXT ON PUMP SINGLE PHASE 921026 PHASE LABEL EXT ON PUMP THREE PHASE 921027 48 32 X 7 8 LG PAN HEAD TAPPING SCREW TYPE 6011671 SERRATED FLANGE HEX LOCKNUT 5 16 18UNC ZP 6010661 20 5 16 180 X 1 LG ROUND HEAD CARRIAGE BOLT 6010662 2 STRAIN RELIE
28. Leveler stored SHIFT LEFT selected Leveler stored SHIFT RIGHT selected July 2012 6003936K Hydraulic Rail Leveler 29 2012 4Front Engineered Solutions Inc HYDRAULIC POWER UNIT ADJUSTMENT Fig 24 N N E je zd 4 00000 E 00000 9 Q Main cylinder extend C1 EJ 9 Main cylinder and lip Sequence valve cylinder retract C3 Main solenoid valve SV3 Lip solenoid valve SV4 Power down Float needle valve FNV solenoid valve SV1 Lip cylinder extend C2 Main solenoid valve A SV2 Fig 25 RV1 SV2 SV3 SV1 Power down needle valve NV1 30 6003936K Hydraulic Rail Leveler July 2012 92012 Engineered Solutions Inc HYDRAULIC POWER UNIT ADJUSTMENT continued A DANGER Fig 26 Do not perform any maintenance or repair in 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 strut and bracket on deck the Leveler Stop button is pressed and barriers are in place NOTICE Before making any adjustments to the power unit always install a hydraulic pressure gauge 3000 PSI liquid filled in line on the C1 port TOOLS REQUIRED e Pressure gauge 3000 PSI liqu
29. MUST M1 LEVELER 309 ADJUSTMENTS CAN BE MADE PUSHBUTTON es 332 E MOTOR 114 203 103 CONTACTOR 3071 No 105 105 104 114 115 116 205 204 204 LEVELER LOWER 510 PUSHBUTTON 555 LEVELER STOP DIAGNOSTIC 511 BUTTON 554 INDICATOR PILOT OVERLOAD TRIPPED INSIDE GREEN 312 571 CONDITION 335 INDICATOR 114 203 103 313 336 FAULT ALARM aE E N gt Dd a FACTORY JUMPER DOOR OPENED SIDE SHIFT 314 337 NOTE 1 iz 415 315 338 516 SIDESHIFT 299 551 LEFT er RIGHT 31771 SIDESHIFT LEFT 517 2194 SELECTOR SWITCH 540 SIDESHIFT OPTION 318 90 5181 ERECTO SWITCH 541 ji 6004809 AND 6004810 MODELS ONLY DTI EORR 1 319 SIDESHIFT OPTION 342 6004809 AND 6004810 MODELS ONLY 520 345 321 A 344 LEGEND PROGRAM NAME 6004090 4100 MODELS RVSOO o PANEL WIRING 322 6004809 4810 MODELS RVS101 5459 aaa FIELD WIRING BY OTHERS NOTES DWN YOUNGBLOOD T INSTALL INPUT DEVICES AS NECESSARY IE PHOTOELECTRIC OR DRY CONTACT LIMIT SWITCH CONSULT DRAWNG CS owe _ KELLEY 4FRONT ENGINEERED SOLUTIONS MANUAL FOR INSTALLATION DETAILS SERCO 1812 HUTTON DR CARROLLTON TX 75006 e 0 PLC BASE CONTROLLER C 07 24 12 MY BUCHER COMPATIBILTY BAR IS ONE INCH LONG ON ORIGINAL DRAWING IF NOT B 06 10 10 TURCK CONNECTIVITY INE T
30. Main solenoid valves SV2 and SV3 open to extend main cylinder GREEN pilot light turns off when leveler raises above working range July 2012 Fully Raised Leveler stored sensor closes Pressure increases Sequence valve shifts Lip cylinder extends LIP RETRACT BUTTON Pump starts fluid directed to lip circuit Lip solenoid SV4 energizes and opens Oncethe lip reaches full retract the pressure increases until the sequence valve shifts and the lip will begin to raise GREEN pilot light turns off when leveler raises above the working range LIP EXTEND BUTTON Pump starts and pressure flows to extend the lip Main cylinder solenoid valve is closed Pressure builds and extends the lip SIDE SHIFT LEFT SIDE SHIFT ONLY Main solenoid valves SV2 amp SV3 are opened e SV5 solenoid valve shifts to divert flow to side shift cylinder Pump starts and pressure flows to Extend the side shift cylinder Deck will shift left SIDE SHIFT RIGHT SIDE SHIFT ONLY Feature only available on assemblies with hydraulic side shift Power down solenoid valves SV1 is opened SV5 solenoid valve shifts to divert flow to side shift cylinder Pump starts and pressure flows to retract the side shift cylinder Deck will shift right 6003936K Hydraulic Rail Leveler 11 2012 4Front Engineered Solutions Inc OPERATIONS A WARNING Before operating the dock leveler read and follow the Safety
31. NG INSTRUCTIONS MOUNTED NEAR CONTROLS WARNING AND OPERATION PLACARD July 2012 6003936K Hydraulic Rail Leveler 2012 4Front Engineered Solutions Inc 19 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 all safety warnings before attempting any maintenance procedure ADANGER Before servicing the dock leveler read and follow the Safety Practices on page 3 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 THE VERTICAL POSITION WITH THE LIP EXTENDED AND THE LOCK OUT PIN INSERTED THROUGH THE MAINTENANCE STRUT 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 strut and bracket on deck the LEVELER STOP button is pressed and barriers are in place If the dock leveler will not raise with the RAISE pushbutton 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 strut and bracket on deck before th
