DLM LHD Manual Dec2014
Contents
1. Provide dock leveler serial and or order number along with voltage and phase when calling or faxing orders 4111 0023 December 2014 35 WEATHER SEALS Toe Guard Weather Seal Options 36 4111 0023 December 2014 Weather Seal Brush Style WEATHER SEALS Item Quantity Part Number Description A 2 DOTH 2818 Channel Weather Seal 84 B 2 DOTH 2824 T Rubber Weather Seal 84 C 2 DOTH 2820 Extrusion Brush Weather Seal 84 CC 2 DOTH 2822 Brush Weather Seal 1 58 x 84 D 2 DOTH 2041 Cap Screw E 4 DOTH 2207 Washer F 1 Below Toe Guard G 1 See Below Toe Guard H 2 DOTH 2131 Nut Nylon Lock J 1 See Below Toe Guard K 1 See Below Toe Guard Item Quantity Part Number Description Toe Guard Weather Seal Options DOTH 2819 Track Weatherstrip 6 A 1 DOTH 2187 Track Weatherstrip 8 DOTH 2843 Track Weatherstrip 10 DOTH 2821 Extrusion For Brush 6 C 1 DOTH 2820 Extrusion For Brush 8 DOTH 2851 Extrusion For Brush 10 DKIT 9179 Full Range Toe Guard Assembly 6 1 DKIT 9180 Full Range Toe Guard Assembly 8 DKIT 9181 Full Range Toe Guard Assembly 10 As Required NOTE Brush or track can be purchased separately as replacement parts Contact factory for part numbers Kits provide all parts hardware to add Toe Guards or Weather Seal to an existing dock leveler Weatherseal chann2. LNIVAInO3 YO LAN 513533939 SH3HLO 8 SNOLL 3NNOO 1291 02 5 SSJINN SH3HLO 8 LINGNOD 4000 5531 SH3HLO 8 SIYM 71 4000 Qv3H33 A0 S IVNINH3L NUVM LNIYYNI LYOHS SNIGNNOYS 3613 LINDMO HONVYE 30 WOWIXVN 3503 JO 300401 9NIN3LHOLL 5 ONIMIM 07313 JO ONILVY 3 1 SHOLOnONOO ONIMIM 01313 40 AVTISY QVOTH3AO YOLOVLINOD NO SALVIdSNVN 335 LXZ T wo xeu Ye Asi La vu vu 4313431 00 LY Q3LV901 SOLOM VH 1 101 VIVO 31V 1d3AVN YOLON 3I8V1 5 3 10 A8 Q3TIVISNI dAV43MOd A8 1 q3S010N3 0 9 CVN n Z t 5831891 335 31 15 GASOTONS JHL OL 1 3 HOLIMS 193 02 1 03504 V 31 201 0193104 LINDYIO HONVSB 404 0351 38 LSAW 53513 JAN JHL Ydd 39IA3Q LNIYYNOYSAO HOLIMS 193NNOOSIQ 193135 SUSHLO A8 30 30 LNIYYNOYMO HOLIMS 193NNOOSIQ ZH 09 3SVHd A 1314416 301519 JIVId3NVN 3314915 035017083 NO 39VL 10A S3HOLVW 39VL 10A 3SVHd 03 5 3 01502 3415 4111 0023 December 2014 ELECTRICAL Electrical Components Provide dock leveler serial number voltage phase and options
3. 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 c Raise maintenance prop D to the service upright position and lock prop in this position using an OSHA approved locking device d Proceed to step 17 4111 0023 December 2014 INSTALLATION Shim Stacking Methods 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 9 17 With Dock leveler tested for binding the rear frame can be welded in place 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 18 Finish weld all shims using a fillet weld Weld all shims within each shim stack to each other then weld the shim stack to the leveler frame Q 2 e Weld the front leveler frame shim stacks to the front pit curb steel NOTE LHD models are shipped with a front frame section C installed This temporary frame holds the leveler frame at the correct dimensions until the leveler is permanently anchored into place Only then should it be removed 19 Last shims to be install
4. Raise Button When the platform rises and the hoist cylinder is fully extended the internal valving redirects the flow of oil to the lip cylinder C This causes the platform to stop rising and lip A to extend When the lip has fully extended the hydraulic oil will flow past the pressure relief valve and back to the oil reservoir Heleasing the raise button will allow the platform to float down to the below dock position The lip will stay extended until the platform reaches the full below dock position Pressing the raise button will return the platform and lip to the stored position INSTALLATION Prepare Pit A Distance Pit Width B Distance Dock Floor to Pit C Distance Pit Length D Distance Pit Corner to Corner Front and Rear Floor Four Corners Post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before installation has been completed Failure to follow the installation instructions can result in damage to dock leveler the facilities and or serious personal injury or death IMPORTANT DO NOT remove the shipping bands around the dock leveler lip until instructed to do so 10 Both Sides of Pit Top Bottom and Both Sides 1 Before lowering the dock leveler into the pit the following must be performed 2 Remove all debris from the pit and sweep the pit clean 3 Check the entire doc
5. 6 With rear hinge frame angle F tight against rear 7 f gap D cannot be obtained equally at both pit curb angle G perform check the following sides of leveler grind or add material at the rear edge of rear hinge frame angle F as needed Pry between the platform and rear hinge frame angle at locations E to make sure rear edge 9 Allow the dock leveler to rest fully on the shim of platform is parallel to the rear hinge frame angle F Gap D must exist equally along both sides of leveler so weather seal if equipped will not bind during dock leveler operation 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 10 If leveler cannot be squared and or made level as instructed in steps 8 10 contact Systems Inc Technical Services 4111 0023 December 2014 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
