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User`s Manual - Curlin, Inc.

1. Fig 16 Safety leg Lois hinge Lip plate Safety leg Lip maintenance bar Exo Essi l IN qu L Adjusting nut Toe guards Main springs ZEN Lip Hold down assy 1 extension spring Al Maintenance strut Subframe D84 spring Safety leg rests Lip keepers November 2013 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 13 2013 4Front Engineered Solutions Inc OPERATIONS LAWARNING Before operating the dock leveler read and follow the Safety Practices on page 3 Use of dock leveler restricted to trained operators Follow procedures on placard posted near dock leveler DO NOT USE DOCK LEVELER IF IT LOOKS BROKEN OR DOES NOT SEEM TO WORK RIGHT Inform your supervisor immediately Before chocking wheels or engaging vehicle restraint dump air from air ride suspensions and set parking brake Always be certain that the vehicle is properly restrained before loading or unloading VISUALLY INSPECT vehicle restraint to make sure vehicle does not pull away unexpectedly Failure to do so could result in death or serious injury Before pulling release ring ensure lip avoids vehicle sides and cargo If the lip does not lower to the vehicle bed reposition vehicle Never walk on leveler lip to lower dock leveler Visually chec
2. 506 2050 Tes 1 Swevtesspg os sss 35055 Le soWawwumcPam 2 zs Ceo a FootAssonby Sei 90215 DOCK LEVELER 600 Capacity Item Qty Part Description 30 000 35 000 40 000 45 000 71 3 Main Spring Extension 6 ft x 16 in 333 049 333 049 333 049 333 049 Main Spring Extension 6 ft x 18 in 333 049 333 049 333 054 333 054 Main Spring Extension 6 ft x 20 in 333 054 333 054 333 054 333 054 Main Spring Extension 6 5 ft x 20 in 333 054 333 054 333 054 333 054 71 2 Main Spring Extension 7 ft x 16 in 333 054 333 054 333 054 333 054 Main Spring Extension 7 ft x 18 in 333 054 333 054 333 054 333 054 Main Spring Extension 7 ft x 20 in 333 054 333 054 333 054 333 054 Main Spring Support Assembly 3 5073 3 5073 3 5073 3 5073 Quantity 2 71 2 Main Spring Extension 6 5 ft x 16 in 333 054 333 054 333 054 333 054 Main Spring Extension 6 5 ft x 18 in 333 054 333 054 333 054 333 054 November 2013 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 31 2013 4Front Engineered Solutions Inc PARTS LIST continued DOCK LEVELER 800 Part Description 30 000 71 2 Main Spring Extension 6 ft x 16 in 333 054 Main Spring Extension 6 ft x 16 in Main Spring Extension 6 ft x 18 in Main Spring Extension 6 ft x 18 in Main Spring Extension 6 ft x 20 in Main Spring Extension 6 ft x
3. ADJUSTMENTS HOLD DOWN ASSEMBLY The hold down uses a friction brake to hold the leveler in position The brake is released to allow the leveler to raise and the lip to extend Fig 34 24 Brake housing e d Rack Spur gear Float spring housing Release lever Gear axle LL g EE 2 Brake band tension adjusting nut Release lever Subframe adjusting nut 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame November 2013 2013 4Front Engineered Solutions Inc ADJUSTMENTS HOLD DOWN ASSEMBLY continued NOTE Before making any adjustments to the leveler mechanisms be sure to clean lube per instructions on page 19 and 20 and operate leveler several times ADANGER Do not lubricate between the brake band and brake drum If the leveler raises without pulling the hold down release ring inspect the gear teeth on the rack bar and pinion gear Also make sure that the pinion gear is free to slide along the axle to engage the clutch teeth on the side of the brake drum assembly If foreign material has accumulated on the gear axle it will interfere with free movement of the spur gear Clean the axle and small compression spring which fits over the axle If the leveler raises by itself or if the leveler will not raise quickly when the hold down release ring is pulled the hold down requires adjustment or replacement To adjust the
4. Latch Assist Arm 2 3 8 Tube L 4 586 2638 586 2638 Lip Hinge Pin 6 ft wide 586 0017 586 0017 586 0287 586 0287 Lip Hinge Pin 6 5 ft wide 586 1494 586 1494 586 1495 586 1495 Lip Hinge Pin 7 ft wide 586 0201 586 0201 586 0392 586 0392 333 043 333 043 333 043 333 043 333 044 333 044 333 043 333 043 333 044 333 044 333 044 333 044 333 043 333 043 333 043 333 043 333 044 333 044 333 044 333 044 333 044 333 044 333 044 333 044 333 043 333 043 333 043 333 043 Extension Spring Lip 7 ft x 18 in 333 044 333 044 333 044 333 044 Extension Spring Lip 7 ft x 20 in 333 044 333 044 333 044 333 044 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Hold down rack 88786 88786 88786 88786 Hold down assy 6013680 6013680 6013680 6013680 Does not include item 77 hold down rack Extension Spring Lip 6 ft x 16 in Extension Spring Lip 6 ft x 18 in Extension Spring Lip 6 ft x 20 in Extension Spring Lip 6 5 ft x 16 in Extension Spring Lip 6 5 ft x 18 in Extension Spring Lip 6 5 ft x 20 in Extension Spring Lip 7 ft x 16 in November 2013 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 33 2013 4Front Engineered Solutions Inc PARTS LIST continued OPTIONAL ENERGY GUARD DOCK LEVELER SEALING SYSTEM Fig 37 Description Quantity Part 6x6 6 5 6 6x7 6x8 6 5 8 7x8 6x10 6 5x10 7x10 Number 6008228 6008229 6008230 6008234 6008232
5. 6008233 6008234 6008235 6008236 5 1 2 Front seal 2 008166 Vertical seal 2 6008173 6 Upper seal 6008167 8 Upper seal 6008169 10 Upper seal Aluminum strip 53 1 2 Aluminum strip 77 1 2 Aluminum strip 101 1 2 6008171 6 Lower seal 2 8 Lower seal 10 Lower seal o 6008175 6008177 6008179 6008168 6008170 6008172 6008174 6008176 6008178 Aluminum strip 6 upper 2 Aluminum strip 8 upper Aluminum strip 10 upper 6 Serco rear seal 1 6007674 6 5 Serco rear seal 1 6007675 7 Serco rear seal 6007676 000699 0392 6008249 328907 328908 328910 6009507 6008247 Tech screws not shown 6 Chain cup seal 0 3 4 10 Set screw W seal 600 W brush W seal 800 W brush W seal 600 W brush cut 2 Corner bulb seal 3 Transition angle seal optional 2 34 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame November 2013 2013 4Front Engineered Solutions Inc LIMITED WARRANTY MECHANICAL DOCK LEVELER THIS LIMITED WARRANTY IS 4FRONT S SOLE AND EXCLUSIVE WARRANTY WITH RESPECT TO THE DOCK LEVELER AND IS IN LIEU OF ANY OTHER GUARANTEES OR WARRANTIES EXPRESS OR IMPLIED 4FRONT warrants that this DOCK LEVELER will be free from flaws in material and workmanship under normal use for a period of one 1 year from the earlier of 1 60 days after the date of initial shipment by 4FRONT or 2 the date of installation of t