32. ON WHEN THE 120VAC LEVELER IS FLOATING UNLESS LEVELER STOP IS PRESSED WHILE LEVELER IS 3261 303 FLOATING OR WHEN THE LEVELER IS 3031 326 3261 BETWEEN STORED AND FLOAT POSITIONS to 109 120 211 AMBER PILOT LAMP IS ON WHEN 24VAC LEVELER STOP IS PULLED INDICATING L POWER TO THE LEVELER 504 SAMBER PLOT LAMP WARNER 327 F4 LEVELER FAULT EXISTS AN OVERLOAD STORED l sum gu SPP __________________________ OR SIMULTANEOUS FLOAT AND STORED LS eee RESTRAINT STOP CONDITION 505 HORN SOUNDS STEADY IF THE LEVELER E e area gt uo PROXIMITY SWITCH 528 mE ha SRED 2 1 2 77 IS BETWEEN FLOAT AND STORED 311 Bin POWER DOWN POSITIONS AND NO LEVELER BLU 4 420 PUSHBUTTONS ARE BEING PRESSED hl LEVELER FLOAT 1 e HORN PULSES WHEN LEVELER STOP IS Le Ad wur ae PRESSED WHILE LEVELER IS IN THE E PROXIMITY SWITCH nem 121 RUE Hf oN FLOAT RANGE HORN CHIRPS PERIODICALLY WHEN 1 52 fi LEVELER STOP IS PRESSED WHILE LEVELER RAISE 3301 3302 Er EE S 507 LEVELER 15 BETWEEN FLOAT AND STORED PUSHBUTTON 550 ER pec FT GRN 1 4 1 POSITIONS AND NO LEVELER d BRN jj PUSHBUTTONS ARE BEING PRESSED edd T THIS IS AN ILLEGAL STORAGE POSITION E 7 7 308 FOR A VERTICAL DEVELER THE CHIRP END 331 31 7 3312 m54 _____ 4 419 SERVES AS A REMINDER OF THIS CONDITION COMPOSITE CABLE NOTE SIDESHIFT ONLY LEVELER
33. ail Leveler 92012 Engineered Solutions Inc July 2012 WORKING RANGE Fig 1 Lip grade Above dock Rail floor Deck and lip grades for centerline length position from dock 108 CL 120 CL Deck ip Deck tp Deck Lip ws 1 1 ve 52 x 82 12 oo 52 a7 Cw 28 32 1 23 41 Below dock Deck and lip grade 4 crown 20 lip July 2012 6003936K Hydraulic Rail Leveler 5 2012 4 Engineered Solutions Inc INSTALLATION INSTALLATION OF DOCK LEVELER Before installing the dock leveler read and follow the Safety Practices on page 3 and the operation section in this manual Important Installer Responsibility Prior to complete electrical and hydraulic installation levelers must be stored safely If leveler is mounted on hinges and stored vertically maintenance strut 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 dock 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 pane
34. 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 carriage Secure the pivot pin with the cotter pins provided See Fig 23 Ensure the grease fitting faces away from the dock face Using the 2 wrench to hold the chrome cylinder rod tighten the jam nut using the 1 1 2 wrench Fig 23 Main cylinder rod wrench Rod end Flat adjuster washer Cotter pin 6003936K Hydraulic Rail Leveler July 2012 92012 Engineered Solutions Inc HYDRAULIC SYSTEM BLEED PROCEDURE continuea A WARNING There must not be more than 1 1 2 of thread showing on the adjustable rod end If more than 1 1 2 of thread shows do not proceed Ensure that the leveler is leaning away from the rail tracks If the leveler is standing vertical or leaning towards the rail tracks then 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 injury 7 Ensurethatthe 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 mai
35. ctioning property Failure to do so could result in death or serious injury 3 Pull out the LEVELER STOP button 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 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 NOTE Place a block behind the main cylinder bracket so the cylinder rod is in the clear If the sound of the pump changes before the cylinder reaches its full stroke 12 stop the pump and retract the main cylinder Check the oil level See step 4 Continue to run the pump until the main cylinder is fully extended Add more fluid if required July 2012 6003936K Hydraulic Rail Leveler 25 2012 4Front Engineered Solutions Inc HYDRAULIC SYSTEM BLEED PROCEDURE continuea 4 26 With the lip cylinder and main cylinder fully retracted and hydraulic side shift cylinder if equipped retracted check the oil level in the reservoir Add fluid as required fluid level should be 1 2 3 4 from top of reservoir Only use fluids specified on page 18 If the oil is foamy leave for approximately 15 minutes to let the oil settle
36. der cylinder rod end assembly longer or shorter 5 Re tighten the lock nut securely 24 92012 4Front Engineered Solutions Inc 6 Press the RAISE button until the leveler is fully raised with the lip extended 7 Try to insert the lock out pin pin must insert freely If there is any resistance repeat these steps until the pin does insert freely Fig 22 2 Wrench flats Main cylinder rod Jam nut 1 1 2 wrench end adjuster 6003936K Hydraulic Leveler July 2012 HYDRAULIC SYSTEM BLEED PROCEDURE Before servicing the dock leveler read and follow the Safety Practices on page 3 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 THE VERTICAL POSITION WITH THE LIP EXTENDED AND THE LOCK OUT PIN INSERTED THROUGH THE MAINTENANCE STRUT AND BRACKET ON DECK 2 The LEVELER STOP button is pressed 3 Barriers are in place 4 The power is disconnected and properly tagged or locked out Failure to do so could result in death or serious injury 1 With the leveler in the stored position install the lock out pin and place a padlock through the hole provided in the lock out pin See page 16 2 Remove the lower main cylinder pin ADANGER Do not remove the lock out pin from the maintenance strut until the following steps have been completed to ensure that the leveler is fun