6. 2 Relief valve adjustment A Lossen jam nut B Turn screw clockwise to increase pressure C Turn screw counter clockwise to decrease pressure D Tighten jam nut 3 Sequence valve is factory set at 750 PSI This valve normally should not need adjustment A Loosen jam nut B Turn screw clockwise to increase pressure C Turn screw counter clockwise to decrease pressure D Tighten jam nut 4 See Trouble shooting section for further adjustment procedures Trouble Shooting 1 If the lip opens as the platform begins to raise turn sequence valve clockwise in 1 4 turn adjustments 2 the lip will not not fully retract when the recycling plate form to stored position turn sequence valve in 1 8 turn increments Note All Adjustments should be made in small increments and should be charted to have reliable information when back tracking through adjustments 28 4111 0023 December 2014 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 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
7. 76 5 mm N from top of reservoir M with platform raised on the maintenance prop D Maintenance prop pivot 4 Add hydraulic fluid if necessary Use only recommended fluid 5 Turn ON electrical power to the leveler 6 Return the platform to the cross traffic position 4111 0023 December 2014 25 NOTES This page intentionally left blank 26 4111 0023 December 2014 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 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 eng
8. December 2014 21 OPERATION Operating Instructions Continued End Loading Unloading Instructions NOTE If ramp loading is required see Ramp Loading Unloading Instructions on page 21 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 transport vehicle bed 1 Check to make sure transport vehicle is positioned squarely against dock bumpers 2 Instruct driver to remain at the dock until the 5 Push the RAISE button A to the platform just loading or unloading process has been completed enough to clear the lip keepers 3 Chock the transport vehicle wheels or use the vehicle restraint if available 6 Proceed with loading or unloading NOTE When end unloading is finished and access to the rest of the transport vehicle is still required the platform lip will need to be extended See Hamp Loading Unloading Instructions on page 21 for further Ce instructions 7 When the loading or unloading is finished return End Loading Unloading Platform at Cross Traffic the dock leveler platform to the cross traffic Position stored position by performing one of the 4 transport vehicle bed is at or above dock floor following level leave leveler at the cross traffic position and proceed with loading or unloading OR e Push the RAISE button A until the lip clears the lip Keepers Release RAISE button leveler will
9. Specifications LHD dock levelers are available in the following sizes weight capacities and options Width 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 3048 mm Capacity CIR 25 000 Ib 11 340 kg 35 000 Ib 15 876 kg 40 000 Ib 18 144 kg CIR Comparative Industry Rating Call Systems Inc to discuss available voltages phases and options to meet your specific needs 4111 0023 December 2014 Component Identification s INTRODUCTION e 7 Cal A Lip B Platform C Lip Cylinder D Powerpack Motor Pump Reservoir E Maintenance Prop F Platform Cylinder THEORY The LHD dock leveler uses a pressure operated valve block and single push button operation for ease of use The dock leveler can be operated remotely using the RAISE button on the control panel Platform B is raised by pushing and holding the RAISE button This activates an electric motor D which in turn drives a hydraulic pump The hydraulic pump forces oil into the platform cylinder F causing the platform to rise Releasing the RAISE button allows the platform to lower 4111 0023 December 2014 G Main Frame H Lip Keepers 2 used J Full RangeToe Guard 4 used
10. or alterations of loading dock equipment shall only be done with prior written approval from the manufacturer and the same shall be at least as safe as the original equipment was prior to the modification and shall also satisfy all safety requirements of the manufacturer for the particular application of the leveling device When industrial moving devices are being used in the loading or unloading of product from the transport vehicle this vehicle shall have the brakes and wheel chocks applied appropriately or all other positive restraining device shall be fully utilized It is recommended that trailers with air ride suspension systems shall have its air exhausted prior to performing loading and unloading operation to minimize trailer bed drop Loading dock safety equipment should never be used outside of its intended use vertical working range or capacity Please consult the manufacturer if you have any questions as to the use vertical working range or capacity of the equipment Only properly trained and authorized personnel should operate the equipment When selecting loading dock safety equipment it is important to consider not only present requirements but also future plans and any possible adverse conditions environmental factors or usage 4111 0023 December 2014 NOTES Placard installation Instructions Owner User is responsible for the installation and placement of placards e Make sure placard is in plain view of doc
11. or contact Systems Inc P O Box 309 Germantown WI 53022 Phone 800 643 5424 Fax 262 255 5917 4111 0023 December 2014 Serial No Poweramp Job No Original Owner Information Date of Installation 41 STANDARD PRODUCT WARRANTY SYSTEMS INC warrants that its products will be free from defects in design materials and workmanship for a period of one 1 year from the date of shipment claims for breach of this warranty must be made within 30 days after the defect is or can with reasonable care be detected In no event shall any claim be made more than 30 days after this warranty has expired In order to be entitled to the benefits of this warranty the product must have been properly installed maintained and operated in accordance with all manufacturer s recommendations and or specified design parameters and not otherwise have been subject to abuse misuse misapplication acts of nature overloading unauthorized repair or modification application in a corrosive environment or lack of maintenance Periodic lubrication adjustment and inspection in accordance with all manufacturers recommendations are the sole responsibility of the Owner User In the event of a defect as determined by SYSTEMS INC covered by this warranty SYSTEMS INC shall remedy such defect by repairing or replacing any defective equipment or parts bearing the cost for the parts labor and transportation This shall be exclusive remedy