6. Item Qty Part Description WS600 WS800 WS1000 WL600 WL800 WL1000 31 Hex Nut 3 8 Nylock 214 538 214 538 Clevis Pin 1 2 DIA x 2 3 4 Ig 231 502 231 502 Spring Pin 231 123 231 123 Plain Washer 3 8 Bolt Size 7 16 Hole 234 101 2 234 101 921 070 921 074 921 117 583 0003 821 034 586 3031 821 033 586 1998 586 1467 586 0003 333 045 Pin 3 4 Dia x 2 1 18 Gr Rng 586 0003 586 0003 Lift Arm Assy Consult Factory Plain Washer 1 Bolt Size 1 1 16 Hole Size 234 161 Hex Nut 1 8 214 341 Pin 1 Dia 5 1 2 Gr Rng 586 1070 234 161 214 341 586 1070 6002984 586 3120 586 2969 51 Upper Safety Leg Assy 6002984 6002984 Lip Plate Maint Bar 586 2969 586 2969 8201 CARS z o 30 6004758M WL WS Series with HYDRA CAM Lip Extension SafeTFrame November 2013 2013 4Front Engineered Solutions Inc PARTS LIST continued CM WL AND WS SERIES DOCK LEVELER continued Part Number CM1000 Item Qty Part Description WS1000 WL1000 Spring Adjusting Loop 586 3009 586 3009 586 3009 Serial tag 6009761 6009761 6009761 58 2 Serco Name Plate 824 002 824 002 824 002 2 Kelley Name Plate 921 140 921 140 921 140 60 2 User Warning Label 6008485 6008485 6008485 Rear WeatherSeal CP 6ft 6015410 6015410 6015410 Rear WeatherSeal CP 6 5ft 6015411 6015411 6015411 Rear WeatherSeal CP 7ft 6015594 6015594 6015594 1
7. 054T 333 054T 333 049 333 049 333 049 333 049 71 Main Spring Extension 6 5 ft x 16 in 333 054 333 054 333 054T 333 054T 333 049 333 049 333 049 333 049 Main Spring Extension 6 5 ft x 18 in 333 054 333 054 333 054T 333 049 333 049 333 049 Main Spring Extension 6 5 ft x 20 in 333 054 333 054 333 054T 333 049 333 049 333 049 333 054T 333 049 333 054T 333 049 71 Main Spring Extension 7 ft x 16 in 333 054 333 054 333 054t Main Spring Extension 7 ft x 18 in 333 054 333 054 333 054t Main Spring Extension 7 ft x 20 in 333 054 333 054 333 054t 1 Main Spring Support Assembly 3 5254 3 5254 3 5254 333 0541 Quantity 2 TQuantity 3 Quantity 4 333 0544 333 0544 72 3 5254 1 1 1 1 1 1 IER 32 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame November 2013 2013 4Front Engineered Solutions Inc PARTS LIST continued DOCK LEVELER ALL Capacity Item Qty Part Description 30 000 35 000 40 000 45 000 73 Lip Assembly L 6 ft x 16 in Lip Assembly L 6 ft x 18 in Lip Assembly Lip Assembly Lip Assembly Lip Assembly Lip Assembly 6 ft x 20 in 6 5 ft x 16 in 6 5 ft x 18 in 7 ft x 16 in T ft x 18 in L L L Lip Assembly L 6 5 ft x 20 in L L L Lip Assembly L 7 ft x 20 in Latch Assist Arm 1 3 4 Tube L 586 2272 586 2272
8. 14 Wananty 2 35 Above Dock 15 Corporate Contact 36 Below Dock Level 17 Below Dock Level End Loading 18 INTRODUCTION Welcome and thank you for choosing this dock leveler for your material handling applications This leveler is equipped with exclusive Posi Trac hold down and Clean Frame design This dock leveler may be equipped with the optional ENERGY GUARD dock leveler sealing system This User s Manual contains information that you need to safely install operate maintain and identify parts for the dock leveler Please read and follow this User s Manual when installing the dock leveler SAFETY SIGNAL WORDS You may find safety signal words such as DANGER WARNING CAUTION or NOTICE throughout this User s Manual Their use is explained below This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible death or injury A DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury 2 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTF
9. 20 lips shims must also be welded in between the lip keepers and the vertical face of the curb angle Before welding the dock leveler permanently into the pit check the frame alignment again to ensure that the lip keepers are parallel to the lip See Fig 6 Shimming of the frame members to a point where the front and rear are not parallel to each other will cause excessive float on one side of the ramp The number of shims placed under the front frame will vary depending upon the runout in the poured pit and the desired location of the ramp when it is in dock level position FINISH WELDING 24 After verifying that both sides of the dock leveler are evenly spaced to the pit sides and the top edge of the rear frame angle is flush to a max 1 16 below the rear curb angle weld the rear frame angle to the rear curb angle using 1 4 bevel joint weld in the grooves provided Shown in Fig 5 IN STALLATION continued Fig 6 9 r Lip keepers not parallel to lip Improper Installation Proper Installation Lip keepers parallel to lip November 2013 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 9 2013 4Front Engineered Solutions Inc IN STALLATION continued 25 26 27 28 29 30 After the rear hinge angle is welded check tha
10. V Both sides W ij Rear hinges and back 7 5 A j ay CNN T aln l Clean Ng as required et November 2013 PLANNED MAINTENANCE continued 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 your authorized 4Front Engineered Solutions Inc distributor DANGER Fig 31 CRUSH HAZARD Maintenance strut must support leveler behind bar Do not force maintenance strut forward of bar to support lip Refer to user s manual for proper use Failure to do so will result in death or serious injury 921 117 ET Do not remove main springs until leveler is securely supported by a suitable lifting device Main springs contain stored energy Be sure springs are fully unloaded and ends are loose before removal Failure to comply will result in death or serious injury Refer to User s Manual for proper maintenance procedure a CRUSH HAZARD Do not work under dock leveler unless this maintenance strut has been secured in the upright position See user s manual for proper procedures 921 074E 4 DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is e securely supported by the maintenance strut Place barriers on driveway and dock floor to indicate service work being performed Failure to comp