37. e doing any maintenance or repair on the dock leveler be certain that 1 THE LEVELER IS STORED IN THE VERTICAL POSITION WITH THE LIP EXTENDED AND THE LOCK OUT PIN INSERTED THROUGH THE MAINTENANCE STRUT AND BRACKET ON DECK 2 The LEVELER STOP button is pressed 3 Barriers are in place 4 The power is disconnected and properly tagged or locked out Failure to do so could result in death or serious injury MAINTENANCE STRUT The vertical dock leveler is equipped with a maintenance strut to hold the leveler in the stored position during maintenance Always follow the procedure below when performing maintenance or adjustments of any kind to the dock leveler 1 Raise the leveler to its fully stored position with the lip extended 2 Press the LEVELER STOP button on the control panel 3 Swing the maintenance strut into position and insert the lock out pin through the hole not the slot in the maintenance strut 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 See Fig 19 5 Place barricades around the dock leveler to show leveler is out of service Fig 19 16 6003936K Hydraulic Rail Leveler 92012 4Front Engineered Solutions Inc July 2012 Be
38. e mechanical lifting means is removed During lifting of the leveler by mechanical means it is likely that hydraulic fluid will vent itself through the breather of the hydraulic reservoir Lift the leveler slowly and without getting in front of the leveler place a container under the reservoir if possible to catch the fluid The lock out pin must not be removed until the hydraulic system has been bled of air and all hydraulic functions have been tested by a qualified service technician If the dock leveler has been raised to the stored position by external means the main cylinder will be full of air and there may be a vacuum exerting a strong retracting force on the cylinder rod A technician will need to perform a bleed procedure to remove the air from the hydraulic cylinder With the lock out pin in place the technician should loosen the hydraulic hose fitting on the top port of the main cylinder and allow air to fill the vacuum before 20 92012 4Front Engineered Solutions Inc 6003936K Hydraulic Rail Leveler attempting to remove the pin from the cylinder rod lower end With the lock out pin in place the technician must remove the pin from the main cylinder rod lower end and perform the cylinder bleed procedure shown on page 25 27 Failure to follow this instruction can allow the leveler to free fall rapidly and may result in severe injury or death ADANGER Do not disconnect hoses unless the leveler is fully rais
39. ed with lip extended the lockout pin is inserted through the maintenance strut LEVELER 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 After replacing hoses and or motor pump perform the cylinder bleed procedure shown on page 25 27 before removing the lock out pin from the maintenance strut and bracket on deck Failure to do so could result in death or serious injury July 2012 TROUBLESHOOTING GUIDE continued Do not disconnect hoses or any hydraulic components If you disconnect any hydraulic components remove the unless the leveler is fully raised with lip extended the from the main cylinder and perform the Hydraulic lock out pin is inserted through the maintenance strut System Bleed Procedure found on page 25 27 before LEVELER STOP button is pressed and barriers are in removing the lock out pin from the maintenance strut place and bracket on deck Failure to do so could result in death or serious injury PROBLEM POSSIBLE CAUSE SOLUTION 1 Leveler does not raise or lower a No electrical power to control panel a Check that voltage is present at Motor not running terminal connections to the control panel b Electrical connections incorrect or b Check that wiring matches the wiring broken diagram C No electrical power to PLC C No electrical wiring to the PLC d PLC not running d If the fault
40. epair under the leveler be certain that the leveler is stored with the lock out pin inserted through the maintenance strut and bracket on the deck the LEVELER 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 doing any maintenance or electrical work on 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 Prior to complete electrical and hydraulic installation levelers should be stored safely If leveler is stored vertically the lock out pin must be inserted through the maintenance strut and the bracket on deck and secured with a padlock until the leveler is completely wired tested and fully operational 6003936K Hydraulic Rail Leveler 3 2012 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 rail car The owner should therefore train and instruct operators in the safe use of dock leveling devices When a rai