12. return to the stored or cross traffic position 8 Remove chocks from transport vehicle wheels or e 8 release the vehicle restraint if used 9 Indicate to the driver that the transport vehicle End Loading Unloading Platform at Below Dock Position may leave the dock 22 4111 0023 December 2014 Service Dock Leveler Safely A Tagout Device Lockout Device C Maintenance Prop 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 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 4111 0023 December 2014 MAINTENANCE M gt NK M D Header Plate Always post safety warnings and barric
13. to identify the grade slope for all variations of length or configuration of the dock leveling device and information identifying the maximum uncontrolled drop encountered when sudden removal of support while in the working range of the equipment It is recommended that when the transport 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 transport vehicle at all times during the loading and unloading process The Owner User must review all name plates placards decals instructions and posted warnings and place the same in view of the operator or maintenance personnel for whom such warnings are intended for Contact manufacturer for any replacements 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 required Loading dock equipment that has been structurally damaged or has experienced a sudden loss of main support while under load such as what might occur when a transport vehicle pulls out from under the leveling device shall be removed from service inspected by a manufacturer s authorized representative and repaired or replaced as needed before being placed back in service Any modifications
14. when calling or faxing controller orders 30 ELECTRICAL Electrical Components Hd amp 1 90 1 SUSHLO A8 Q3TIVISNI dNVUGMOd A8 09 C 09 OFZ 09 dAvM3MOd A8 SIYM M LINGNOD X314 e se P WSH 1N3IVAInO3 YO LAN SIN3S3Hd3M SUSHLO SNOILO3NNOO ejdldviS IOdJSOION3 jSIMN3HLO Q31VOIONI 5531 SYIHLO LINGNOD 7 SU3HLO Ad 31V9IQNI SSTINN SYSHLO A8 SAYIM 3131 JHL NO 40 96 VNIWH3L OL IVNINH3L LV 0351 LON LOVLNOD 4000 3l 0351 ATINA SI 4000 N3HM 035010 OL LOVINOD 035 4 ATINA LON SI 4000 N3HM N3dO 38 OL LOVINOO LOVINOD 4000 1350 31 LOVLNOD 3004 ONILVY 1 384802 LYOHS 3614 HONVYE 30 WONIXVM 3514 HONVYE 30 300801 LOVLNOD 4000 4000 QV3H33A0 SHOLONGNOD ONIMIM 1314 JO ONILWY Juni vs3aWat 5401210 00 1314 30 404 AV 138 QVO TH3AO 9 3019910 NO S3lV d3AVN 33S S 1 1 Y8 ow vei o voc d ww vu AJIAJ 5900 LV 0319001 SOLON VH 1101 V1VQ 3LVTId3AVN YOLON 318 1 5 A8 Q3TIVISNI A8 3S0
15. 32 0988 KEEPER LIP 20 24 PIT 9201 0006 Prop Pin amp Clip 4111 0023 December 2014 33 PARTS Hydraulic Components Hydraulic Components FRAME SHOWN FOR REFERENCE ONLY BILL OF MATERIAL PART NO DESCRIPTION SIZE 2 BORE X 6 STOKE 3 BORE X 14 STROKE DOTH 2814 BREATHER VENT PLUG 13 8 MALE NPT HOSE ASSEMBLY MAIN 1 4 X 30 OL R S HOSE ASSEMBLY LIP 1 4 X 70 OL R S 1 DOTH 2854 PPAC MONARCH NEUTRON 115V 230V 1 PHASE 60 HERTZ 230V 460V 3 PHASE 60 HERTZ 1 DOTH 2856 PPAC MONARCH NEUTRON 110V 220V 1 PHASE 50 HERTZ 208V 380V 3 PHASE 50 HERTZ 1 DFRA 1205 PIN 1 OD X 9 1 8 2 DOTH 2205 WASHER 1 3 4 OD X 1 1 8 D X 1 8 11 2 DOTH 2582 PIN COTER 2 DOTH 2815 2 DOTH 2816 PIN CLES XS 1 DPLA 0389 PIN MAIN HOST X 4 1 2 34 4111 0023 December 2014 Control Box 7 1 8 DANGER Hole Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De energize equipment before working on or inside Do not open cover without appropriate PPE Refer to NFPA 70E for PPE requirements This panel may contain more than one power source Hazardous Voltage Will Cause Sever Injury or Death 7141 Push Button Controller B 1 1751 0247 Decal English 1751 0477 Decal English D 1 1751 0736 Decal Arc Flash
16. 983 049 1 ONY 241 531971 335 1 15 13607083 OL LX3N HOLIMS 193NNOOSIQ 03503 V 31 201 ur NOLLO3LONd 403 0351 38 LSAW 53514 Gc 5 JHL M3d 39 30 LNSYYNOYSAO Q HOLIMS 193NNOOSIQ 193135 S43HI0 30 30 LNIYYNOYJAO 9 C JIVIGINVN NO HOLIMS 193NNOOSIQ WOSJ T 39VL10A SSHOLVW 39VL 10A 3SVHd ZH 09 A 09 0 gt gt gt 03 9905 YAWOLSND 3415 03 9905 3301515 CS DOO jud O gt 31 Provide dock leveler serial number voltage phase and options when calling or faxing controller orders 4111 0023 December 2014 COMPONENTS 7 Z 2 2 32 4111 0023 December 2014 COMPONENTS LIPS a La lol 6 0 FOOT DLIP 1250 DLIP 1256 DLIP 1259 18 DLIP 1251 DLIP 1257 DLIP 1260 DLIP 1252 DLIP 1258 DLIP 1261 6 5 1262 1268 DLIP 1271 18 DLIP 1263 DLIP 1269 DLIP 1272 DLIP 1264 DLIP 1270 DLIP 1273 7 0 FOOT DLIP 1274 DLIP 1280 DLIP 1283 2 pPLAet03 0 FOOT LIP SHAFT 8432 0983 KEEPER LIP 16 8432 0984 KEEPER LIP 18 C 2 8432 0985 20 8432 0986 LIP 16 24 PIT eji 8432 0987 KEEPER LIP 18 24 PIT 84
17. A Division of Systems Inc LHD SERIES DOCK LEVELER Dock Leveler MANUFACTURING Owner s User s Manual DLM Division of Systems Inc e W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 257 7399 www docksystemsinc com techservices docksystemsinc com Printed in U S A Manual No 4111 0023 Copyright 2014 Dec 2014 Table of Contents Page Safety Recognize Safety Information 1 General Operational Safety Precautions 1 Operational Safety 2 Maintenance Safety 4 Safety m 5 Owner s User s Responsibilities 6 Introduction General Gave cmt avouer muti Grau aS CU 8 Dock Leveler Stock Specifications 8 Component Identification cce eeeee creer eere 9 line 9 Installation Prepare rip 10 Prepare Dock Leveler 1 0 11 Install Dock Leve
