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NHS Dock Leveler Manual

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1. 741 0172 OPTIONAL BILL OF MATERIAL BRL OF MATERIAL LIP OUT 61 41 WTG W CONTACT BLOCKS MAX OPTIONAL BLL OF MATERIAL E STOP SE Jut Sim JF eI ey 0881 0202 PUSH BT F MOT SO SEEN 1 FGLASS te Eee SG ES Sedan b COMPLETE LABEL AS SHOW BELOW AFFIX INSIDE OF DOOR SEE TABLE 3 USE ENCLOSURE ADJACEWT COMPOMENET REFFERED 70 2 14 07 TERM BLOCK CLAMP ENCLOSURE DOOR HAS A GROUNDING PROVISION RON CONTACT BLOCK IF WOT FOLASS 1 mw RR REUS EURE 1 e CONTACT FRECFRAS Ti 1 1451 0218 TERMINAL EE 1 01 044 BUTTON IF CONTACT BLOCKS IF MOT FG GLASS Ware 16 18 awe L CR YELLOW 14 16 AWG 18111 11 15 hf Co PHL GRD Se fre DS DFTKMAL WANG AUTO RETURN 13 RED 18 18 WAE 13 KE 14 16 18 TEA LE CE Lau ET ONE 38 NY EEE Wifi KB 4 RED 16 18 15 RED 16 18 AWS MRE 15 TERMMAL
2. AUTO RETURN 17 RED 18 18 AWG RE 17 TERMINAL RB 18 RED 16 18 AWG T NENNEN 0881 0297 BASE W CONTACT BLOCKS IF NOT NET FGLASS 95 sO ta ar ETT OE DS GN gt SONT 19 095 19 09 E 1751 0568 1751 0577 1781 0677 RES LIRE DES Mme SIN JC X 1755 0588 1751 0574 1751 0582 1751 0682 f y ONLY OME TERMINAL BLOCK 17 15 REQUIRED NT HAS BOTH OUT AN 38 4111 0018 Nov 2009 June 2010 DOOR AS VIEWED FROM INSIDE WITH DOOR OPEN EXACT LOCATION OF COMPONENTS MAY BE DIFFERENT THAN WHAT 15 SHOWN NO AUTO RETURN IF AUTO RETURN HINGE ENCL PNL 4111 0018 Nov 2009 June 2010 CONTROL BOX PARTS SINGLE PHASE HINGE 14 IF AUTO RETURN amp E STOP 15 IF AUTO RETURN amp NO E STOP 18 IF E STOP 39 CONTROL BOX PARTS PHASE BILL CF MATERIAL mE TA es 5 2 ww RED YELLOW 14 10 AWG TBI M TE 13 MD 5 1B AWG TR RBIS i es yen pri du us E z nn ae um TERM
3. Service Dock Leveler Safely 23 Periodic Maintenance Adjustments Hydraulic Schematic af aac M Ree 26 Adjust Main System Pressure 27 Adjust Auto Return To Dock ARTD Below Dock Control 28 Adjust Down Speed and Lip Extension 30 Electrical PA ue on om un cam En 32 Three Phase re a RTS ses 38 Signal Phase Control 38 Three Phase Control Box 2 40 Troubleshooting Troubleshooting 42 Parts Frame and Platform TETIERE TITEL Hydraulic Components Fui dx 50 Weather Seal Rubber Style and Brush Style 52 Full Range Toequard amp 54 Power Pack Assembly rur rm mmm ne 53 Miscellaneous x XO eS 54 Customer Information a DE VIBITBDDE RIT TETE II Back Cover 4111 0018 Nov 2009 June 2010 Recognize Safety Information Safety Alert Symbol The Safety Alert Symbol identifies important safety messages on equipment safety signs in manuals or elsewhere When you see this symbol be alert to the
4. 4111 0018 Nov 2009 June 2010 Safety Decals Every 90 days quarterly inspect all safety labels and tags to ensure they are on the dock leveler and are easily legible If any are missing or require replacement please NOVA for replacements 4111 0018 Nov 2009 June 2010 SAFETY 1751 0727 1751 0730 2 1751 0330 i dsce nigced in sama pasion on bol sides DANGER 1751 0138 DAPIT REA anre TA EN nn ee eee meu ez Fabre oi ramba copi or 1751 0726 5 9 5 RESPONSIBILITIES 1 The owner user should recognize the inherent dangers of the interface between the loading dock and the transportation vehicle The owner user should therefore train and instruct all operators in the safe operation and use of the loading dock equipment in accordance with manufacturer s recommendations and industry standards Before operation of the equipment all operators shall read understand and be familiar with all functions of equipment as described in the owner s user s manual 2 The manufacturer shall provide to the initial purchaser all necessary information with regards to Safety Information Operation Installation and Safety Precautions Recommended Initial and Periodic Inspections Procedures Planned Maintenance Schedule Product Specifications Troubleshooting Guide Parts Break Down Warranty Information and Manufa
5. Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the Always post safety warnings and barricade the maintenance prop work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Unless the dock leveler is equipped with tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death Before performing the detailed troubleshooting procedures check the following items first Check all fuses inside the control panel s Replace any blown fuse s with a fuse of equal specification Make sure to pull the fuses out of the circuit to test Platform does not rise Motor overload device Reset overload relay three phase or replace Motor does not energize tripped or fuse blown fuse s single phase Determine cause of overload Make sure the correct voltages are present at the proper locations inside the control panel s
6. field at installation electrical drawings are included with each order or by contacting NOVA Technical Services Once again thank you and congratulations on your purchase of a NOVA hydraulic dock leveler INTRODUCTION Dock Leveler Stock Specifications NHS dock levelers are available in the following sizes weight capacities and options Width NHS 6 ft 1828 8 mm 6 1 2 ft 1981 2 mm 7 ft 2133 6 mm Length 6 ft 1828 8 mm 8 ft 2438 mm 10 ft 8048 mm 12 ft 8658 mm Capacity CIR 25 000 11 340 kg 30 000 Ib 13 608 kg 35 000 Ib 15 876 kg 40 000 Ib 18 144 kg 45 000 Ib 20 412 kg 55 000 Ib 24 948 kg 75 000 Ib 34 019 kg 100 000 Ib 45 359 kg CIR Comparative Industry Rating Call NOVA to discuss available voltages phases and options to meet your specific needs 4111 0018 Nov 2009 June 2010 INTRODUCTION Component Identification A Lip D Powerpack MotorPump Reservoir G Main Frame J Toe Guard 2 used B Platform E Prop Pin and Clip H Lip Keepers 2 used C Lip Cylinder F Platform Cylinder Maintenance Prop THEORY The NHS dock leveler uses hydraulics and one button operation for ease of use Platform B is raised by pushing and holding the RAISE button K This activates an electric motor D which in turn drives a hydraulic pump The hydraulic pump forces oil into the platform cylinder s F causing the pla
7. r The NHS hydraulic dock leveler is designed to compensate for a maximum 12 in 305 mm of height difference between the loading dock and the truck bed DO NOT use the dock leveler if the truck trailer bed is more than 12 in 305 mm higher or lower than the dock floor service height may vary with design specifications DO NOT overload the dock leveler DO NOT operate any equipment while under the influence of alcohol or drugs DO NOT leave equipment or material unattended on the dock leveler Failure to follow these instructions may result in personal injury and or damage to equipment 4111 0018 Nov 2009 June 2010 Operating Instructions Continued Ramp Loading Unloading Instructions NOTE If end unloading is required see End Loading Unloading Instructions on page 20 For ramp loading or unloading the NHS dock leveler can be operated by using the RAISE button on the control panel 1 Check to make sure truck trailer is positioned squarely against dock bumpers 2 Instruct driver to remain at the dock until the loading or unloading process has been completed 3 Chock the truck trailer wheels or use the truck restraint if available A RAISE Button 4 Extend the platform lip onto truck trailer as follows a Raise the platform by pushing and holding RAISE button b Hold the RAISE button until the lip is fully extended then release the RAISE button The platform will lower until the