11. and allow the lip to fall See Fig 24 If the lip does not fall to the stored position the dock leveler requires maintenance or adjustment Notify your supervisor Do not use the dock leveler until it has been repaired Failure to comply could result in death or serious injury 2 When the lip is fully retracted and clear of the vehicle walk forward to the front of the ramp The dock leveler will lower until the lip is resting in the lip keepers See Fig 25 Fig 25 e November 2013 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 17 2013 4Front Engineered Solutions Inc OPERATIONS BELOW DOCK LEVEL END LOADING Use these instructions when end loading a vehicle which is lower than the loading dock A WARNING Fig 26 Always secure the vehicle with a vehicle restraint or wheel chocks before operating the dock leveler Do not operate dock leveler with anyone standing on or in front of it Do not lift the leveler lip by hand Always keep hands and feet clear of all moving parts Always restore the leveler to its safe dock level position with the lip supported in both lip keepers after servicing the vehicle 1 Gently pull the hold down release ring until the leveler is about 6 above dock level See Fig 26 2 Walk towards the front of the dock leveler Pull the safety leg release ring to retract the safety legs and extend the lip ahead of the lip ke
12. brake band before the float tube extends at least 1 1 2 or the brake will not hold replace the hold down assembly November 2013 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 25 2013 4Front Engineered Solutions Inc TROUBLESHOOTING GUIDE Be certain before climbing into the dock leveler pit or doing any maintenance or repair under the dock leveler that the maintenance strut is raised and supporting the top plate in case of emergency Failure to do so could result in death or serious injury Use the Troubleshooting Guide if ever the leveler fails to perform properly Find the condition that most closely matches your situation and make the recommended adjustments PROBLEM 1 Leveler will not raise when release ring is pulled b Hold down is binding or rack is bent c Brake band dragging d Main springs require adjustment 2 Leveler cannot be walked down b Main spring over adjusted 3 Lip plate will not fully extend when leveler is raised b Debris or corrosion in rear hinge c Lip spring adjustment incorrect d Hold down not releasing freely e Main spring adjustment 26 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 2013 4Front Engineered Solutions Inc POSSIBLE CAUSE a How down release chain is binding a Rack assy is binding or bent a Debris or corrosion in lip hinge Before ser
13. lip maintenance bar a Support the lip manually and swing up the lip maintenance bar so the lip will rest on it Ensure the lip maintenance bar is fully raised before releasing the lip See Fig 14 2 release the lip maintenance bar a Support the lip manually and pull the lip maintenance bar down LIP WILL DROP without manual support G Fig 14 Ensure your head and fingers are away from the lip Fig 15 and any moving parts See Fig 15 a 9 IL CT ar il ro E US E 12 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame November 2013 2013 4Front Engineered Solutions Inc COMPONENTS The main components of the dock leveler are shown below See the Parts List for specific part numbers
14. the lip is supported by the vehicle floor or the lip is supported by both lip keepers before driving on the ramp Store the dock leveler at dock level with lip in both lip keepers after use Ensure lip avoids contact with vehicle sides and cargo If lip does not lower to vehicle bed reposition vehicle Move all equipment material or people off the dock leveler and store the dock leveler before allowing the vehicle to pull out Do not walk on lip to lower the dock leveler SAFETY PRACTICES Do not use a fork truck or other material handling equipment to lower the ramp Before chocking wheels or engaging the vehicle restraint dump all air from the air ride suspensions and set the parking brake INSTALLATION MAINTENANCE AND SERVICE Service of dock levelers restricted to trained personnel Place barricades on the dock floor around the dock leveler pit and in the driveway in front of the pit while installing maintaining or repairing the dock Do not operate the dock leveler when anyone is standing in front of the dock leveler unless they are securing the maintenance strut Do not enter pit or do any maintenance or repair under dock leveler unless leveler is securely supported by maintenance strut Failure to follow these instructions could result in death or serious injury to operators and or bystanders November 2013 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 3 2013 4F
15. 1 7 8 0 14 8 2 1 11 1 1 6 8 8 3 8 gt gt a 6 0 10 5 4 2 7 9 1 6 6 3 0 0 a 6 0 11 9 0 7 9 0 3 6 7 2 5 4 lt 4 0 7 8 1 5 5 8 0 5 4 7 1 6 lt 4 0 9 2 3 4 6 9 5 7 5 5 7 1 2 0 5 0 1 3 3 8 2 5 3 0 3 3 2 0 6 4 6 2 4 8 7 8 3 8 8 8 0 0 2 2 4 0 4 6 4 6 1 3 4 9 0 0 3 6 9 0 2 7 9 9 2 2 10 4 x 2 0 0 5 6 8 6 7 17 2 0 3 6 6 x 2 0 0 9 11 8 0 6 12 0 0 5 12 1 4 0 3 3 9 6 8 8 20 4 2 0 8 3 S 4 0 2 1 14 6 14 14 1 1 1 13 8 A 6 0 6 0 124 10 8 18 6 3 6 9 9 A 6 0 4 7 17 4 3 5 16 2 2 8 15 5 2 8 0 8 8 15 2 12 9 16 8 53 11 6 z 8 0 7 4 20 3 5 6 18 3 4 5 17 2 10 0 11 6 18 0 15 1 15 0 7 0 13 3 10 0 10 2 23 2 7 7 20 5 6 1 18 9 m 12 0 14 4 20 9 17 2 13 3 8 6 15 0 a 12 0 13 0 26 1 9 8 22 7 7 8 20 6 Ramp and lip grade 4 lip bend 16 lip Ramp and lip grade 7 lip bend 16 lip November 2013 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 5 2013 4Front Engineered Solutions Inc INSTALLATION PIT CHECK 1 Inspect the pit and remove all loose trash and construction debris Prepare the rear of the pit for the leveler mounting feet Usinga chisel remove any high spots visible within 6 ofthe rear wall below the rear curb angle Verify that the pit matches the pit details for your leveler See the installation troubleshooting on page 11 if the pit varies from the sp
16. 20 in 333 054 333 054 333 054 333 049 333 054 Main Spring Extension 6 5 ft x 16 in Main Spring Extension 6 5 ft x 16 in Capacity 333 054 333 054 333 049 333 054 333 049 333 054 333 049 333 054 333 049 333 054 333 054 333 054 333 054 333 049 333 054 35 000 40 000 45 000 333 054 333 049 333 054 333 049 333 054 333 049 333 054 333 049 333 054 Main Spring Extension 6 5 ft x 18 in Main Spring Extension 6 5 ft x 18 in Main Spring Extension 6 5 ft x 20 in Main Spring Extension 6 5 ft x 20 in 333 049 333 054 333 049 333 054 333 049 333 054 333 049 333 049 333 054 333 049 333 054 333 049 333 054 333 049 333 049 333 054 333 049 333 054 333 049 333 054 333 049 333 049 333 054 333 049 333 054 333 049 333 054 333 049 Main Spring Extension 7 ft x 16 in Main Spring Extension 7 ft x 16 in Main Spring Extension 7 ft x 18 in Main Spring Extension 7 ft x 18 in Main Spring Extension 7 ft x 20 in 333 054 333 054 333 054 333 054 Main Spring Extension 7 ft x 20 in 333 049 333 049 333 049 333 049 1 2 1 2 1 71 2 1 2 1 2 1 71 2 1 2 1 2 1 DOCK LEVELER 1000 71 Main Spring Extension 6 ft x 16 in 333 054 333 054 333 054 333 054T 333 049 333 049 333 049 333 049 Main Spring Extension 6 ft x 18 in 333 054 333 054 333 054T 333 0541 333 049 333 049 333 049 333 049 Main Spring Extension 6 ft x 20 in 333 054 333 054 333