41. fore servicing the dock leveler read follow the Safety Practices on page 3 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 THE VERTICAL POSITION WITH THE LIP EXTENDED AND THE LOCK OUT PIN INSERTED THROUGH THE MAINTENANCE STRUT AND BRACKET ON DECK 2 The LEVELER 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 Checkthatthe lock out pin can be freely inserted through the maintenance strut 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 Verify both control panel indicator LEDs are working Replace if necessary 4 Clean away any debris from the operating area If washing out take care not to direct spray at any electrical parts page 18 5 Clean away any dirt and debris from the lip hinge See page 18 6 Clean away any dirt and debris from the surfaces of the wall mounted track so the leveler will slide freely from side to side See page 18 July 2012 PLANNED MAINTENANCE QUARTERLY 1 Inspect and lubricate all mechanical pivot points on the leveler with S A E 30 oil Cycle the leveler when l
42. ge 25 27 Failure to follow this instruction can allow the leveler to free fall rapidly and may result in severe injury or death INTRODUCTION The hydraulic rail leveler is designed to span and compensate for space and height differences between a loading dock and rail car floor to allow safe efficient freight transfers The hydraulic rail leveler uses push button controls to raise and lowerthe 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 rail car floor 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 Pushthe LEVELER STOP when leveleris stored to prevent operation With the dock leveler in its fully stored position a maintenance strut may be secured with a lock out pin to prevent inadvertent operation Before lowering the leveler can be side shifted manually within a certain range if necessary to line up with the opening in the rail car hydraulic side shift is an option July 2012 OPERATIONS continued NORMAL OPERATION Fig 12 Press Lower 1 To lower the dock leveler pull the LEVELER STOP button button on control panel to switch on power AMBER light indica
43. id filled e 3 16 hex wrench e 16 open end wrench e 9 16 open end wrench Description Purpose Primary relief Controls maximum valve RV1 pressure in the hydraulic system and protects the other components from excessive force Needle valve Controls the lowering FNV speed of the leveler in the float range when the green light is on Sequence valve Controls lip plate retraction and extension Power down Controls the lowering needle valve speed of the leveler while NV1 under power tre S f p Ex o E EXPE m 0 Test gauge 3 000 PSI port Adjustment Loosen the lock nut Turn screw clockwise to increase relief pressure Relief pressure is factory set at 2 500 PSI and should not require adjustment Do not adjust without a pressure gauge or pump may be damaged Reference TSB2009 0722G equipment requirements Loosen jamb nut with 7 16 wrench Turn the knob clockwise to decrease lowering speed The speed of the deck while lowering in the float range should be equal to or slower than the speed in the powered range Loosen locknut turn set screw CW inward to increase pressure CCW outward to reduce pressure If the lip extends 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 Trial run the leveler lowering it from stored to below doc
44. in this manual Remove shipping plug from the hydraulic reservoir and replace with the dipstick breather cap Pull out the LEVELER STOP button The AMBER power light should be on Press and hold the RAISE button for 5 seconds only The main cylinder should be fully extended Ensure that the area in front of the leveler is clear Remove the padlock from the lock out pin Press and hold the RAISE button until the maintenance strut pin slides freely If the pump motor runs and the leveler does not move the motor is likely turning in the wrong direction Disconnect electrical power and switch motor wires to reverse rotation refer to troubleshooting guide and electrical schematics in this manual Stand at the side of the leveler reach in and remove the lock out pin from the maintenance strut Fig 6 2 Brake bolt Guide tube Fig 7 E 1 9 ym T 0 Anchor holes Sa 6003936K Hydraulic Rail Leveler July 2012 2012 4Front Engineered Solutions Inc INSTALLATION continued 12 Press hold the LOWER button The pump will run 19 Clamp the new brace in position perpendicular to the the leveler will move forward and start to lower The horn wall Leave a 1 8 1 4 gap between the brace and the will sound if the leveler is stopped bet
45. just the DOCK LEVELER properly Parts requiring replacement due to damage resulting from vehicle impact abuse or improper operation are not covered by this warranty 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 including premature product wear product failure property damage or bodily injury resulting from use of unauthorized replacement parts or modification of the DOCK LEVELER 4FRONT s sole obligation with regard to a DOCK LEVELER 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 4AFRONT 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 AWARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE ALL OF WHICH 4FRONT HEREBY DISCLAIMS July 2012 6003936K Hydraulic Rail Leveler 51 2012 4 Engineered Solutions Inc Please direct questions about your hydraulic rail leveler to your local distributor or to 4Front Engineered Solutions Inc Corporate Head Office Your