8. sure prop is solidly shimmed b Using the appropriate lifting device attached to the platform lifting lugs slowly raise the dock to the fully open position c Raise maintenance prop B to the service d Proceed to step 18 upright position and lock prop in this position using an OSHA approved locking device Supplied by others 4111 0018 Nov 2009 June 2010 INSTALLATION Make sure the platform is properly supported in the raised position before entering the pit to finish weld the shims Failure to do this may result in serious personal injury or death 18 All model levelers Install shims at locations B C Ref page 10 using the pyramid or stepped shimming method Both platform cylinder trunnions must be solidly shimmed the entire length of the trunnion Make sure the trunnions are level from side to side as well as from front to back 19 Finish weld all shims using a fillet weld e Weld all shims within each shim stack to each other then weld the shim stack to the leveler frame e Weld the front leveler frame shim stacks to the front pit curb steel 20 When all welding has been completed paint all the welds and shims NOTE To pick up unit from the front move forks closer to gether and slide over the frame and under the cross member It may be necessary to unband the unit to gain access to the front by lifting the lip up then sliding the forks under the cross member Ref page 9 shim stackin
9. Attach lifting chains to lifting brackets A and to a Failure to follow these instructions may result in lifting device 1 hoist or fork truck having the damage to dock leveler and or serious personal appropriate lifting capacity and reach injury or death 4 Remove shipping pallet if present before putting the dock leveler into the pit 4111 0018 Nov 2009 11 June 2010 Install Dock Leveler 12 res lye el 7 A Distance Leveler Frame Height B Shim Locations Under Rear Vertical Supports C Shim Location Under Maintenance Frop Lip keepers Main cylinder D Dock Floor E Rear Pit Curb Angle F String G Rear Hinge Frame Angle H Distance Dock Flaor to Pit Floor J Distance Top of Shim Stack to Dock Floor K Shim Stack L Dock Leveler Frame M Pyramid Preferred N Stepped Acceptable P Offset Not Acceptable Straight Not Acceptable shim stacking Methods E 2 4111 0018 Nov 2009 June 2010 NOTE dock levelers are designed with nominal 1 2 in 12 7 mm shimming distance to allow for pit inconsistencies 1 Determine height of shim stack K for each shim location B by performing the following a Measure leveler frame height distance A b Measure dock floor to pit floor distance H at each shim location B Write down the dimensions obtaine
10. INSTALLED PRIOR TO OPERATING UNIT MUST USE A HYDRAULIC FLUID EQUIVALENT TO MIL 5606 AIRCRAFT HYDRUALIC FLUID 801 021 B EFFECTIVE DATE JUNE 23 2008 FLOW CONTROL VALVE CONTROLS RAMP LOWERING SPEED 30 4111 0018 Nov 2009 June 2010 ELECTRICAL OVERVIEW Motor 1HP TENV No 56 frame 15 minute duty cycle Return Switch Maintain contact type oil tight enclosure spring arm actuation with adjustable tripper arrangement Lip Control Switch Momentary contact oil tight enclosure Actuated by lip cylinder Fluid Content UNIVIS HVI 26 Replacement Hydraulic Fluid We strongly recommend using the UNIVIS HVI 26 however you may replace the fluid with automatic transmission fluid type or Dextron Mixing any other fluid with UNIVIS HVI 26 will cause the fluid to break down If in climates below zero we recommend replacing and refilling with UNIVIS HVI 26 CAUTION DO NOT USE ANY HYDRAULIC FLUID MENTIONED ABOVE Note UNIVIS HVI 26 is designed for extremely cold climates and will break down if mixed with any other fluid however you may mix with any hydraulic fluid for emergency use WE STRONGLY RECOMMEND DRAINING AND REFILLING WITH FRESH UNIVIS HVI 26 or EQUIVELENT AS SOON AS POSSIBLE Tank Capacity 25K To 75K Levelers 4 quarts 100K Levelers 5 quarts Motor Electrical Specifications DRAW Elect Serv Motor MOTOR Amperage Voltage RPM Hz PHASE RUNNIN
11. NOTE When replacing fuse s the new fuse must have the same specification as the old fuse Motor starter three phase Check voltage at starter or relay coil or motor relay single phase not energizing If voltage is present and starter or relay does not energize replace starter or relay If voltage 15 not present check all components in series with the starter or relay coil 42 4111 0018 Nov 2009 2010 TROUBLESHOOTING Three phase units only No voltage is present on Check for blown fuses at branch circuit disconnect Platform does not rise one line Replace fuse Determine cause of blown fuse Motor hums but does not run NOTE motor that is missing voltage on one line is said to be single phased Check motor starter as follows 1 Disconnect wires at load side of starter 2 Energize the starter 3 Measure line to line voltage at line side of starter 4 line to line voltage at load side of starter 5 Line side and load side voltages should be approximately the same Replace starter if voltage values are considerably different from one another Check all wiring to motor for high resistance or no connection Three phase units only Phase reversed Reverse any two legs at the branch circuit Platform does not rise disconnect Motor runs in reverse Single phase units only Line voltage too low Check wiring to motor for high resistance Check for Pl
12. ROCK EMD TERM ROCK B oo 4 ORCUT BEAMER O _ ___________ L RELAY 230 V a gt Sj __ SS DITS m 16 RED 18 HE Dr TE TO TI TERMINAL E CE gt m m ma Bu 0345 _ ix 279 0082 2751 0047 2731 0072 27 0047 2751 0141 273 4177 271 02 7751 0047 AT MOTOR FLA b COMPLETE LABEL AS SHOWN BELOW AFFIX INSIDE 2 a iis AFFIX ADJACENT TO COMPONENT REFERRED DO DUPLICATE TERMINAL BLOCK 17 ONLY OME TERMINAL BLOCK 17 5 REQUIRED IF UNT HAS BOTH QUT E STOP 40 4111 0018 Nov 2009 June 2010 CONTROL BOX PARTS PHASE DOOR AS WEWED FROM INSIDE DOOR EXACT LOCATION OF COMPONENTS MAY BE DIFFERENT THAN WHAT 15 SHOWN 14 NO AUTO RETURN 5 IF AUTO RETURN HINGE IF NO AUTO RETURN amp E STOP 15 F AUTO RETURN amp E STOP 18 IF E STOP HINGE 4111 0018 Nov 2009 41 June 2010 Troubleshooting When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death TROUBLESHOOTING
13. and the lip hinge eas The hinge areas must be kept free of dirt and debris Build up of foreign material in the hinge areas will cause abnormal operation Quarterly Maintenance IMPORTANT Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler Lubricate the following areas with light weight machine oil A Lip hinge area unless equipped with grease fittings apply oil to the top of the entire length of lip hinge when platform is at the full below dock position and lip is folded C Platform hinge area apply oil to top of all platform hinges when platform is at the full below dock position E Platform cylinder to platform frame F Lip cylinder to platform frame pin Lubricate the following areas with white lithium grease NOTE Apply grease to lip hinge grease fittings if equipped 4111 0018 Nov 2009 June 2010 MAINTENANCE Breather Cap Lowel Reservoir N 3 76 5mm From of Reservoir IMPORTANT A low fluid level or the use of hydraulic fluids not equivalent to the fluid types recommended will cause abnormal operation of the leveler and WILL void warranty Before performing any maintenance under the dock leveler lock the electrical power source in OFF position and lock the maintenance prop in the service position using an approved locking device See Service Dock Leveler Safely in this
14. are free por aus come frre Tor GUARD TH LOWER TOE HH M HH MIDDLE ewm um mL m HEN CONSULT FACTORY ICONSULT IFAC TORY 4 aT 4111 0018 Nov 2009 is June 2010 PARTS Motor and Pump 111 374 Reservoir Pump with Motor Drive Plate Single Phase 111 375 Reservoir Pump with Motor Drive Plate Three Phase Provide dock lavaler serial number and tyge of installation when calling or faxing orders Provide dock laveler serial number voltage and phase wher calling or faxing orders 4111 0018 Nov 2009 53 June 2010 MISCELLANEOUS 54 NOTES 4111 0018 Nov 2009 June 2010 MISCELLANEOUS NOTES 4111 0018 Nov 2009 55 June 2010 MISCELLANEOUS 56 NOTES 4111 0018 Nov 2009 June 2010 MISCELLANEOUS Customer Information NOTE Refer to illustration for left right orientation of dock leveler The model serial number decal A is located on the left platform joist near the front lip of dock leveler When you receive your NHS dock leveler write down the dock leveler model and serial number in the form provided This will help ensure safe keep ing of the numbers in the event the model serial number decal A becomes lost or damaged Also write down NOVA s job number the company that installed the dock leveler and the original owners name This will all help to identify