17. Mechanical Dock Levelers Models CM WL and WS with HYDRA CAM Lip Extension This manual applies to dock levelers manufactured beginning November 2013 with the serial numbers 61095303 and higher A WARNING U M Do not install operate or service this product unless you S e r S a n u a have read and understand the Safety Practices Warnings n sta ati on O p e rati ons Installation and Operating Instructions contained in this 4 7 User s Manual Failure to do so could result in death or M al nten ance a nd P a rts serious injury Part No 6004758M TABLE OF CONTENTS Introduction eee 2 Planned 19 Safety Signal WORKS osisssoseees athecatdeeeheeeeenien NEP SUIS 0 m 22 Safety PraptipBeu 3 Lip Assist with HYDRA CAM 22 Owner s Responsibilities 4 Main Spring Counterbalance 23 Ramp and Lip Grades 5 Hold Down 24 Installation Rr EE Troubleshooting Guide rennen 26 Service Tools ccccccccceecceecceeeceeeeeeeeeeeeeeeeeeteeeeneess 12 Parts List Components ssssssssee eee 13 Dock 28 Operations ENERGY GUARD aa 34 CWO Mop m
18. adjusting Bellcrank Pivot plate Walk the leveler down approximately 12 The lip should start to drop very slowly If the lip does not start to fall decrease the lip spring tension by turning the adjusting bolt counter clockwise Securely tighten the locknut after adjusting Walk the leveler down an additional 6 The lip should fall tothe pendant position Further decrease lip spring tension if required Securely tighten the locknut after adjusting After the lip spring has been properly adjusted walk the leveler down to dock level The lip should fall completely within 20 seconds Because the force of the Hydra Shock is affected by temperature the bellcrank has three mounting holes The front of the Hydra Shock is normally mounted in the outermost position To adjust the Hydra Shock the lip must be pendant If the lip falls too quickly remove the spring clip and clevis pin and move it to a hole farther from the center of the bellcrank If the lip falls too slowly move the pin to the hole closer to the center of the bellcrank and secure with pin NOTE Before making any adjustments to the leveler mechanisms be sure to clean lube per instructions on page 19 and 20 and operate leveler several times Three mounting holes Hydra Shock Adjusting bolt Locknut l SSS T d SSS Lip spring WWW ESSER S p ERES f Q E m 22 6004758M CM WL a
19. ck leveling devices shall be made only with written permission of the original manufacturer When industrial vehicles are driven on and off transport vehicles during the loading and unloading operation the brakes on the transport vehicle shall be applied and wheel chocks or positive restraints that provide the equivalent of wheel chocks engaged The dock leveler should never be used outside its vertical working range or outside the manufacturer s labeled rated capacity It must also be compatible with the loading equipment and other conditions relating to the dock 4 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 2013 4Front Engineered Solutions Inc November 2013 RAMP AND LIP GRADES Ramp grade Lip grade x Ramp and lip grades Ramp lip grades Vehicle bed 96 for each dock leveler length Vehicle bed 96 for each dock leveler length position position from dock 6 Leveler 8 Leveler 10 Leveler from dock 6 Leveler 8 Leveler 10 Leveler in amp Lip amp Lip amp Lip in amp Lip amp Lip amp Lip in R L R Lip R L in R L R Lip R L 15 0 13 9 7 5 15 0 14 7 2 0 x x 12 0 19 1 12 6 14 2 7 9 11 4 5 0 S 12 0 20 5 7 7 15 3 2 6 12 2 0 4 Q 10 0 16 2 9 8 12 1 5 8 9 7 3 4 a 10 0 17 6 4 9 13 2 0 5 10 5 2 1 8 0 13 3 7 0 10 0 3 7 8 0
20. crete work attempt to flatten out the rough surface using a chisel or grinder to take out the large obstructions The rear leveling legs can be installed on out of plane surfaces up to 1 8 at each leg See Fig 12 Weld 4 x 4 shims to the bottom of the adjustable legs Fig 10 Fig 11 Fig 12 Shim and weld flush L i ii NS E e E 1 8 max mu mE m allowable step t it no greater than n 4 1 x3 in size A o a l Equal o gap 6 zi m gt contact uiii zone November 2013 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 11 2013 4Front Engineered Solutions Inc SERVICE TOOLS Read and follow the Safety Practices on page 3 of this manual before doing any service or repair to the dock leveler RAISE Maintenance strut before climbing into the dock leveler pit or doing any maintenance or repair under the dock leveler Failure to follow these instructions could result in death or serious injury MAINTENANCE STRUT 1 To raise the maintenance strut a Pull the hold down release chain to raise the dock leveler to the full above dock position b Lift the maintenance strut up and forward c Allow it to drop down into the locked position See Fig 13 2 To lower the maintenance strut a Lift the maintenance strut straight up b While holding it up push it back It will then lower to the stored position LIP MAINTENANCE BAR 1 To Raise the
21. ecification See Fig 12 LEVELER CHECK 1 Visually check that all rear hinge pins cotter pins and kliprings are in place 2 Visually check that the lip pin retainers are in place on both ends of the lip rod 3 Visualy check that both the lip maintenance bar and maintenance strut are undamaged and pins securely attached 4 Visually check that the foot assemblies atthe rear of the leveler are in place and undamaged INSTALLATION 1 4 x4 steel shims are to be placed under the safety leg rests D84 spring bracket the outboard end of the D84 mounting plate and the maintenance strut bracket at the front of the frame See Fig 1 and step 13 2 Hold the leveler closed with shipping banding securing the lip plate to the frame Install two load centering eye bolts into the front and rear of the top plate and hoist the leveler into the pit The dock leveler should not be lifted in any other manner when placed into the pit See Fig 2 Inadequate lifting equipment or practices can cause a lifted load to fall unexpectedly Make sure lifting chain or other lifting devices are in good condition and have a rated capacity of at least 3500 Ibs for the lifting angle used Never allow anyone to stand on or near dock leveler when it is being lifted or placed into the pit Stand clear of the dock leveler when it is being placed into the pit Failure to follow this warning can allow the dock leveler to fall tip or swing into people resulting i