46. k position Record time observed NV1 Adjustment With the leveler at rest in below dock position loosen the Recommended settings NV1 needle valve lock nut and turn the Descent knob clockwise to slow lowering speed Leveler Time or counter clockwise to increase speed Size ft Hold the adjustment knob in place while tightening the lock nut Raise the leveler and test lowering speed Make adjustments in 1 4 to 1 2 turn increments with each test July 2012 6003936K Hydraulic Rail Leveler 31 2012 4Front Engineered Solutions Inc HYDRAULIC SCHEMATIC STANDARD Fig 27 MAN CYLINDER FF LIP CYLINDER 1 2 61 e 6 SAE 6 SAE 6 SAE SV4 elm SV3 mus 5 2 E SEQUENCE O VALVE NEEDLE 2000PSI VALVE PO SV N POWER E DOWN eae EEDLE VALVE RVI 2400PSI M 1 0 GPM lt gt Ne 32 6003936K Hydraulic Rail Leveler 2012 4Front Engineered Solutions Inc July 2012 HYDRAULIC SCHEMATIC WITH HYDRAULIC SIDE SHIFT
47. l 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 installed location of the control panel must be specified on a job specific Approval Drawing Check with the general contractor or sales person for this information SITE CHECK Check the entire mounting site for proper construction according to the job specific 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 Check the control panel for wiring diagram if unable to locate follow the schematics located in this manual 6 6003936K Hydraulic Rail Leveler 92012 4 Engineered Solutions Inc 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 Rigging hooks 2 NOTICE Take care when moving the dock leveler to ensure that the electrical and hydraulic components are not damaged J
48. l car 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 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 leveler that is 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 The dock leveler should never be used outside its vertical working range or outside the manufacturer s labeled rated capacity Itmustalso be compatible with the loading equipment and other conditions relating to the dock 4 6003936K Hydraulic R
49. ler along the rail When lip is aligned with the area of the railcar to oONDock form a bridge release the selector switch Proceed with leveler use LIGHT IS ON GREEN LIGHT Y ac Db 5 7 S QM dab yl Feat Brod Sasa Uk dii us Pa I Fey Oe Bos Cate 272 PARRA cba Power On t Do not use leveler if light is flashing Fig 18 b p 10 Ju an Shift left Shift right July 2012 6003936K Hydraulic Rail Leveler 15 2012 4Front Engineered Solutions Inc SERVICE TOOLS Before servicing the dock leveler read and follow the Safety Practices on page 3 and the Operation section in this manual Befor
50. lights 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 OUTPUTS Physical layout of Display Lower Valve SV1 Main Valve SV2 SV3 Lip Valve SV4 Motor Amber Lamp Pilot Green Lamp Leveler Stored Sensor Float Sensor Raise Push Button Lip Extend Push Button Lip Retract Push Button Lower Push Button Leveler STOP Audible Horn Overload Tripped Side Shift Valve Spare SV5 Door Opened Interlock Spare Spare 9 Leveler Stored No Spare Horn Condition Side Shift Selector Left Side Shift Selector Right INPUTS OUTPUTS NOOR WN 0 1 2 3 4 5 6 7 8 9 Co The charts below show all of the valid conditions for the PLC Unit Leveler Stored No push buttons pressed LEVELER Stop Leveler Stored LOWER button pressed pulled out Leveler between float and stored LOWER button pressed Leveler stored RAISE button pressed 28 6003936K Hydraulic Rail Leveler July 2012 92012 4 Engineered Solutions Inc PLC DIAG NOSTICS continued Leveler between float and stored RAISE button pressed Horn condition 151 and LS2 both on or overload tripped No buttons pressed
51. ll where the gap is the NS smallest It may be necessary to adjust the bar s position slightly if it scrapes the wall Leave the leveler in this spot 3 July 2012 6003936K Hydraulic Rail Leveler 9 2012 4Front Engineered Solutions Inc COMPONENTS AND SPECIFICATIONS The main components of the leveler are shown below See the Parts List for specific part numbers Fig 10 Lip plate Deck 9 Lip cylinder assembly Lip hinge Ted d N Z zt Carriage stop 6 N C 9 bolt hole A 7 T cylinder 4 Adjustable rod end S 7 Fig 11 54 Control Panel D gt DONOTDRIVEON Maintenance strut Track Carriage stop assembly bolt hole Raise Blue Push button Lip Extend Green Push button Lip Retract Black Push button E SEN Lower Yellow Push button Leveler Stop Red Push Pull Mushroom Style Push button 10 6003936K Hydraulic Rail Leveler July 2012 92012 4 Engineered Solutions Inc COMPONENTS AND SPECIFICATIONS continued Control Panel Standard NEMA 12 motor starter thermal overload U L approved Pilot Light LED Solenoid Valves 24VAC Motor NEMA Standard T E N V