15. possibility of personal injury or death Follow the instructions in the safety message The use of the word DANGER signifies the presence of an extreme hazard or unsafe practice which will most likely result in severe injury or death The use of the word WARNING signifies the presence of a serious hazard or unsafe prac tice which may result in serious injury or death The use of the word CAUTION signifies possible hazard or unsafe practice which could result in personal injury IMPORTANT The use of the word IMPORTANT is to draw attention to a procedure that needs to be followed to prevent machine damage 4111 0018 Nov 2009 June 2010 SAFETY General Operational Safety Precautions Read and understand the operating instructions and become thoroughly familiar with the equipment and its controls before operating the dock leveler Never operate a dock leveler while a safety device or guard is removed or disconnected Never remove DANGER WARNING or CAUTION signs or decals on the equipment unless replacing them Do not start the equipment until all unauthorized personnel in the area have been warned and have moved outside the operating zone Remove any tools or foreign objects from the operating zone before starting Keep the operating zone free of obstacles that could Cause a person to trip or fall SAFETY Operational Safety Precautions A Learn the safe way to operate this equipment Rea
16. section Failure to follow these instructions may result in serious personal injury or death e Check reservoir fluid level Q see note 3 1 Put the dock leveler platform at the full above dock position and the lip extended 2 Turn OFF all electrical power to the leveler 3 Measure fluid level The fluid level should be approximately 3 in 76 5 mm N from top of reservoir M with platform raised on the maintenance prop 4 Add hydraulic fluid if necessary Use only recommended fluid See page 22 5 Turn ON electrical power to the leveler 6 Return the platform to the cross traffic position 25 HYDRAULIC SCHEMATIC MAIN C1 103 BAR 1500 PSI 13 138 BAR 26 4111 0018 Nov 2009 June 2010 Adjust Main Pressure Relief When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service positio
17. the lip extended NOTE If a truck is present the platform will lower until the lip rests on the truck trailer bed See Operating Instructions in Operation section 4111 0018 Nov 2009 June 2010 INSTALLATION 7 When the platform lowers to the full below dock position push and hold the RAISE button until the retracts and platform rises just enough to have the lip clear the lip keepers then release the RAISE button to allow the platform to lower to the cross traffic stored position lip engages lip keepers NOTE For dock levelers equipped with Auto Return To Dock ARTD the platform will automatically return to the cross traffic position if the ARTD is in NORMAL mode When the platform is about 1 00 inch from the full below dock position the platform will automati cally rise to the cross traffic position See below dock servicing and end loading for additional instructions 8 Perform steps 5 7 at least four times to purge any air that may be in the hydraulic system and to ensure proper operation Unless the dock leveler is equipped with tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop 9 Raise the platform fully Hold the platform at this position using the RAISE button and move the maintenance prop to the service upright position Release the RAISE button to allow the platform to low
18. the spe cific dock leveler if more information is required When ordering use part numbers and description to help identify the item ordered Do not use item numbers These are only for locating the position of the parts Always give dock leveler MODEL NUMBER and or SERIAL NUMBER For service call or contact NOVA Technology 90 W14507 Commerce Drive Menomonee Falls WI 53051 Phone 800 236 7325 www novalocks com 4111 0018 Nov 2009 57 June 2010 NOVA WARRANTY NHS SERIES LEVELER NOVA guarantees the materials components and workmanship in your NOVA NHS dock leveler to be of the highest quality and to be free of defects in material and workmanship for a full One 1 Year Base Warranty on the structural hydraulic and electrical Additional 4 years pro rated based on application from date of shipment specifically the deck section lip section frame rear hinge front hinge for the NHS series The NHS series also carries the 4 year warranty and is NOT pro rated based on application Specifically this guarantee applies to e All hydraulic cylinders e Hydraulic pressure lines e Hydraulic pump and motor In the event of any defect covered by this guarantee NOVA will remedy said defect by repairing or replacing all defective parts bearing all of the costs for parts labor and transportation All guarantee claims will be settled on a timely basis when defects are found to be from other than imprope
19. 0595 5056 0595 5065 0585 5074 0555 5083 0585 5097 Jossssuss Josossors _ osas soss ajesas soso 0595 5068 0595 5068 0505 5077 0595 5086 0505 5085 gt 5 um em Lm e i EE 0588 5093 4 4 4 1 E um Lh E ejosessoas Josossoss osessorz Josossost osos soso 2 5 om OF a 1elosos sos2 05 5 ______20 5 5053 0595 5062 0595 5071 355107 ____ esroor ask o515 5062 Josisso astssros amp sroor ___ esroor _ ostssors _ osis soe2 _ se asas sos4 0585 5060 0595 5088 0505 5078 0595 5087 0585 5096 9515 5080 8515 5084 95155084 0515 092 EEE 1531858108 9515 5081 9515 5085 18515 5093 9515 5097 9515 5101 fossana 1 Provide dock leveler serial number platform size and lip size when calling or faxing orders For left right orientation of dock leveler see inside b
20. 097 5 100Ki24 100Ki24 eoroor 10024 pi eene umo aston 8435514 208435507 204355140 __ ru 71 943555 1884355 sse messe 2043552 100 124 pit 5 5100 35 5101 d 35 5111 435 5112 35 5113 5 2 0 FOOT 8435 5126 843565127 _ 5130 1818435 5133 435 5123 8435 5124 8435 5125 4111 0018 Nov 2009 June 2010 4111 0018 Nov 2009 June 2010 This page intentionally left blank PARTS 49 PARTS Hydraulic Components 5 BB a 2010 Hydraulic Components m umi SEAL KIT MAIN CYL 3 x 18 FITTING ELBOW SWIVEL 1 FITTING ELBOW VALVE SOLENIOD OPTIONAL REPLACES ITEM 411 1 FOR E STOP OR INDEPENDANT LIP VELOCITY FITTING 1 FITTING ELBOW FITTING ELBOW SWIVEL PIN CLEVIS LIP FIN CLEVIS MAIN WASHER FLAT OCH Y WITH E STOF FITTING TEE 1 Provide length and diameter of hose when calling or faxing orders 2 Provide dock leveler serial number voltage and phase when calling or faxing orders 4111 0018 Nov 2009 June 2010 PARTS 91 PARTS Weather Seal Rubber Style and Toe Guards 6 FOOT 8 FOOT 10 FOOT a
21. 4 in 6 6 mm thick shim at locations B and C is used only as a starting point The final shim stack height will be deter mined after dock leveler is lowered into the pit The dock leveler is heavy Use chains and lift ing device with the appropriate lifting capacity and reach Failure to do so may result in damage to dock leveler and or serious personal injury or death 5 Using an appropriate lifting device connected to the lifting brackets lower dock leveler into the pit so rear hinge frame angle G is tight against rear pit curb angle E across full width of the leveler frame 6 Allow rear of dock leveler to rest on the rear shims while keeping the front of the dock leve ler level with the dock floor 7 For all NHS models add shims at front shim locations C so front of dock leveler will stay Level with dock floor when leveler is resting fully on shims 13 INSTALLATION 4 e pow 4 te 4 F 4 a e c 6 12 9 5 A Front of Dock Pit Dock Leveler Frame C Side Pit Curb Angle D Gap 3 4 19 Minimum 8 With rear hinge frame angle F tight against rear pit curb angle G perform check the following Pry between the platform and rear hinge frame angle at locations E to make sure rear edge of platform is parallel to the rear hinge frame ang