22. epers The dock leveler will lower to the below dock position See Fig 27 STORING LEVELER 1 To return the leveler to the stored position gently pull the hold down release ring to raise the leveler from the vehicle floor and allow the lip to fall See Fig 28 If the lip does not fall to the stored position the dock leveler requires maintenance or adjustment Notify your supervisor Do not use the dock leveler until it has been repaired Failure to comply could result in death or serious injury 2 When the lip is fully retracted and clear of the vehicle walk forward to the front of the ramp The dock leveler will lower until the lip is resting in the lip keepers See Fig 29 Fig 29 e 18 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame November 2013 2013 4Front Engineered Solutions Inc ADANGER Be certain before climbing into the dock leveler pit or doing any maintenance or repair under the dock leveler that the maintenance strut is raised and supporting the top plate in case of emergency Failure to do so could result in death or serious injury WEEKLY 1 Inspect for debris in lip hinge Clean as required 2 Inspect for debris in rear hinge area of the leveler and between the sides and curb angles to ensure smooth operation Clean as required 3 Inspectthe safety leg system for free operation structural flaws pull chain and return spring operatio
23. etract safety legs and lubricate or repair as required b Check float as shown on page 24 and adjust hold down if required a Clean adjust and lubricate hold down as shown on pages 19 and 24 25 Replace entire hold down assy if leveler will not stay down after lubrication and adjustment 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 27 2013 4Front Engineered Solutions Inc PARTS LIST continued CM WL AND WS SERIES DOCK LEVELER Top plate assy November 2013 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 28 S Inc ed Solution 2013 4Front Engineer PARTS LIST continued CM WL AND WS SERIES DOCK LEVELER Part Number CM600 CM800 CM1000 Part Description WS600 WS800 WS1000 WL600 WL800 WL1000 Toe Guard 2nd stage left when specified 586 1659 586 0440 586 1045 Toe Guard 2nd stage right when specified 586 1660 586 0441 586 1044 Toe Guard 1st stage left when specified 586 1657 586 0439 586 1043 Toe Guard 1st stage right when specified 586 1658 586 0438 586 1042 Pusher Assy for safety legs 3 4666 3 4666 3 4666 Pusher Assy below dock control 3 4799 3 4799 3 4799 4 otter Pin 1 8 x 3 4 231 341 231 341 231 341 C Chain Assy B D C below dock control 8 9610 8 9610 8 9610 Maintenance Strut 600 CP 586 2966 586 2966 586 2966 Weather Seal Mounting Strip with rubber seal
24. f the leveler subframe below the D84 spring at the end of the D84 mounting plate and the maintenance strut support These shims should be flush with the front of the leveler frame below or behind the lip keepers and of the proper thickness until top of deck is level with the dock surface The shims at the end of the D84 mounting plate should be flush with the end of the plate to prevent the D84 chain from getting caught underneath it See Fig 6 NOTE Ensure that the D84 shim fully supports the spring mount and is lined up with the outer edge of the support bracket 14 15 16 17 Pull the release chain located at the rear of the ramp assembly and allow the ramp to rise to its above dock position The lip will extend automatically as the leveler raises Walk the dock leveler down then pull the release chain once more to raise the leveler to a slightly above dock position Walk the dock leveler down to its stored dock level position Check to ensure that the lip plate is supported in the lip keepers Bevel groove weld locations 5 5 2 1 2 PR 5 2 1 2 lt _ 2 1 2 gt 2 1 2 5 dE le 5 ryt Pit H rear y curb angle Frame Rear hinge uprights assembly 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame November 2013 2013 4Front Engineered Solutions Inc 18 To ensure that the ramp wi
25. he DOCK LEVELER by the original purchaser provided that the owner maintains and operates the DOCK LEVELER in accordance with this User s Manual Main Spring Warranty All main springs are warranted to cover the cost of replacement parts and freight only for an extended period of four 4 years after the initial 1 year warranty period Parts warranty All spare parts or replacement parts are warranted to cover the cost of replacement parts and freight only for ninety 90 days from the date of shipment In the event that this DOCK LEVELER proves deficient in material or workmanship within the applicable Limited Warranty period owner shall so notify 4FRONT and 4FRONT will at its option 1 Replace the DOCK LEVELER or the deficient portion s thereof without charge to the owner or 2 Alter or repair the DOCK LEVELER on site or elsewhere without charge to the owner This Limited Warranty does not cover any failure caused by improper installation abuse improper operation negligence or failure to maintain and adjust the DOCK LEVELER properly Parts requiring replacement due to damage resulting from vehicle impact abuse or improper operation are not covered by this warranty 4AFRONT DISCLAIMS ANY RESPONSIBILITY OR LIABILITY FOR ANY LOSS OR DAMAGE OF ANY KIND INCLUDING WITHOUT LIMITATION DIRECT INDIRECT CONSEQUENTIAL OR PUNITIVE DAMAGES OR LOST PROFITS OR LOST PRODUCTION arising out of or related to the use installation or mainte