52. llowed to rotate if desired after unpinning the main cylinder rod end from the carriage Tie the loose end of the cylinder with wire so it does not swing The carriage can also be held in position using the pin through the slot in the maintenance strut See Fig 3 3 Align the carriage rollers with the track and feed the carriage onto the end of the rail section Ensure the rollers in the carriage contact the rail properly See Fig 4 4 Once the leveler is mounted you must install the stop bolts at the end of the rail section which will prevent the leveler from sliding off the end of the rail See Fig 10 ADANGER The lock out pin must be inserted through the slot in the maintenance strut 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 5 for lock out pin location July 2012 INSTALLATION continued 5 Once the carriage is mounted and the stop bolts are secured use the load centering eyebolt and carefully raise the leveler to the stored position Fit the lock out pin through the hole in the end of the maintenance strut and the bracket on the deck Place a padlock through the hole provided in the lock out pin See Fig 5 This will prevent any unauthorized activation of the leveler and is essential to the personal safety of anyone near this leveler Replace the main cylinder lower clevis pin that was removed i
53. n step 2 Fig 3 M al Carriage rollers Fig 4 Fig 5 6003936K Hydraulic Rail Leveler 7 2012 4Front Engineered Solutions Inc INSTALLATION continuea 6B For levelers built with manual side shift install the brake pad and steel plunger into the guide tube indicated in Fig 6 Adjust brake bolt to prevent rail leveler movement when in working range The steel disk must contact the adjustment bolt Too much pressure on brake pad can cause damage OPTIONAL HYDRAULIC SIDE SHIFT MODELS ONLY With the rail ramp in the stored vertical position with the side shift cylinder fully retracted and the leveler shifted fully right as shown in Fig 18 attach the side shift cylinder to the mounting bracket with pin cotter and washer as shown on page 43 and anchor the bracket with the 4 supplied 3 4 concrete anchors as shown in Fig 7 and page 43 Remove the lifting device from the leveler lip Leave the lip fully extended ADANGER Do not remove the lock out pin from the maintenance post until steps 8 through 11 have been completed to ensure that the leveler is functioning properly Failure to do so could result in death or serious injury 8 10 11 Connect wires from control box to motor solenoid manifold and if present side shift solenoid Ensure that wires have free movement through the entire carriage operating range before terminating See electrical schematics located
54. ntenance strut 8 Press and hold the LOWER button The pump will run and the leveler will move forward and start to lower The horn 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 Press the LIP RETRACT button on the control panel until the lip is pendant 9 Press and hold the RAISE button until the leveler is raised above the working range and the GREEN light goes off Release the button The leveler should remain in position and the horn should sound 10 Cycle the leveler from full up to full down 4 times 11 Press and hold the R AISE button until the leveler reaches the stored position and the lip is fully extended The GREEN light on the control panel should remain off and the horn should not sound The lock out pin must insert freely If there is any resistance adjust the hydraulic cylinder as described on page 24 July 2012 6003936K Hydraulic Rail Leveler 27 2012 4Front Engineered Solutions Inc PLC DIAGNOSTICS A WARNING The dock 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 horn and warning
55. rd opening in carriage 3 See preventive maintenance for label placement and items 24 and 25 Reverse View of Carriage 17 We 16 34 6003936K Hydraulic Leveler July 2012 92012 4Front Engineered Solutions Inc zx x c 1 9 20 NIN N N C2 NO NOT CO Oo X Quantity 1 1 3 1 0 1 0 July 2012 PARTS LIST DOCK LEVELER continuea RFC 6 5 Lip Hinge Pin 50K 5861495 RFC 7 Lip Hinge Pin 50K 5860392 7 5 Lip Hinge Pin 6001714 RFC 8 5 Lip Hinge Pin 50K 035460 RFC 9 Lip Hinge Pin 50K 6001736 Operation Placard Not Shown 6004101 Grease fitting drive fit 417113 Kelley Identifier 6001713 Serco Identifier 6001712 PW 1 Bolt Size 1 1 16 Hole HHMB 3 4 10 UNC X 2 ZP shipped loose HN 3 4 10 finished zinc plt bulk shipped loose Brake pad 5 8 thick 2 dia shipped loose HHMB 3 4 10 UNC X 3 5 LG full thrd Padlock lockout shipped loose Decal Keep Clear 824001 User safety label 6004112 6003936K Hydraulic Rail Leveler 3 2012 4Front Engineered Solutions Inc PARTS LIST DOCK LEVELER continuea Du au Male elbow 37 flare NPTF WHL 1 7 8 OD 1 WD camrol tapped Female pipe NPTF x SAE 37 flare JIC bulkhead union with locknut J box 4 port 6008051 Serial tag 6009761 36 6003936K