18. 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 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 as the lip folds NOTE If a transport vehicle is present the platform will lower until the lip rests on the transport vehicle See Operating Instructions in Operation section 4111 0023 December 2014 INSTALLATION 7 When the platform lowers to the full below dock position wait 5 seconds after the lip has folded to allow lip cylinder to fully retract Push and hold the RAISE button until the platform rises just enough to 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 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 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 9 Raise the
19. HAISE button on the control panel Q 1 Check to make sure transport vehicle is positioned 5 Proceed with loading or unloading the transport squarely against dock bumpers vehicle 6 If end loading is necessary see End Loading 2 Instruct driver to remain at the dock until the Unloading Instructions on page 22 loading or unloading process has been completed 3 Chock the transport vehicle wheels or use the vehicle restraint if available A RAISE Button 2 tere 7 When loading or unloading is finished raise the platform by pushing and holding RAISE button A RAISE Button Hold the RAISE button until the lip folds enough 4 Extend the platform lip onto transport vehicle as to clear the transport vehicle bed then release follows the RAISE button The lip will fold and the platform will return to the cross traffic position a Raise the platform by pushing and holding RAISE button 8 Remove chocks from transport vehicle wheels or release the vehicle restraint if used b Hold the RAISE button until the lip is fully extended then release the RAISE button The 9 Indicate to driver that transport vehicle may leave platform will lower until the lip is resting on the the dock transport vehicle bed c Make sure that the lip is fully extended and supported on the transport vehicle along the entire width of the platform with at least 4 in 102 mm of lip contacting the transport vehicle bed 4111 0023
20. ade 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 Whenever maintenance is to be performed under the dock leveler platform support the platform with maintenance prop C Position the maintenance prop behind front header plate D while staying clear of the lip The lip will fold down after the platform has rested on the maintenance prop Lock the maintenance prop in the service upright position using an OSHA approved lockout device B and tagout 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 devices The tagout devices must inform that repairs are in process and clearly state who is responsible for the lockout condition Refer to regulation 1910 146 Refer to OSHA regulation 1910 147 23 MAINTENANCE Periodic Maintenance A Lip Area B Platform Hinge Area C Main Cylinder Pins D Maintenance Prop Pivot 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 Sa
21. age 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 0023 December 2014 ADJUSTMENTS A Motor C Reservoir B Breather Fill Cap D Main Pressure Relief To adjust the main pressure relief 1 Raise the platform fully and engage the maintenance prop in the service position Turn OFF all electrical power to the dock leveler Attach safety lockout and tagout devices Loosen locking nut Adjust hex adjusting screw in small 1 4 turn increments as follows Turn clockwise to increase pressure relief e Turn counterclockwise to decrease pressure relief Tighten the jam nut Turn ON electrical power to the dock leveler Disengage the maintenance prop Check leveler operation Repeat steps 1 8 as necessary 27 ADJUSTMENTS Adjust Lip Function SEQUENCE VALVE ADJUSTABLE RELIEF VALVE SEQUENCE VALVE C2 OUTLET PORT TO LIP CYLINDER C1 OUTLET PORT TO MAIN CYLINDER Valve Adjustments 1 Relief valve is factory set at 1500 PSI This valve is main the main systems relief
22. ate service work being performed Failure to comply will result in death or serious injury Refer to owner s user s manual for proper maintenance procedures 1751 0726 Rev A 4111 0023 December 2014 5 OWNER S USER S RESPONSIBILITIES 1 The owner user should recognize the inherent dangers of the interface between the loading dock and the transport 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 Effective operator training should also focus on the owner s users company policies and operating conditions Maintaining updating and re training all operators on safe working habits and operation of the equipment regardless of previous experience should be done on a regular basis and should include an understanding and familiarity with all functions of the equipment Owner s user s shall actively maintain update and retrain all operators on safe working habits and operations of the equipment The manufacturer shall provide to the initial purchaser all necessary information regarding 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 Manufacturers Contact Information as well as tables