22. DS ALL LOADS 110 120 VAC LEGEN LOCATION CONTROL ASSY 0 SOLA DOCK LEVELER __ OPTIONAL GIA M IST o OVERHEAD DOOR BY OTHERS 32 4111 0018 Nov 2009 June 2010 ELECTRICAL 1 PHASE O O O N gt O Z o5 ON T 5 ELECTRICAL 3 PHASE DRAWING SHOWS SYSTEM AT REST WTH POWER OFF DOCK LEVELER STORED amp OVERHEAD DOOR NOT FULLY RAISED 1 REPRESENTS A TERMINAL BLOCK DOOR CONTACT LINES 109 THRU LE BY OTHERS DOOR CONTACT BE PROVIDED BY POWERAMP SPECIFIED DOOR CONTACT PREVENT OPERATION OF LEVELER UNTIL DOOR FULLY RAISED DOOR CONTACT TO BE OPEN WHEN DOOR NOT FULLY RAISED DOOR CONTACT TO BE CLOSED WHEN DOOR FULLY RAISED DOOR CONTACT IS USED REPLACE JUMPER AT TERMINAL BLOCKS 11 AND 13 WTH DOOR CONTACT WIRES TERMINAL BLOCKS 14 15 AND 16 ARE USED ONLY IF UNIT HAS AUTO RETURN TERMINAL BLOCK 17 15 USED ONLY IF UNIT HAS LIP OUT AND OR E STOP PB2 ONLY USED IF UNIT HAS LIP QUT WRE 14 15 CONNECTED TO 2 4 IF UNIT DOES NOT HAVE AUTO RETURN 15 IS CONNECTED TO 2 4 IF UNIT HAS AUTO RETURN ONLY USED IF UNIT HAS E STOP 14 IS CONNECTED TO PB3 1 IF UNIT DOES NOT HAVE AUTO RETURN WRE 15 15 CONNECTED TO 3 1 IF UNIT HAS AUTO RETURN WRE 14 15 CONNECTED TO 1 1 IF UNIT DOES NOT HAVE AUTO RETURN OR E STOP WRE 15 IS CONNECTED TO 1 1 IF UNIT HAS AU
23. G Rec 1104 15 120 3450 1 14 4 30 208 3451 Bt 1 220 230 240 60 1 208 34540 3 3 6 10 220 24 34 60 3 3 7 10 244 460 880 3450 1 8 10 ofa 3450 1 4 10 Guide to Wire Sizes Length 1208208 240 olt 220 alt 460Vot 575Volt ot Run in Feet 1 Phase 1 Phase 3 Phase Phase 3 Phase Wire Size Wire Size Wire Size Size Wire Size 0 25 10 12 12 12 12 25 15 8 12 12 12 12 45 75 HG HA 10 10 10 75 120 WE 110 10 120 150 o B 8 150 220 CAUTION Sufficient voltage must reach the Leveler Control Panel to operate the 1 HP motor Voltage drop caused by long wire runs or undersized wire increase the Amp draw and will cause the breaker to trip and or more serious damage to occur Therefore it is important for installation to be done to meet all codes by a licensed electrician IMPORTANT NOTE The values given are intended to only be a guide Be sure to check all electrical codes before installation This chart indicates the length of branch circuit having a 2 voltage drop at full load start up current in feet Values are for THHN copper wire only 4111 0018 Nov 2009 31 June 2010 ELECTRICAL 1 PHASE DRAWING SHOWS SYSTEM AT REST POWER OFF DOCK LEVELER STORED amp OVERHEAD DOOR NOT FULLY RAISED CJ REPRESENTS TERMINAL BLOCK DOOR CONTACT LINES 107 THRU 11 0 BY OTHERS DOOR CONTACT MAY BE
24. NHS NOVA Dock Leveler TECHNOLOGY 5 Manual Nova Technology International LLC N90 W14507 Commerce Drive Menomonee Falls WI 53051 800 236 7325 Fax 262 502 1511 Www novalocks com Manual No 4111 0018 Nov 2009 Copyright 2010 June 2010 Table of Contents Page Safety Recognize Safety Information 1 General Operational Safety Pr cautions 1 Operational Safety Precautions 2 Maintenance Safety Precautions 4 sos GM none email Owner s User s Responsibilities Sa RUES Introduction General Inf mallo n 8 Dock Leveler Stock 5 8 Component identification 9 chelates be yah a ERE DNI I D TE MM ME 9 Installation Prepare 10 Me DOCK LOORI install Dock Leveler Install Control Panel and Wiring A Put New Leveler Into Service 19 Operation Operating Instructions 20 Ramp Loading Unloading Instructions RE RR Va RO RO End Loading Unloading Instructions SR ES
25. OW DOCK position DO NOT turn the ARTD switch to the NORMAL position until end loading or unloading is finished 29 ADJUSTMENTS HYDRAULIC MOTOR ADJUSTMENTS NOTES 1 RAMP LOWERING SPEED CONTROLS RAMP S DOWNWARD MOTION IN TIME A IF PLATFORM IS LOWERING TOO SLOW TURN ADJUSTMENT COUNTER CLOCKWISE TO INCREASE ITS RATE OF DESCENT B IF PLATFORM IS LOWERING TOO FAST TURN ADJUSTMENT CLOCKWISE TO DECREASE ITS RATE OF DESCENT 2 SEQUENCE VALVE CONTROLS LIP EXTENSION TIMING ONCE RAMP HAS EXTENDED A IF LIP EXTENDS BEFORE RAMP IS AT FULL RAISED POSITION TURN ADJUSTMENT CLOCKWISE TO DELAY THE LIP EXTENSION B IF LIP EXTENDS SLOWLY OR DELAYED AFTER RAMP IS AT FULL RAISED POSITION TURN ADJUSTMENT COUNTER CLOCKWISE TO EXTEND THE LIP SOONER 3 LIP CONTROL ADJUSTMENT CONTROLS THE POWER LIP FEATURE A IF LIP DOES NOT COME FULLY PENDANT AS UNIT IS BEING STORED TURN ADJUSTMENT COUNTER CLOCKWISE 1 4 TURN AT A TIME B IF LIP DRAGS HEAVILY ON THE TRAILER OR LIP KEEPERS WHEN UNIT IS BEING STORED TURN ADJUSTMENT CLOCKWISE 1 4 TURN AT A TIME 4 LIP FLOAT VALVE SET LIP FLOAT THEN ADJUST THE SEQUENCE VALVE USE 3 16 ALLEN HEAD WRENCH LIP PORT MAIN SYSTEM RELIEF VALVE t s m hag 5 1 4 1 i s r 7 Le 7 3 a i SEQUENCE VALVE CONTROLS LIP EXTENSTION WHEN RAMP HAS EXTENDED TURN QUT 1 5 TURNS TO START _ BREATHER CAP MUST BE
26. OW DOCK position if equipped 3 Chock the truck trailer wheels or use the truck restraint if available 7 Push the Raise button B to the platform just enough to clear the lip keepers 8 When the platform lip clears the lip keepers push the Lip Out button C just long enough to clear the lip Keepers Release Lip Out button The platform will drift down to the full below dock position 9 Proceed with loading or unloading End Loading Unloading Platform at Cross Traffic Position 4 If truck trailer bed is at or above dock floor NOTE When end unloading is finished and access level leave leveler at the cross traffic position to the rest of the truck trailer is still required and proceed with loading or unloading the platform lip will need to be extended See Ramp Loading Unloading Instructions on page 19 for further instructions 10 When the loading or unloading is finished return the dock leveler platform to the cross traffic stored position by performing one of the G following e Turn the ARTD switch A to the NORMAL position if equipped The platform will automatically rise to the cross traffic position End Loading Unloading Platform at Below Dock Position 5 If truck trailer bed is below the dock floor level and the dock is equipped with the optional lip out OR button perform steps 6 12 e Push the Raise button B until the lip clears the keepers Release Raise button leveler wi
27. PROVIDED BY POWERAMP IF SPECIFIED DOOR CONTACT PREVENT OPERATION LEVELER UNTIL DOOR FULLY RAISED DOOR CONTACT TO BE OPEN WHEN DOOR NOT FULLY RAISED DOOR CONTACT TO BE CLOSED WHEN DOOR FULLY RAISED IF DOOR CONTACT IS USED REPLACE JUMPER AT TERMINAL BLOCKS 11 AND 13 DOOR CONTACT WIRES TERMINAL BLOCKS 14 15 AND 16 ARE USED ONLY IF UNIT HAS AUTO RETURN TERMINAL BLOCK 17 15 USED ONLY IF UNIT HAS LIP OUT AND OR E STOP PB2 ONLY USED IF UNIT HAS LIP QUT WIRE 14 15 CONNECTED TO 2 4 IF UNIT DOES NOT HAVE AUTO RETURN WIRE 15 15 CONNECTED TO PB2 4 IF UNIT HAS AUTO RETURN PB3 ONLY USED IF UNIT HAS E STOP WIRE 14 15 CONNECTED TO PB3 1 IF UNIT DOES NOT HAVE AUTO RETURN WIRE 15 15 CONNECTED TO 5 1 IF UNIT HAS AUTO RETURN 14 15 CONNECTED 1 1 IF UNIT DOES NOT HAVE AUTO RETURN OR E STOP WIRE 15 15 CONNECTED IF UNIT HAS AUTO RETURN BUT DOES NOT HAVE E STOP WIRE 18 15 CONNECTED TO 1 1 IF UNIT HAS E STOP WIRE COLORS NEAR COMPONENT REFER TO COLOR OF WIRE SUPPLIED BY THE COMPONENT OR BY POWERAMP USING MULTICONDUCTOR CORD NUMBERS NEAR COMPONENT REFER TO NUMBERS FOUND ON THE TERMINALS OF THE COMPONENT ONLY THE CONTROL ASSY 5 A UL LISTED PANEL ALL OTHER EQUIPMENT 15 REMOTE FROM THE CONTROL ASSY AND IS NOT PART OF THE UL LISTED CONTROL ASSY _ COMPONENT LOCATION TABLE COMPONENT LOCATION LOAD DATA INDICATED BY PHANTOM LINES EXTERNAL LOA
28. TO RETURN BUT DOES NOT HAVE E STOP 18 IS CONNECTED IF UNIT HAS E STOP WIRE COLORS NEAR COMPONENT REFER TO COLOR OF WIRE SUPPLIED BY THE COMPONENT OR BY POWERAMP USING MULTICONDUCTOR CORD NUMBERS NEAR COMPONENT REFER TO NUMBERS FOUND ON THE TERMINALS OF THE COMPONENT ONLY THE CONTROL ASSY IS UL LISTED PANEL ALL OTHER EQUIPMENT IS REMOTE FROM THE CONTROL ASSY LOAD DATA AND 15 NOT PART OF THE UL LISTED CONTROL ASSY L LOADS LOAD COMPONENT LOCATION TABLE COMPONENT LOCATION ALL LOADS 110 120 VAC _INDICATED BY PHANTOM UNES RATING 0 18 A 115 V TABLE 2 MOTOR NAMEPLATE DATA 2 9 V 4607 054 208 V 8 34 4111 0018 Nov 2009 June 2010 ELECTRICAL 3 PHASE en wi 35 2009 4111 0018 2010 CONTROL PANEL 10 75 Hole Centers 36 4111 0018 Nov 2009 June 2010 PARTS E n o xt 24 A LES Tar aati mini Typical 3PH panel layout Provide dock leveler serial number voltage phase and options when calling or faxing controller orders 4111 0018 Nov 2009 June 2010 3 CONTROL BOX PARTS SINGLE PHASE BLL MATERIAL 1 1491 0038 TERM BLOCK JUMPER 1 143 0220 BLOCK END 2 1 TERM BLOCK CLAMP M 1 01 01 ORCUTT