56. t Engineered Solutions Inc NOTES 50 6003936K Hydraulic Rail Leveler July 2012 2012 4Front Engineered Solutions Inc LIMITED WARRANT Y THIS LIMITED WARRANTY IS 4FRONT S SOLE AND EXCLUSIVE WARRANTY WITH RESPECT TO THE DOCK LEVELER AND IS IN LIEU OF ANY OTHER GUARANTEES OR WARRANTIES EXPRESS OR IMPLIED 4FRONT warrants that this DOCK LEVELER will be free from flaws in material and workmanship under normal use for a period of 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 by the original purchaser provided that the owner maintains and operates the DOCK LEVELER in accordance with this User s Manual Hydraulic Limited Warranty The hydraulic power unit and cylinders for this dock leveler are warranted to cover the cost of replacement costs only for an extended period of four 4 years beyond the base warranty period In the event that this DOCK LEVELER 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 or the deficient portion s thereof without charge to the owner or 2 Alter or repair the DOCK LEVELER on site or elsewhere without charge to the owner This Limited Warranty does not cover any failure caused by improper installation abuse improper operation negligence or failure to maintain and ad
57. t or bracket out of position a Sensor mounting bracket out of position b Leveler float proximity sensor damaged or connection to sensor lost SOLUTION a Check the reservoir fluid level with the leveler in the stored position with the lip extended and hydraulic sideshift cylinder if equipped fully positioned to the right The fluid level should be between the fill marks on the dip stick when using the fluid check procedure on page 17 Only use fluids specified on page 18 b Decrease sequence valve setting See pages 30 31 C Inspect hinge area for damage or trapped debris d Set primary relief valve RV1 to 2500 PSI See pages 30 31 Do not adjust relief valve without a pressure gauge Reference TSB 2008 0722G for equipment requirements a Turn sequence valve clockwise to increase pressure so the lip plate does not extend until the leveler is fully raised See pages 30 31 a Inspect and clean pilot check valve b Inspect and clean 5 4 Replace cylinder a Adjust as required See page 24 a Adjust main cylinder see page 24 b Replace proximity sensor or repair wiring between sensor and control panel and or adjust bracket angle a Adjust sensor bracket angle b Replace proximity sensor or repair wiring between sensor and control panel 6003936K Hydraulic Rail Leveler 23 2012 4Front Engineered Solutions Inc MAIN CYLINDER ADJUSTMENT TO ALIGN LOCK OUT PIN NOTE
58. t 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 area between the dock leveler and the rail car Never drive on dock leveler unless green light is lit on the dock leveler control panel and the rail car supports the extended lip or the ramp is supported by the extendable arms July 2012 SAFETY PRACTICES OPERATION continued Always restore leveler to its safe stored vertical position with lip extended and LEVELER STOP button pressed after servicing rail car DO NOT walk in front of dock leveler until you Restore the leveler to its safe stored vertical position with lip extended Press LEVELER STOP button to stop the leveler and lip from moving Secure the maintenance strut with padlocked lock out pin 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 INSTALLATION MAINTENANCE AND SERVICE Place barricades on the dock floor around the dock leveler and in the area in front of the dock leveler while installing maintaining or repairing the dock If 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 r
59. tag the lock out pin Press 116 the LEVELER STOP button See page 16 1 2 for manual side shift 4 for hydraulic side shift Must clear side shift cylinder do not obstruct side shift pin 16 Check the reservoir fluid level with the leveler in the stored position with the lip extended and hydraulic sideshift cylinder if equipped fully positioned to the right The fluid level should be between the fill marks on the dip stick when using the fluid check procedure on page 17 Only Fig 9 use fluids specified on page 18 Le 17 The proper stored position shall be as shown in Fig 9 The leveler deck should rest between 2 and 5 past vertical center line The cylinder should be fully extended and the lockout pin free to slip in out of deck bracket Store position Refer to maintenance section on page 24 for adjustment 2 5 over center procedures INSTALL THE MAIN CYLINDER SUPPORT 18 Measure the wall run out To do this clamp the included al wall bumper to the side of the cylinder mount near the 2 main 5 lower clevis pin See Fig 8 Orient the bar so it is perpendicular to the wall and nearly touching the wall Leave approximately a 1 8 1 4 gap to the wall Have an assistant slide the leveler frame to the left and right hand limits of travel as you observe the bar s proximity IR to the wall Find the spot on the wa
60. tes 5 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 rail car floor See Fig 12 Pull for power on 2 To stop the leveler release the LOWER button Audible horn will sound if the button is released before the leveler is in its operating range Push the LEVELER STOP button at any time to stop all operation and silence the audible horn 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 Fig 13 To resume operation of the leveler pull the LEVELER STOP button AMBER light on and press and hold the LOWER button and leveler will float down to the rail car Push to stop floor Release the LOWER button when GREEN light on Pull for power on leveler control panel indicates leveler has reached the operating range See Fig 13 NOTE Audible horn pulses and green lamp goes off if the LEVELER STOP button is pressed while leveler is in float range AMBER lamp flashes if both 151 and LS2 are on or an overload condition exists A WARNING Never drive on dock leveler unless GREEN LIGHT is lit on the dock leveler control panel AND rail car supports either the extended