23. ct power and follow proper lockout tagout procedures for the dock leveler before entering the dock leveler pit or doing any repair or inspection under the dock leveler FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DEATH OR OTHER SERIOUS INJURY mowERAwp 1 262 255 1510 or 1 800 643 5424 AE isin Call for additional placards or manuals or with questions regarding proper use maintenance and repair of dock leveler wwwDockSystemsInc com Loading Dock Equipment 1751 0874 PARTS OPERATING INSTRUCTIONS DOCK LEVELERS NORMAL OPERATION 1 Raise the platform by depressing and holding the RAISE button 2 Hold the RAISE button until the lip is fully extended then release the RAISE button The platform will lower until lip is resting on the transport vehicle STORING LEVELER 1 Depress the RAISE button until the lip is completely folded When the lip is folded release the RAISE button The platform will lower returning to the cross traffic position BELOW DOCK ENDLOADING HYDRAULIC ONLY Depress and hold the RAISE button until the leveler is fully raised As the lip starts to extend release the RAISE button The leveler will lower to the below dock position provided the lip extension allows the lip to clear the lip keepers AIR POWERED ONLY Depress and hold the RAISE button until the leveler is 12 above dock level Pull the below dock level chain until the l
24. death IMPORTANT DO NOT connect the dock leveler electrical 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 0023 December 2014 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 otart 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 a
25. ding 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 a DANGER Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De enemize equipment before working on ar Inside Do mat apen cover without appropiate PPE Refer to 70E for FFE recduirernernts Thes panel may contain mare than ane ONDE UCE Refer to OSHA regulation 1910 146 Hazardous Voltage Refer to OSHA regulation 1910 147 Will Cause Sever Injury or Death 4111 0023 December 2014 SAFETY 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 call 1 800 643 5424 A DANGER CRUSH HAZARD Maintenance prop must fo r re m nts support leveler behind bar 1 751 0727 Do not force maintenance prop forward of bar to support lip Failure to comply will result in death or serious injury Refer to owner s user s manual for proper use 1751 0727 Rev 1751 0730 2 SAFETY INFORMATION 1 Read and follow all inst d Unsupported dock leveler ramps can lower unexpectedly Before allowing vehicle to leave ihe dock always e Ensur
26. e no equipment material or people are on dock leveler Return dock leveler to its stored position at dock level Failure to follow posted instructions will result in death or serious injury 262 255 1510 for replacement placards waming labels or owner sjusers manuals decal placed in same position on both sides 1751 0329 x2 decal placed in same position on both sides 1751 0330 x2 decal placed in same position on both sides DANGER CRUSH HAZARD 1 7 5 1 01 3 8 DO NOT REMOVE hydraulic cylinder until leveler is safely supported by maintenance prop Refer to owner s user s manual for proper maintenance procedure Failure to comply will result in death or serious injury 1751 0729 AADANGER CRUSH HAZARD Do not work under dock leveler unless this maintenance prop has been secured in the upright position Failure to comply will result in death or serious injury See owner s user s manual for proper procedures 1751 0729 Rev A DANGER CRUSH HAZARD Rotate prop to maintenance position Open the pin latch 1 1 1 and insert through the maintenance prop housing Close the pin latch to secure prop Use every time dock leveler is serviced Failure to comply will result in death or serious injury 1751 0731 4 DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is 1 751 0726 safely supported by maintenance prop Place barriers on driveway and dock floor to indic
27. e starting Keep the operating zone free of obstacles that could cause a person to trip or fall SAFETY Operational Safety Precautions Learn the safe way to operate this equipment Read and understand the Z manufacturer s instructions If you have any questions ask your supervisor ee Stay clear of dock leveling device when transport vehicle is entering or leaving area Do not move or use the dock leveling device if anyone is under or in front of it Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts ex Chock restrain all transport vehicles Never remove the wheel chocks until loading or unloading is finished and truck driver has been given permission to drive away EN Tee Do not use a broken or damage dock leveling device Make sure proper service and maintenance procedures have been performed before using _ er Make sure lip overlaps onto transport vehicle at least 4 in 102 mm Keep a safe distance from both side edges 4111 0023 December 2014 SAFETY Do not use dock leveling device if transport vehicle is too high or too low Do not overload the dock leveling device 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 0023 December 2014 3 SAFETY Maintenance Safety Precautions Hydraulic and el
28. ectrical 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 barricade 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 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 grin
29. ed are the shims under the hoist cylinder The shim stacks be placed under both sides of the hoist cylinder before welding in place verify the hoist cylinder gland is level side to side and back to front See Page 12 21 For all LHD models remove the Shipping Bar C by grinding the tack welds that hold it in 20 When all welding has been completed paint all place during transport Paint after complete the welds and shims For left right orientation of dock leveler see inside back cover of this manual 4111 0023 December 2014 17 INSTALLATION Install Control Panel and Wiring The electrical power must be OFF prior to electrical 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 A Disconnect Panel provided by others the disconnect panel control panel and final xdi p connections to the pit junction box must be performed by a certified electrician and conform to all local and applicable national codes 1 Mount the push button control pan