29. Tighten the jam nut 6 Turn ON electrical power to the dock leveler 7 Disengage the maintenance prop 8 Check leveler operation 9 Repeat steps 1 8 as necessary 27 Adjust Auto Return To Dock C ARTD UMIT SWITCH D ARTD SWITCH ARM ACTIVATE B ARTD DE ACTIVATE NHS levelers are equipped with the optional Auto Return To Dock ARTD if leveler not interlocked with a truck restraint The ARTD allows the platform to automatically return to the cross traffic stored position after the truck departs Adjust the ARTD as Follows NOTE Placement of A B and C are typical factory settings ATRD is set to engage approximately one 1 in before the front header hits the header stops 1 Raise platform fully and engage the maintenance prop in the service position 2 Turn OFF all electrical power to the dock leveler Attach safety lockout and tagout devices Supplied by others 3 Loosen nuts A Slide bolt up to engage ARTD higher below dock or slide down to engage ARTD lower below dock Tighten nuts 4 Turn power back on and run the unit through a full cycle and repeat if necessary 5 Loosen nut B and slide bolt up to shut ARTD higher above dock or slide the bolt down to shut off the ARTD less above dock 28 ADJUSTMENTS When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the ma
30. ack cover of this manual E 993933220 4111 0018 Nov 2009 47 June 2010 PARTS 48 0 FOOT IN CLEVIS PIN M 2160 UT HEX 5 8 11 UNC DOTH 2074 OLT 5 8 11 UNC X 2 00 INCH B OTH 2382 PIN COTTER 1 4 X 2 PROP PIN AND CLIP 8432 11129 KEEPER LIP 16 8432 1130 KEEPER LIP 18 8435 5075 _ 435 5076 EE 1 UN 2 ht 6 5 FOOT 16 E jn 2 Tem 1 TN ______1 iN 2 6 5 gt 18 UA NN NE TENE 8432 1131 KEEPER LIP 20 0 8435 5032 20 8435 5035 20 8435 5038 3435502 8435 5043 1884355046 1884355040 77717 ofa 7 0 FOOT ______ roroor 8435 5053 208435506 208 soroor sapin 6 0 FOOT forcer Gus ____ 0 1684355072 777 708 casse passera 6435508 20843550 2084355074 1 2 5078 188955081 sasssors 18843552 18 8435 5045 8435500 208435508 2084455085 5500 168435509 55091 188435504 1884355
31. al wiring and ground connections until all welding has been completed DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler Always ground welding equipment to the dock leveler frame NEVER to the platform Failure to follow these instructions may damage the motor hoist cylinder wiring and or control panel NOTE The illustration on the previous page shows a typical weld pattern The weld pattern will vary slightly depending on size of dock leveler 4111 0018 Nov 2009 June 2010 INSTALLATION IMPORTANT DO NOT weld continuously along the full length of the rear hinge frame angle This can put unnecessary stress on the leveler components causing the leveler to malfunction and shorten the lifespan of the affected components 11 With the rear hinge frame angle F tight against the rear pit curb angle G weld the rear hinge frame angle F to the rear pit curb angle G using a 3 8 in 9 5 mm flare bevel skip weld each weld being 6 in 152 mm long Start at each end with a 6 in 152 mm long weld Space all the other welds out evenly leaving approximately 6 in 152 mm space between each weld 12 Weld front of dock leveler frame B to shims located under the keepers then weld the shims to the front pit curb steel 13 With leveler welded into place remove the shipping bands from around lip and leveler frame If the platform is raised using an ext
32. arricade the work area at dock level and ground level to prevent unauthorized use of the unit before maintenance is complete The maintenance prop must be in the upright service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the device ALWAYS disconnect electrical power source and ground wire before welding on dock leveler DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler Always ground to the dock leveler frame Failure to follow these instructions may result in damage to dock leveler and or serious personal injury or death DO grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present Stray Sparks can ignite spills or leaks near the work area Always clean up the oil leaks and spills before proceeding with grinding or welding Always keep a fire extinguisher of the proper type nearby when grinding or welding Failure to follow these instructions may result in serious personal injury or death ALWAYS stand clear of dock leveler lip when working in front of the dock leveler Failure to do this may result in serious personal injury or death
33. atform does not rise loose or corroded connections Check if gauge of Motor energizes but wires to motor are of correct size and specification does not run for load requirement Replace if necessary Defective motor centrifugal Replace motor switch Defective motor capacitor Replace motor Dock leveler equipped The auto return limit switch Adjust the bolts as needed See Adjust Auto Return with ARTD Platform not activating correctly To Dock ARTD in the Adjustment section does not automatically return to the Defective limit switch Replace switch cross traffic position or operates abnormally Broken wire Loose or Repair or replace wires and connections as corroded wire connections necessary 4111 0018 Nov 2009 43 June 2010 TROUBLESHOOTING Platform does not rise Heavy object s on Remove object s from platform Pump operates in platform pressure relief mode NOTE For safety reasons the dock leveler is designed to lift only the platform s own weight The motor will continue to run which will result in melting the reservoir Dock leveler binds Check for visible obstructions that could cause binding Remove obstructions no obstructions found call Systems Inc Technical Services See inside back cover for phone number and address Pressure relief set too low Increase pressure relief See Adjust Main Pressure Relief in the Adjustment section NOTE The pressure relief valve must not be
34. cle shall have the brakes and wheel chocks applied appropriately or all other positive restraining device shall be fully utilized 8 Loading dock safety equipment should never be used outside of its intended use range or capacity Please consult the manufacturer if you have any questions as to the use range or capacity of the equipment 9 When selecting loading dock safety equipment it is important to consider not only present requirements but also future plans and any possible adverse conditions environments or use 6 4111 0018 Nov 2009 June 2010 NOTES 4111 0018 Nov 2009 7 June 2010 General Information Congratulations on your choice of NOVA dock leveler This manual covers the NHS series hydraulic dock leveler Designed to be a marvel of simplicity and efficiency your dock leveler when properly installed will provide many years of trouble free performance with an absolute minimum of maintenance Its revolutionary hydraulic system efficiently controls and operates every function To obtain maximum performance and longest possible use a simple program of preventive maintenance is recommended The NHS series dock leveler comes equipped with an electrical control panel which allows pushbutton operation of the dock leveler functions Each NHS dock leveler unit and control panel has been factory prewired and tested to ensure satisfactory operation To illustrate which connections are to be made in the