26. hold down to provide optimum performance the following adjustments are to be made in the sequence shown 1 Clean the hold down rack and gears and apply a light automotive grease Do not lubricate between the brake band and brake drum 2 Release Lever Adjusting Nut The end of the release lever should be approximately 5 away from the chain guide assembly as shown Adjust the release lever adjusting nut to maintain the 5 distance 3 Brake Band Tension Adjusting Nut The brake spring applies tension to the brake band The spring is factory set to 3 compressed length as shown in Fig 34 To check the adjustment of the brake spring to provide proper hold down float e Pull the hold down release chain and hold until the lip fully extends e Engage the lip maintenance bar e Lower the leveler to dock level e Lift up on the leveler until the brake housing moves away from the float spring housing e Measure the brake housing extension distance when the brake starts to slip Do not lubricate between the brake band and brake drum When the dock leveler is forced upward the brake should not slip until the brake housing has extended at least 1 1 2 away from the float spring housing Tighten the brake band tension adjusting nut to increase the braking force if required Do not tighten the brake spring to less than 2 1 2 long or the brake may not release properly If slippage occurs in either the gears or the
27. k leveler lip as the ramp is being raised from its stored position When the leveler is lowered the extended lip rests on the trailer floor forming a bridge After loading pulling and holding the release chain allows the ramp to raise The lip will retract as the leveler is raised Walking out onto the ramp lowers the leveler to the stored dock level position With the dock leveler in the stored position lip keepers support the dock leveler ramp at a position level with the dock floor For below dock loads the safety legs can be retracted by pulling the below dock chain located near the front of the deck before the deck lowers past dock level 14 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 2013 4Front Engineered Solutions Inc November 2013 OPERATIONS ABOVE DOCK LEVEL Use these instructions for normal operations when the height of the vehicle is above the loading dock Always secure the vehicle with a vehicle restraint or wheel chocks before operating the dock leveler Do not operate dock leveler with anyone standing on or in front of it Do not lift the leveler lip by hand Always keep hands and feet clear of all moving parts Always restore the leveler to its safe dock level position with the lip supported in both lip keepers after servicing the vehicle RAISING THE LEVELER 1 Before operating the dock leveler secure the vehicle with a vehicle restraint or whee
28. k that the lip is supported by the vehicle floor or the ramp is supported by both lip keepers before driving or walking on the ramp Always return the dock leveler to its dock level stored position before allowing the vehicle to leave the dock If the vehicle pulls away before the dock leveler is stored the lip will fall to its pendant position and may not be supported by the lip keepers In addition failure to properly store the dock leveler may leave the leveler in a position below the level of the dock floor These conditions may result in unexpected drop of personnel or material handling equipment and result in death or serious injury Failure to follow these instructions could result in death or serious injury to operators and or bystanders If the vehicle unexpectedly pulls away leaving the dock leveler unsupported the maximum drop is as follows 1 If the leveler is above dock it will fall approximately 2 below dock floor level 2 If the leveler is below 2 below dock level it will fall to full below dock level INTRODUCTION The dock leveler is designed to span and compensate for space and height differences between a loading dock and freight carrier to allow safe efficient freight transfers The dock leveler uses a hold down mechanism to position the ramp Pulling and holding the release chain allows springs to raise the ramp Walking out onto the ramp causes the ramp to lower Amechanical linkage extends the doc
29. l chocks See Fig 17 2 Toraisetheleveler pulland hold the hold down release ring at the rear When the leveler is fully raised the lip will automatically extend See Fig 18 Ifthe lip does not extend fully do not lift by hand Restore the leveler to dock level and try again If lip still does not extend fully the dock leveler requires maintenance or adjustment Notify your supervisor Do not use the leveler until it has been repaired Failure to comply could result in death or serious injury November 2013 Fig 17 Fig 18 6004758 CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 15 2013 4Front Engineered Solutions Inc OPERATIONS ABOVE DOCK LEVEL continue 3 When the lip is fully extended release the ring Walk Fig 19 o forward to the front of the ramp The dock leveler will lower until the lip is resting on the vehicle See Fig 19 Never walk on leveler lip to lower dock leveler STORING LEVELER 1 To return the leveler to the stored position gently pull the hold down release ring to raise the leveler from the vehicle floor and allow the lip to fall See Fig 20 If the lip does not fall to the stored position the dock leveler requires maintenance or adjustment Notify your Fig 20 supervisor Do not use the dock leveler until it has been repaired Failure to comply could result in death or serious injury 2 When the lip is f
30. ll be flush with the dock floor where the overhead door makes contact under normal operation proceed with steps 19 24 19 Pull the release chain located at the rear of the ramp and allow the ramp to raise but release the chain before the lip starts to extend 20 Walk forward to the front of the ramp section of the dock leveler Your weight will force the ramp down to its dock level stored position with the lip supported by both lip keepers 21 When you step off the ramp it may raise slightly Adjust shims under the front of the both subframe members below the safety leg supports and behind the lip keepers until the top of the ramp is at the desired floor level 22 Ensure the safety legs are centered on the safety leg posts If not adjust the frame runners as necessary Tack weld the shims together and to the dock leveler subframe and front pit curb angle 23 Check the shim height by repeating steps 19 and 20 When you step off the top of the ramp should be at the desired floor level If the ramp did not return to a position level with the dock floor add or subtract shims as required Then repeat steps 19 and 20 NOTE Shims must be placed under the maintenance post bracket below the safety leg supports under D84 spring frame bracket and behind the lip keepers The shims at the end of the D84 mounting plate should be flush with the end of the plate to prevent the D84 chain from getting caught underneath it On 18 and