30. el B so bottom of control panel to dock floor distance C is 48 in 1219 2 mm DAN 2 Install electrical disconnect panel A if not already A installed 3 Install and connect the control wiring 4 Connect the dock leveler power cable to the outlet in the pit junction box Refer to the electrical drawings supplied with the dock leveler Arc Flash and Shock Hazard 5 After all electrical connections in the pit have PPE Personal Protection been made raise the leveler disengage the Equipment Required maintenance prop and allow the platform to lower De energize equipment before 6 Install the Placard s D in close proximity to the working on or inside Do not control box and in plain sight open cover without appropriate PPE Refer to NFPA 7OE for PPE requirements This panel may contain more than one power source Hazardous Voltage Will Cause Sever Injury or Death 18 4111 0023 December 2014 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 keepers evenly If an excessive transition exists between the dock floor and leveler and or lip does not contact both lip keepers evenly contact Systems Inc Technical Services for further instructions 3 Install the dock bumpers as required 4 Turn the main electrical power ON
31. el must be welded to leveler Note see Safety section P 4 Pay special attention to removing grounds to motor anc control box before welding Provide dock leveler serial number and size of platform when calling or faxing orders 4111 0023 December 2014 37 NOTES This page intentionally left blank 38 4111 0023 December 2014 DANGER e Read and follow all instructions warnings and maintenance schedules in the manual and on placards Operation and servicing of dock leveler is restricted to trained personnel Always chock transport vehicle wheels or engage vehicle restraint and set parking brakes before operating dock leveler or beginning to load or unload Before activating dock leveler ensure lip avoids contact with transport vehicle sides and cargo If lip does not lower to transport vehicle bed reposition transport vehicle Ensure the transport vehicle floor supports extended lip or the leveler frame lip keepers or below dock endload supports supports the ramp before driving on ramp Stay clear of hinges and front and sides of moving dock leveler Never use hands or equipment to move the ramp or lip Never use damaged or malfunctioning dock leveler Report problems immediately to supervisor Always store dock leveler and remove people material and equipment from ramp before vehicle leaves the dock DO NOT ENTER PIT unless dock leveler is securely supported by the maintenance prop Disconne
32. eveler passes the below dock position HYDRAULIC WITH INFINITE LIP CONTROL If equipped raise the platform by depressing and holding the RAISE button When the lip is just above the lip keepers simultaneously depress and hold the RAISE button and the LIP OUT button until lip has extended beyond the lip keepers Release both buttons NOTE If equipped depressing E STOP button will stop platform from lowering 4111 0023 December 2014 39 PARTS This page intentionally left blank 40 4111 0023 December 2014 MISCELLANEOUS Customer Information NOTE Hefer to illustration for left right orientation of dock leveler The model serial number decal A is located on the right platform joist near the front lip of dock leveler When you receive your LHD dock leveler write down the dock leveler model and serial number in the form provided This will help ensure safe keeping of the numbers in the event the model serial number decal A becomes lost or damaged Also write down Systems Inc s job number the company that installed the dock leveler and the original owner s name This will all help to identify the specific 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
33. fely in this section Failure to follow these instructions may result in serious personal injury or death IMPORTANT Use of fluids that do not have equivalent specifications to those in the following list will result in abnormal operation of the dock leveler and voiding of warranty 24 E Lip Cylinder to Platform Pin To ensure normal operation of the dock leveler use only aircraft hydraulic fluid designed to meet or exceed military specification MIL H 5606G It is recommended that the following hydraulic fluids be used e ULTRA VIS HVI 15 Aero Shell Fluid 4 or Fluid 41 Mobile Aero Mil HS606A or Aero Texaco Aircraft Hydraulic Oil 15 or 5606 Exxon Univis J13 These fluid brands can be mixed together Mixing with fluids that do not meet or exceed MIL H 5606G may damage the equipment and WILL void warranty Use of hydraulic fluids with equivalent specifications to those listed here are acceptable 4111 0023 December 2014 MAINTENANCE Regular maintenance must be performed on a weekly and quarterly schedule Follow All Safety Precautions 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 M Reservoir P Breather Cap N 3 in 76 5mm Q Fluid Level From Top of Reservoir IMPORTANT Inspect the platform
34. for all claims whether based on contract negligence or strict liability WARRANTY LIMITATIONS THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES WHETHER EXPRESSED IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SYSTEMS INC AND ITS SUBSIDARIES SHALL NOT IN ANY EVENT BE LIABLE TO ANYONE INCLUDING THIRD PARTIES FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO BREACH OF WARRANTY LOSS OF USE LOSS OF PROFIT INTERUPTION OF BUSINESS OR LOSS OF GOODWILL