35. cturers Contact Information The owner user shall be responsible to verify that this information is available and received as well as proper instructions training and familiarity of the equipment for all operators has been completed Owner s User s shall actively maintain update and re train all operators on safe working habits and operations of the equipment 3 It is recommended when the transportation vehicle is positioned correctly in the dock Opening and in contact with both bumpers there shall be a minimum of 4 00 inches 100mm overlap of the leveling device and the transportation vehicle at all times during the loading and unloading process 4 Name plates placards decals instructions and posted warnings shall not be obscured from the view of the operator or maintenance personnel for whom such warnings are intended for Contact manufacturer for any replacements 5 Manufacturer s recommended periodic maintenance and inspection procedures in effect at the date of shipment shall be followed at all times Written documentation of maintenance replacement parts or damage should be retained In the event of damage notification to the manufacturer is requested 6 Any modifications or alterations of loading dock equipment shall only be done with prior written approval from the original equipment manufacturer 7 When industrial moving devices are being used in the loading or unloading of product from the transportation vehicle this vehi
36. d and understand the manufacturer s instructions If you have any questions ask your supervisor Stay clear of dock leveling device when freight Chock restrain all freight carriers Never remove carrier is entering or leaving area the wheel chocks until loading or unloading is finished and truck driver has been given permission to drive away Do not use a broken or damaged dock leveling device Make sure proper service and maintenance procedures have been performed before using Do not move or use the dock leveling device if anyone is under or in front of it _ or Keep hands and feet clear of pinch points Avoid Make sure lip overlaps onto trailer at least 4 in putting any part of your body near moving parts 102 mm Keep a safe distance from both side edges 2 4111 0018 2009 2010 SAFETY 7 er Do not use dock leveling device if freight carrier is too high or too low Do not operate any equipment while under the influence of alcohol or drugs Do not leave equipment or material unattended on dock leveling device 4111 0018 Nov 2009 3 June 2010 SAFETY Maintenance Safety Precautions Hydraulic and electrical power must be OFF when servicing the equipment For maximum protection use an OSHA approved locking device to lock out all power sources Only the person servicing the equipment should have the key to unlock the device Always post safety warnings and b
37. d at each location c Subtract distance A from distance H to obtain the shim height Repeat for each shim location IMPORTANT The minimum size of the shim that contacts the leveler frame i e the top shim of each shim stack must be at least 4 1 2 x 4 1 2 in 114 3 x 114 3 mm to support the full width of the frame rail and to provide a shelf for a fillet weld Use the thickest shim stock possible for stability and weld penetration purposes DO NOT use multiple layers of 1 8 in 3 18 mm or thinner shim stock 2 Using the results obtained in step 1 create the individual shim stacks on the pit floor at locations B Build each shim stack K using the pyramid method M preferred or stepped method N with the top shim having a minimum size of 4 1 2 x 4 1 2 in 114 3 x 114 3 and each successive lower shim being larger so the shims can be welded together using a fillet weld DO NOT use offset method P or straight method NOTE To assist in obtaining an accurate measurement of distance J use a string F pulled tight across the pit opening directly over the shim locations 3 Verify that each shim stack is at the correct height by measuring distance J top of shim stack K to dock floor Distance J must equal the dock leveler height A 4111 0018 Nov 2009 June 2010 INSTALLATION 4 For all NHS models put a minimum 1 4 in 6 6 mm thick shim at locations B and C NOTE A 1
38. e inside cover of the control panel 44 4111 0018 Nov 2009 June 2010 TROUBLESHOOTING 2 Symptom Possible Possible Cause does not rise to hydraulic fluid Add fluid as needed Periodic Maintenance in full height the Maintenance section Platform DOES rise to Low hydraulic fluid Add fluid as needed See Periodic Maintenance in full height but lip DOES the Maintenance section NOT extend or extend fully The BELOW DOCK switch Turn the switch to the NORMAL position is in the BELOW DOCK position Lip does not extend Sequence valve out of Adjust the sequence valve out counter clock wise adjustment to get the lip to swing out sooner Lip extends almost Sequence valve out of Adjust the sequence value in clock wise to keep immediately when the adjustment the lip from swinging out too soon RAISE button is pushed Platform locks into Platform lowering speed is Adjust platform down speed control safety as platform too fast lowers Lip drops to See Down Speed Control in the Adjustment section vertical position NOTE Extreme cold weather OR incorrect fluid may cause platform to lock Adjustment is same 4111 0018 Nov 2009 A5 June 2010 PARTS Frame Platform Lip 4111 0018 Nov 2009 2010 June 46 PARTS Lip and Platform mu ax a lo 5 gt pu pum 0595 5047
39. er until it 5 resting on the maintenance prop 10 With the maintenance prop supporting the platform remove the lifting brackets on both sides of the unit 11 Push and hold the RAISE button until the maintenance prop drops to its stored position Release the RAISE button and allow the platform to lower fully 12 Perform step 7 if not equipped with ARTD 19 OPERATION Stay clear of dock leveler when freight carrier is entering or leaving dock area DO NOT move or use the dock leveler if anyone is under or in front of leveler Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts Failure to follow these instructions may result in severe personal injury or death Only trained personnel should operate the dock leveler DO NOT use a broken or damaged dock leveler Make sure proper service and maintenance procedures have been performed on leveler before USING Truck trailer wheels must be chocked unless the truck restraint is used Never remove the wheel chocks until loading unloading is finished and truck driver has been given permission to leave Make sure platform lip rests on the truck trailer bed with at least 4 in 102 mm of overlap Maintain a safe distance from side edges of leveler during the loading unloading process Failure to follow these instructions may result in serious personal injury or death 20 in 305 mm a2 W U JL u 1
40. ernal lifting device or the hydraulic system is opened to atmosphere air will enter into the hydraulic system Whenever this happens always cycle the leveler at least 4 times using the leveler s own hydraulic power system before allowing the leveler to be put into service This is to make sure all air is purged from the hydraulic cylinders Failure to do this may result in serious personal injury or death 15 INSTALLATION A Platform Joists B Platform Maintenace Prop C Prop Pin and Clip 14 Using an external lifting device i e crane or fork truck attached to the platform lifting brackets slowly raise the platform Check for binding as Two people are required to engage the platform is being raised maintenance prop one person to operate the 15 If binding occurs lower the platform Reposition lifting device the other person to engage the leveler and or add or remove shims as maintenance prop necessary Slowly raise platform again If plat form still binds contact NOVA Technical Services for further instructions DO NOT use the maintenance prop to support the raised platform until the maintenance prop has been properly shimmed and welded The shims must be welded to each other the leveler frame and to the front pit curb steel Failure to do this may result in serious personal injury or death 16 All NHS models a Install shims under maintenance prop B where prop attaches to leveler frame Make