31. ly will result in death or serious injury Refer to user s manual for proper maintenance procedures ADANGER OPERATING INSTRUCTIONS 6001946 Lr3 4 WARNING AND OPERATION PLACARD MOUNTED ON WALL NEAR LEVELER November 2013 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 21 2013 4Front Engineered Solutions Inc ADJUSTMENTS LIP ASSIST WITH HYDRA CAM ADANGER Before servicing the dock leveler always position traffic cones or a barricade behind the dock leveler to warn fork vehicle operators and pedestrians away from the leveler Always position traffic cones or a barricade in front of the leveler to warn against vehicle traffic Always notify a foreman or supervisor that you are working under the equipment Always make sure that the maintenance strut is in the raised position before working under the dock leveler Always make sure that the overhead door is securely held in the raised position 1 Ensure that lip hinges have been greased and all other pivot pins have been lubricated 2 Fully raise the leveler and extend the lip The lip should remain fully extended Check that all lip assist pivot points are lubricated with light oil 3 If the lip starts to fall increase the lip spring tension by turning the adjusting bolt clockwise Securely tighten locknut after
32. n 4 Inspect the operation of the telescopic toe guards optional to ensure they are not distorted or binding when operating the leveler QUARTERLY 1 Inspect all warning labels and placards See page 21 Replace as necessary 2 Clean out the inside of the pit area 3 Inspect and lubricate all mechanical pivot points on the leveler with a light oil such as S A E 30 See Fig 30 ADANGER Do not lubricate between the brake band and brake drum 4 Clean the hold down rack and gear Apply a light coat of S A E 30 oil to the gear and all sides of the rack Lubricate the spur gear axle by rotating the spur gear by raising or lowering the leveler until the 1 4 hole is visible on the gear next to the teeth Apply a couple of drops of S A E 30 oil into this hole PLANNED MAINTENANCE LA WARNING Before servicing the dock leveler read and follow the Safety Practices on page 3 and the operations sections of this manual Failure to follow the Safety Practices could result in death or serious injury QUARTERLY continued 5 Check hold down for proper float as described on page 24 Make any adjustments required 6 Inspect the main springs and pivot pin for excessive wear 7 Inspect the lip push out arm and lip counterbalance assemblies for damage and check the chain and springs for elongation 8 Inspect all welds under the leveler for fatigue or failure particularly the lip plate hinge and top plate beams and fron
33. n death or serious injury 3 Position the dock leveler in the pit so that the gaps along both sides of the leveler are equal 1 8 and the rear of the leveler frame touches the rear pit curb angle See Fig 4 NOTE The rear frame angle should be about 3 4 lower than the pit curb angle before leveling This is normal Do not finish weld the rear angle until after performing the LEVELING THE FRONT FRAME Steps on pages 8 9 Before installing the dock leveler read and follow the Safety Practices on page 3 and the operating instructions on pages 14 18 Failure to follow the safety practices could result in death or serious injury NOTE Shim under front frame for all sizes of dock levelers in all shim locations shown Fig 2 30 Min angle NOTE If the pit width conforms to the certified pit drawing there be a 1 8 gap between the ends of the dock leveler s rear frame angle and the pit side curb angles If this is not the case the ends ofthe rear frame angle may require trimming to allow the gaps along both sides of the leveler to be equal 1 8 6 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 2013 4Front Engineered Solutions Inc November 2013 ca ode THE REAR FRAME Using a 1 2 square drive 1 2 ratchet work from one side to the other turn each 4 of the leveling screws on the rear angle counterclockwise until the top surface of the rear angle is level
34. nance of the DOCK LEVELER including premature product wear product failure property damage or bodily injury resulting from use of unauthorized replacement parts or modification of the DOCK LEVELER 4FRONT s sole obligation with regard to a DOCK LEVELER that is claimed to be deficient in material or workmanship shall be as set forth in this Limited Warranty This Limited Warranty will be null and void if the original purchaser does not notify 4FRONT s warranty department within ninety 90 days after the product deficiency is discovered THERE ARE NO WARRANTIES EXPRESS OR IMPLIED WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF INCLUDING BUT NOT LIMITED TO A WARRANTY OF MERCHANTABILITY OR OF FITNESS FORA PARTICULAR PURPOSE ALL OF WHICH 4FRONT HEREBY DISCLAIMS November 2013 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 35 2013 4Front Engineered Solutions Inc Please direct questions about your dock leveler to your local distributor or to 4Front Engineered Solutions Inc Corporate Head Office Your local 4Front Engineered Solutions Inc distributor is 1612 Hutton Dr Suite 140 Carrollton TX 75006 Tel 972 466 0707 Fax 972 323 2661 Clean Frame ENERGY GUARD HYDRA CAM Posi Trac SafeTFrame 4Front Engineered Solutions 2013 4Front Engineered Solutions Inc Part No 6004758M