35. 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 1 Raise platform fully and engage the maintenance prop in the service position Allow platform to rest on the prop so the lip will fully fold until it contacts the lip stops 2 Turn OFF all electrical power to the dock leveler Attach safety lockout and tagout devices 4111 0023 December 2014 29 lt lt Hdt H l 25565 5 EN SYIHLO GITWISNI alo 09 0 lt 2 611 SIYM x3 Loo o gt gt gt SdIM3S H I WSH Q3H 229 431 145 GSASOIONS WoOlalosls 5 Ad Lid 30 LV X08 331315 NO 66 IWNINYSL OL IWNINYSL 0351 LON 19VLNOO 3000 JI 35 4 ATINA SI 4000 N3HM 035012 OL LOVINOD 035 4 LON 4000 N3HM N3dO 38 OL 1210402 SU3HLO A8 LOVLNOD 4000 1350 4 LOVLNOD 3000 Su3HL0
36. hinge and the lip hinge areas 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 A low fluid level or the use of hydraulic fluids not e Weekly Maintenance equivalent to the fluid types recommended will cause abnormal operation of the leveler and WILL void warranty IMPORTANT Failure to properly lubricate the dock leveler will THIEVES cause abnormal operation of the leveler 1 Put the dock leveler platform at the full above dock position engage prop e Lubricate the following areas with light weight 2 Turn OFF all electrical power to the leveler B Platform rear hinge area apply oil to top of all platform hinges when platform is at the full below dock position Before performing any maintenance under the dock leveler lock the electrical power source in Lubricate the following areas with white lithium OFF position and lock the maintenance prop in the grease service position using an approved locking device See Service Dock Leveler Safely in this section A Lip hinge area apply oil to each of lip and platform hinge when platform is at the full Failure to follow these instructions may result in below dock position and lip is folded serious personal injury or death C E Both Hoist and Lip cylinder trunnions 3 Measure fluid level The fluid level should be approximately 3 in
37. k leveler operations Suggested placement of placard is near control box attached to electrical conduit by using nylon tie If there is no control box present mount placard on wall to the immediate left of leveler at eye level TRS BN 4111 0023 December 2014 7 INTRODUCTION General Information Congratulations on your choice of a Systems Inc dock leveler This manual covers the LHD series hydraulic dock leveler Designed by Systems Inc 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 LHD series dock leveler comes equipped with an electrical control panel which allows pushbutton operation of the dock leveler functions Each LHD 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 field at installation electrical drawings are included with each order or by contacting Systems Inc Technical Services Once again thank you and congratulations on your purchase of a Systems Inc hydraulic dock leveler Dock Leveler Stock
38. k leveler pit for proper construction according to approved certified pit drawings Make sure pit is square by making the following measurements e Measure pit width distance A at both front and rear of pit e Measure dock floor to pit floor distance B at all four corners e Measure pit length distance C at sides e Measure corner to corner criss cross dis tance D at both sides Take measurements at dock floor level and at pit floor level lf any measurement is off by more than 1 8 in 3 18 mm contact Technical Services before proceeding 4 Make sure the field junction box for the dock leveler E is at the correct location per pit diagrams 4111 0023 December 2014 Prepare Dock Leveler A Lifting Bracket 2 used B Shipping Bands oystems Inc dock levelers are designed with installation in mind Each unit is shipped with lifting brackets A fastened to the platform side joists The dock leveler is heavy Use a lifting device and chains with the appropriate lifting capacity and reach Always use the lifting brackets provided with the unit whenever lowering or lifting a dock leveler into or out of a pit Failure to follow these instructions may result in damage to dock leveler and or serious personal injury or death 4111 0023 December 2014 INSTALLATION IMPORTANT DO NOT remove the shipping bands B around the platform lip and leveler frame at this time The shipping ba
39. ler e M 12 Install Control Panel and Wiring 18 Put New Leveler Into 19 Operation Operating Instructions cc 20 Ramp Loading Unloading Instructions 21 End Loading Unloading Instructions 22 Maintenance Service Dock Leveler Safely 23 Periodic 24 Adjustments Adjust Main Pressure Relief 27 LD 28 Parts COMPONEN 32 Hydraulic ES diu US 34 35 Weather Seal Rubber Style amp Toe Guards 36 Miscellaneous Electrical Wiring Single Phase 30 Electrical Wiring Three Phase 31 acp Me 39 Customer Information 2 2 4 0 41 qnl M Back Cover 4111 0023 December 2014 Rec
40. leveler is designed to compensate for a maximum 12 305 mm of height difference between the loading dock and the transport vehicle bed DO NOT use the dock leveler if the transport vehicle 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 The dock leveler operating instructions are divided into the two methods of loading and unloading Make sure platform lip rests on the transport vehicle bed with at least 4 in 102 mm of overlap Maintain a safe distance from side edges of leveler during the loading unloading process For ramp loading and unloading see Ramp Loading Unloading Instructions on page 21 Failure to follow these instructions may result in serious personal injury or death For end loading and unloading see End Loading Unloading Instructions on page 22 20 4111 0023 December 2014 OPERATION Operating Instructions Continued Ramp Loading Unloading Instructions NOTE If end unloading is required see End Loading Unloading Instructions on page 22 For ramp loading or unloading the LHD dock leveler can be operated by using the