41. g Methods Front Pick Up Rear Pick Up For onentation af dock leveler see inside back cover of this manual 4111 0018 Nov 2009 17 June 2010 INSTALLATION Install Control Panel and Wiring The electrical power must be OFF prior to electri cal installation For maximum protection use an OSHA approved locking device to lock out all power sources Only the person installing the equipment should have the key to unlock the power source Failure to follow these instructions may result in serious personal injury or death DO NOT make any final electrical connections until all welding has been completed Failure to do this may result in serious personal injury or death All electrical work including the installation of the disconnect panel control panel and final connections to the pit junction box must be performed by a certified electrician and conform to all local and applicable national codes RE ES T A Disconnect Panel provided by others B Control Panel C Distance 48 in 14 630 mm minimum 1 Mount the pushbutton control panel B so bottom of control panel to dock floor distance C is a minimum 48 in 1219 2 mm 2 Install electrical disconnect panel A if not already installed 3 Install and connect the control wiring 4 Connect the dock leveler power cable to the field wires in the pit junction box Refer to the electrical drawings s
42. intenance prop Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death NOTE The unit must raise enough to allow the lip to fully retract to have the lip rest in to the lip keepers NOTE The ARTD Switch arm D must be between both A and B to work properly 4111 0018 Nov 2009 June 2010 Full Below Dock Position In the full below dock position the switch arm D will be activated by the front bolt A and trapped under the back The switch will active approximatly 1 inch before the front header is fully be
43. le F Gap D must exist equally along both sides of leveler so weather seal if equipped will not bind during dock leveler operation 14 L E Ms i G Locations G Rear Cum Angle F Rear Hinge Frame Angle H Flare Bevel Weld Typical To Fit Spacing 9 If gap D cannot be obtained equally at both sides of leveler grind or add material at the rear edge of rear hinge frame angle F as needed 10 Allow the dock leveler to rest fully on the shim stacks Check that a smooth and level transition exists between the dock floor and the dock leveler platform Add or remove shims as necessary until a smooth transition is obtained 11 If leveler cannot be squared and or made level as instructed in steps 8 10 contact NOVA Technical Services 4111 0018 Nov 2009 June 2010 DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present Stray sparks can ignite spills or leaks near the work area Always clean up the oil leaks and spills before proceeding with grinding or welding Always keep a fire extinguisher of the proper type nearby when grinding or welding Failure to follow these instructions may result in serious personal injury or death IMPORTANT DO NOT connect the dock leveler electric
44. leveler use only aircraft hydraulic fluid designed to meet or Before performing any maintenance under the exceed military specification MIL L 5606 It is dock leveler lock the electrical power source in recommended that the following hydraulic fluids be OFF position and lock the maintenance prop in the used service position using an approved locking device See Service Dock Leveler Safely in this section ULTRA VIS HVI 15 Flomite 530 ZF Aero Shell Fluid 4 or Fluid 41 Mobile Aero Mil HS606A or Aero Texaco Aircraft Hydraulic Oil 15 or 5606 Exxon Univis J13 IMPORTANT These fluid brands can be mixed together Mixing with Use of fluids that do not have equivalent fluids that do not meet or exceed MIL L 5606 may specifications to those in the following list will result damage the equipment and WILL void warranty Use in abnormal operation of the dock leveler and of hydraulic fluids with equivalent specifications to voiding of warranty those listed here are acceptable Failure to follow these instructions may result in serious personal injury or death 24 4111 0018 2009 2010 Regular maintenance must be performed on a weekly and quarterly schedule Weekly Maintenance Operate the dock leveler through the complete operating cycle to maintain lubrication NOTE To thoroughly inspect the platform hinge area put the platform in the full below dock position e Inspect the platform hinge
45. lip is resting on the truck trailer bed c Make sure that the lip is fully extended and supported on the truck trailer along the entire width of the platform with at least 4 in 102 mm of lip overlapping the truck bed 4111 0018 Nov 2009 June 2010 OPERATION 5 Proceed with loading or unloading the truck trailer 6 If end loading is necessary see End Loading Unloading Instructions on page 20 7 When loading or unloading is finished raise the platform by pushing and holding RAISE button A Hold the RAISE button until the lip folds enough to clear the truck trailer bed then release the RAISE button The lip will fold and the platform will return to the cross traffic position 8 Remove chocks from truck trailer wheels or release the truck restraint if used 9 Indicate to driver that truck may leave the dock 21 OPERATION Operating Instructions Continued End Loading Unloading Instructions NOTE If ramp loading is required see Ramp Loading Unloading Instructions on page 19 End loading or unloading can be done with the dock at the cross traffic position or below dock position depending on the height of the truck trailer bed 1 Check to make sure truck trailer is positioned squarely against dock bumpers A ARTD Switch 2 Instruct driver to remain at the dock until the loading or unloading process has been completed 6 Turn the ARTD switch A on the control panel to the BEL
46. ll return to the stored or cross traffic position Whenever end loading or unloading with the platform in 11 Remove chocks from truck trailer wheels or the below dock position make sure the ARTD switch is aeree in the OFF position DO NOT turn the ARTD switch to the ON position until end loading or unloading is finished 12 Indicate to the driver that the truck may leave the dock 22 4111 0018 Nov 2009 June 2010 Service Dock Leveler Safety A Tagout Device B Maintenance C Prop Pin B Lockout Device Prop MAINTENANCE Side View D Header Plate Note Lockout amp Tagout Devices are not supplied with leveler They are to be supplied by others When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA ap proved locking device to lock the maintenance prop in the service position Only the person ser vicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a teth ered remote two people are required to engage the maintenance prop one person t
47. low dock As the platform starts to recycle the lip will pull in first and then the platform will start to raise Once the platform is high enough to have the lip clear the lip keepers the back bolt will de activate the switch and turn off the pump and the platform will float down to rest in the lip keepers in the cross traffic position Below Dock End Load Switch 4111 0018 Nov 2009 June 2010 ADJUSTMENTS The Below Dock End Load Switch controls the when end loading below dock To activate turn the selector switch F to BELOW DOCK position This will DEACTIVATE the Auto Return to Dock feature Push and hold the RAISE button until the platform is fully open The lip will extend until the switch opens up and stops the pump The lip will be extended only 2 3 inches to stay within the bumper spacing The platform will float to the full below dock position and the trailer and be loaded unloaded When complete turn the Selector Switch F back to the NORMAL position and the platform will start to Auto Recycle to the cross traffic position NOTE When servicing trailers that are lower than dock height it is recommended the BELOW DOCK selector switch F be in the BELOW DOCK mode AFTER the lip is in the bed of the trailer to prevent the Auto Return feature to activate inadvertently Whenever end loading or unloading with the plat form in the below dock position make sure the ARTD switch is in the BEL