61. 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 strut and bracket on deck before the mechanical lifting means is removed 12 92012 4Front Engineered Solutions Inc 6003936K Hydraulic Rail Leveler During lifting of the leveler by mechanical means it is likely that hydraulic fluid will vent itself through the breather of the hydraulic reservoir Lift the leveler slowly and without getting in front of the leveler place a container under the reservoir if possible to catch the fluid The lock out pin must not be removed until the hydraulic system has been bled of air and all hydraulic functions have been tested by a qualified service technician If the dock leveler has been raised to the stored position by external means the main cylinder will be full of air and there may be a vacuum exerting a strong retracting force on the cylinder rod A technician will need to perform a bleed procedure to remove the air from the hydraulic cylinder With the lock out pin in place the technician should 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 lower end With the lock out pin in place the technician must remove the pin from the main cylinder rod lower end and perform the cylinder bleed procedure shown on pa
62. ubricating See Fig 20 2 Inspect the hydraulic cylinders valves and hoses for any leaks or chaffing Check the reservoir fluid level with the leveler in the stored position with the lip extended If hydraulic side shift is present the leveler should be fully positioned to the right Unscrew the oil level dip stick and remove Wipe the dipstick clean Re insert the dipstick into the reservoir but do not screw in Read the dipstick The fluid level should be between the fill marks Refill as required using only the fluids specified on page 18 3 Inspect all welds under leveler for fatigue or failure particularly the lip plate hinge and under the top plate 4 Inspectall safety labels and placard Replace as required See page 19 for part numbers and label location 5 Grease all locations shown on page 18 6003936K Hydraulic Rail Leveler 17 2012 4Front Engineered Solutions Inc PLANNED MAINTENANCE continued Hydraulic Fluid Acceptable Hydraulic fluids Legend Shell Tellus T 15 Mobil Aero HFA 49011 Symbol Exxon Univis Grade J13 Lubricate Oil Texaco Aircraft Oil 1554 Light Oil SAE 30 U S Co Inc ZZFI 5606 Low Temp Lubricate Grease Molybdenum Disulfide NLGI 2 Cleaning Location Frequency Visually Inspect Replace Damaged Or Worn Oil level dip stick
63. uly 2012 HANDLING AND UNLOADING The rear embed channel or track will be installed first by the concrete contractor 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 of three 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 Make sure there are no obstructions at the ends of the rail section since you will be sliding it on to the end of the rail 2 Pick up the leveler using the load centering eyebolt and suspend the leveler as shown in Fig 2 using the eyebolt and two rigging hooks Unpin the main cylinder on the rod end See Fig 23 The carriage can be a
64. ween the lowered wall Weld the brace securely to the leveler frame working range and the stored position Continue to press the LOWER button until the pump stops The leveler will NOTE hesitate momentarily when it reaches the working range sure the welding machine s ground clamp is attached then continue to float down Observe the lowering speed of the carriage assembly and not on the leveler the leveler after it reaches the working range The leveler lowering speed in the working range should match the leveler 20 Permanently mount the laminated DANGER and power down portion of the lowering Adjust needle valve as OPERATION instruction placard near the dock leveler necessary see pages 30 31 The GREEN light on the control control panel Make sure the customer gets the User s panel should be on while in the working range Manual and is properly trained 13 Press and hold the RAISE button until the leveler is raised above the working range and the GREEN light goes off Fig 8 Release the button The leveler should remain in position and the horn should sound Press and hold the RAISE button until leveler is fully raised and lip is extended 14 Cycle the leveler from full up to full down 4 times 15 Raise the leveler to the stored position Fit the lock out 1 4 pin through the leveler deck bracket through the hole 3 Eri not the slot in the maintenance strut securing the maintenance strut Lockout and

User`s Manual - Curlin, Inc.

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