41. 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 mm and each successive lower shim being larger so the shims can be welded together using a fillet weld DO NOT use offset method O or straight method P NOTE Shims required at location 1 see step 17 4111 0023 December 2014 INSTALLATION The dock leveler is heavy Use chains and a lifting 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 3 Using an appropriate lifting device connected to the lifting brackets lower dock leveler into the pit so rear hinge frame angle H is tight against rear pit curb angle F across full width of the leveler frame 4 Allow rear of dock leveler to rest on the rear shims while keeping the front of the dock leveler level with the dock floor 5 For all LHD add shims at front shim locations D so front of dock leveler will stay level with dock floor when leveler is resting fully on shims INSTALLATION B Z B 1 gt NONAS 55559 lt SN 3 8 6 in 152 G 9 5 i H A Front of Dock Pit C Side Pit Curb Angle E Pry Locations B Dock Leveler Frame D Gap 3 4 in 19 mm F Rear Hinge Frame Minimum Angle G Rear Pit Curb Angle H Flare Bevel Weld Typical To Fit Spacing
42. nd leveler frame If the platform is raised using an external 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 levelers 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 INSTALLATION A Platform Joists B Shim Locations Under Platform Cylinder Trunnions 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 platform is being raised 15 If binding occurs lower the platform Reposition leveler and or add or remove shims as necessary Slowly raise platform again If platform still binds contact Systems Inc Technical Services for further instructions 16 LHD models a Install shims under maintenance prop D where prop attaches to leveler frame Make 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 16 C Removable Frame Section D Maintenance Prop Two people are required to engage the maintenance prop one person to operate the lifting device the other person to engage the maintenance prop
43. nds are needed to hold the leveler together during the installation process 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 Overtightening can damage the weather seal if equipped NOTE Overall width of platform and lifting brackets A must be kept to a minimum to prevent interference between the lifting brackets and the pit walls as the dock leveler is lowered into the pit 2 Make sure the mounting hardware of lifting brackets A is snug The brackets should pivot relatively freely on the mounting cap screw DO NOT overtighten 3 Attach lifting chains to lifting brackets A and to a lifting device i e hoist or fork truck having the appropriate lifting capacity and reach 4 Remove wood blocks that are attached to the leveler frame before putting the dock leveler into the pit INSTALLATION Install Dock Leveler A Distance Leveler Frame Height B Shim Locations Under Rear Vertical Supports C Shim Location Under Maintenance Prop D Shim Location under Lip Keepers E Dock Floor F Rear Pit Curb Angle G String 12 H Rear Hinge Frame Angle I Shim Locations Under Hoist cylinder J Distance Dock Floor to Floor K Shim Stack L Dock Leveler Frame M Py
44. ognize 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 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 practice 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 0023 December 2014 SAFETY General Operational Safety Precautions Head 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 Hemove any tools or foreign objects from the operating zone befor
45. platform fully Hold the platform at this position using the RAISE button and move the maintenance prop to the service upright position Helease the RAISE button to allow the platform to lower until it is resting on the maintenance prop 10 With the maintenance prop supporting the platform remove the lifting brackets and front shipping bar in between lip keepers 11 Push and hold the RAISE button until the maintenance prop drops to its stored position Helease the RAISE button and allow the platform to lower fully OPERATION Operating Instructions Stay clear of dock leveler when transport vehicle 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 Transport vehicle wheels must be chocked unless the vehicle restraint is used Never remove the wheel chocks until loading unloading is finished and transport vehicle driver has been given permission to leave 305 69 6 12 305 The LHD hydraulic dock
46. ramid Preferred N Stepped Acceptable O Offset Not Acceptable P Straight Not Acceptable Q Shim Location Snubber Spring Shim Stacking Methods Q e 4111 0023 December 2014 NOTE Systems Inc dock levelers are designed with a 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 J at each shim location B Write down the dimensions obtained at each location c Subtract distance A from distance J 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 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 NOTE To assist in obtaining an accurate measurement of distance J use a string G pulled tight across the pit opening directly over the shim locations 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
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