48. n when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death NOTE The main pressure relief may need to be increased if the platform does not rise or rises slowly and the system operates in pressure relief mode See Troubleshooting section The main pressure relief may need to be decreased if the pump motor loads down when platform reaches the full raised position See Troubleshooting section 4111 0018 Nov 2009 June 2010 ADJUSTMENTS Reservoir P Breather Cap Xin 78 5mm Fluid Level From of Reservoir To adjust the main pressure relief 1 Raise the platform fully and engage the maintenance prop in the service position 2 Turn OFF all electrical power to the dock leveler Attach safety lockout and tagout devices 3 Loose nut on valve F 4 Adjust hex adjusting screw F in small 1 4 turn increments as follows Turn clockwise to increase pressure relief e Turn counterclockwise to decrease pressure relief 5
49. o operate the unit the other person to engage the mainte nance prop Failure to follow these instructions may result in serious personal injury or death 4111 0018 Nov 2009 June 2010 Always post safety warnings and barricade the work area at dock level and ground level to pre vent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Whenever maintenance is to be performed under the dock leveler platform support the platform with maintenance prop B Position the mainte nance prop behind front header plate D while staying clear of the lip Lock the maintenance prop in the service upright position using an OSHA approved lockout device B and tagout device A Whenever servicing the dock leveler lock the electrical power disconnect in the OFF position Use only an OSHA approved lockout device B and tagout device A Only the person servicing the equipment should have the capability to remove the lockout de vices The tagout devices must inform that re pairs are in process and clearly state who is re sponsible for the lockout condition Refer to OSHA regulation 1910 147 23 MAINTENANCE Periodic Maintenance Lip Hinge Area C Platform Hinge Area E Platform Cylinder Pins E Power Unit and Reservoir O Platform Cylinder Trunnion F Lip Cylinder Pina To ensure normal operation of the dock
50. ock leveler E is at the correct location per pit diagrams 10 4111 0018 Nov 2009 June 2010 INSTALLATION IMPORTANT DO NOT remove the shipping bands around the platform lip and leveler frame at this time The shipping bands are needed to hold the leveler together during the installation process Turn to page 15 for front pick up 1 Remove any control panel and bumpers that may be banded to the frame of the dock leveler DO NOT remove the shipping bands B around the platform lip and leveler frame at this time IMPORTANT DO NOT overtighten the lifting bracket hardware NOVA dock levelers are designed with installa Overtightening can damage the weather seal if tion in mind Each unit is shipped with lifting equipped brackets A fastened to the platform side joists SEE NOTE Overall width of platform and lifting brackets A must be kept to minimum to prevent interference between the lifting brackets and the pit walls as the dock leveler is lowered The dock leveler is heavy Use a lifting device into the pit andchains with the appropriate lifting capacity and reach 2 Make sure the mounting hardware of lifting brackets is snug The brackets should pivot relatively freely on the mounting cap screw DO Always use the lifting brackets provided with the 4 overtighten unit whenever lowering or lifting dock leveler into or out of pit 3
51. r installation operating contrary to instructions or beyond rated load capacities abuse careless or negligent use or failure to maintain the unit as recommended by the owner s manual There are no guarantees either expressed or implied including any implied guarantees of merchantability or fitness for a particular purpose which shall extend beyond the guarantee periods indicated above This guarantee is valid only if the unit s is unaltered from original condition as delivered from the factory and a survey is completed by a NOVA representative 4111 0018 Nov 2009 June 2010
52. set at a level that causes the motor operating current to exceed the full load amp value at any time including when operating in pressure relief The full load amp value can be found on the inside cover of the control panel Platform rises slowly Low hydraulic fluid Add fluid as needed See Periodic Maintenance in the Maintenance section Contaminated hydraulic Clean and inspect valves Flush contaminated oil system from hydraulic system Fill system with new oil See Periodic Maintenance in the Maintenance section Damaged or restricted Replace damaged hose s Remove restriction hydraulic hose s Increase pressure relief See Adjust Main Pressure Relief in the Adjustment section Pressure relief set too low NOTE The pressure relief valve must not be set at a level that causes the motor operating current to exceed the full load amp value at any time including when operating in pressure relief The full load amp value can be found on the inside cover of the control panel Pressure relief set too high Decrease pressure relief See Adjust Main Pressure Relief in the Adjustment section Pump motor loads down when platform reaches the full raised position NOTE The pressure relief valve must not be set at a level that causes the motor operating current to exceed the full load amp value at any time including when operating in pressure relief The full load amp value can be found on th
53. tform to rise Releasing the RAISE button allows the platform to lower 4111 0018 Nov 2009 9 June 2010 INSTALLATION Prepare Pit A Distance Pit Width B Distance Dock Floor to Pit Distance Pit Length D Distance Pit Corner to Corner Front and Rear Floor All Four Corners Both Sides of Pit Top Bottom and Both Sides Before lowering the dock leveler into the pit the following must be performed Post safety warnings and barricade the work area at dock level and ground level to prevent 1 Remove all debris from the pit and sweep the pit unauthorized use of the dock leveler before clean installation has been completed 2 Check the entire dock leveler pit for proper Failure to follow the installation instructions can construction according to approved certified pit result in damage to dock leveler the facilities drawings Make sure pit is square by making the and or serious personal injury or death following measurements Measure pit width distance at both front and rear of pit Measure dock floor to pit floor distance B at all four corners Measure pit length distance C at both sides Measure corner to corner criss cross distance D at both sides Take measurements at dock floor level and at pit floor level If any measurement is off by more than 1 8 in 3 18 mm contact NOVA Technical Services before proceeding 3 Make sure the field junction box for the d
54. upplied with the dock leveler 5 After all electrical connections in the pit have been made disengage the maintenance prop and lower the platform using the external lifting device connected to the platform lifting brackets 4111 0018 Nov 2009 June 2010 Put New Dock Leveler Into Service 1 Disconnect the external lifting device and chains from the lifting brackets 2 Check that the leveler is flush with the dock floor and that the platform lip contacts both lip 5 an excessive transition exists between the dock floor and leveler and or lip does not contact Both lip 5 evenly contact Technical Services for further instructions 3 Install the dock bumpers as required 4 Turn the main electrical power ON Always stand clear of platform lip when working in front of the dock leveler Serious personal injury or death may result 5 Raise the leveler platform fully by pushing and holding the RAISE button NOTE The platform of a properly operating dock leveler will automatically stop rising when it reaches its full raised height at which point the lip extends If the lip does not extend or extend fully see Platform Rises to Full Height But Lip Does Not Fully Extend in the Troubleshooting section 6 Release the RAISE button to lower the platform As long as there is no truck present at the dock the platform will lower to the full below dock position with

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