35. nd WS Series with HYDRA CAM Lip Extension SafeTFrame November 2013 2013 4Front Engineered Solutions Inc ADJUSTMENTS MAIN SPRING COUNTERBALANCE The main spring should be adjusted so that the leveler raises enough to fully extend the lip yet still be easy to walk down NOTE NOTE Make sure that the hold down is operating freely Excessive Before making any adjustments to the leveler mechanisms drag from the hold down may cause the leveler to raise too sure to clean lube per instructions on page 19 and 20 slowly and operate leveler several times Make sure that the lip hinge and deck hinges are lubricated and are operating freely Excessive friction in the lip or deck hinges can prevent the lip from raising easily A DANGER Extended springs contain stored energy Never attempt to remove main springs without completely removing the load from the springs first Do not remove the main springs until the leveler and the lip are safely supported by a suitable lifting device Fig 33 Adjusting nut Tools Required 1 1 2 open end wrench 1 If the lip does not fully extend turn the adjusting nut clockwise to increase the main spring tension 2 Ifthe leveler is too hard to walk down turn the adjusting nut counter clockwise to decrease the main spring tension November 2013 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 23 2013 4Front Engineered Solutions Inc
36. only 328 897 328 898 328 898 Weather Seal Narrow Projection Rubber 1 1 4 152 324 5ft 152 324 Tft 152 324 Tft Weather Seal Wide Projection Rubber 1 3 4 152 325 5ft 152 325 Tft 152 325 Tft Weather Seal Narrow Projection Brush 328 886 328 887 328 888 Weather Seal Wide Projection Brush 328 907 328 908 328 909 4 7 1 1 4 H Decal Maint Strut Danger 921 217 921 217 921 217 ellcrank Weldment HYDRA CAM CP 3 3332 3 3332 3 3332 Chain Stop 341 014 341 014 341 014 YDRA SHOCK Plate Assy 8 9043 8 9043 8 9043 ydra Shock 328 729 328 729 328 729 xtension Spring D84 333 029 333 029 333 029 2 22 2 24 2 26 xtension Spring Latch Bar 333 042 333 042 333 042 Retaining Ring 5304 75 236 110 236 110 236 110 R ing 5304 75 etaining Ring 5304 50 236 106 236 106 236 106 ing z Lip Assist Bar HS 328 685 328 685 328 685 T 7 Compression Spring 332 069 332 069 332 069 0 1 20 1 3 5 Retaining Ring 5304 100 236 114 236 114 236 114 lain Washer 3 4 ID x 1 2 OD Hardened 234 143 234 143 234 143 November 2013 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 29 2013 4Front Engineered Solutions Inc B H H E E P 7 1 1 1 IEEE MH 2 2 En p EIEN EIEE EXEN Cp EIEE EEN race PARTS LIST continued CM WL AND WS SERIES DOCK LEVELER continued Part Number CM600 CM800 CM1000
37. r near each leveling leg NOTE Do not finish weld the rear angle until after performing the LEVELING THE FRONT FRAME steps on pages 8 9 7 Remove the shipping banding from the lip plate IN STALLATION continued j SN ma NM ANS Raises rear lt J angle ma ANS Fig 3 Fig 4 Rear frame angle Rear pit p curb angle Evenly spaced gaps Ramp EI ld Pit side curb angle November 2013 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 7 2013 4Front Engineered Solutions Inc IN STALLATION continued 10 11 12 Pull the release chain located at the rear of the ramp Fig 5 assembly and allow the ramp to rise to its above dock position The lip will extend automatically as the leveler raises Walk out onto the dock leveler lowering it until the safety legs contact the safety leg rests on both sides of the frame The lip should fall slowly After walking the dock leveler down pull the release chain once more to raise the leveler to a slightly above dock position Walk the dock leveler down to its stored dock level position Check to ensure that the lip plate is supported in the lip keepers LEVELING THE FRONT FRAME 13 With the lip stored in the lip keepers place 4 x 4 steel shims of the appropriate thickness underneath the front o
38. rained Fig 9 32 Optional where applicable install rear angle cap plugs part number 6004488 into adjustment socket holes Press cap flush with top surface to rear angle WARNING and OPERATING INSTRUCTION placard 10 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame November 2013 2013 4Front Engineered Solutions Inc INSTALLATION TROUBLESHOOTING The following procedures apply after the leveler is level in the pit PROBLEM 1 Leveler will not fit properly in pit POSSIBLE CAUSE a Pit is out of square with the sides b One side and rear angle is out of square Pit floor irregular in rear d Pit is too deep IN STALLATION continued a SOLUTION Align the sides of the leveler so that both sides are equal 1 8 With the leveler s rear frame angle touching the rear curb angle any gaps between the frame and the rear curb angle must be filled with steel shims of appropriate thickness and length equal to the frame s beveled weld locations See Fig 10 If the gap between the leveler and the side of the pit is less than 1 2 at any point the performance of the leveler may be impaired especially if weatherseal is attached to the leveler Please consult 4Front Technical Services should this be the case If large deformations exist in the con
39. rame 2013 4Front Engineered Solutions Inc Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury NOTICE Notice is used to address practices not related to personal injury November 2013 Read these safety practices before installing operating or servicing the dock leveler Failure to follow the safety practices could result in death or serious injury If you do not understand the instructions ask your supervisor to explain them to you or call your authorized 4Front Engineered Solutions Inc distributor OPERATION Use of dock leveler restricted to trained operators Do not use this unit to service vehicles outside of its intended working range which is 12 above dock and 12 below dock 15 above dock and 12 below dock for 10 models Do not operate the dock leveler when anyone is in front of it Follow procedures on placard s posted near dock leveler Stay clear of the dock leveler when it is moving STAY CLEAR OF HINGES AT ALL TIMES Do not use hands to position dock leveler ramp or lip or to store dock leveler Do not use the dock leveler if it appears damaged or does not operate properly Inform your supervisor immediately Do not stand in the driveway between the dock leveler and the backing vehicle Chock vehicle wheels or lock vehicle into place with vehicle restraining device and set brakes before loading or unloading Visually check that
40. ront Engineered Solutions Inc OWNER S RESPONSIBILITIES The owner s responsibilities include the following The owner should recognize the inherent danger of the interface between dock and transport vehicle The owner should therefore train and instruct operators in the safe use of dock leveling devices When a transport vehicle is positioned at the dock there shall be at least 4 of overlap between the front edge of the lip of the dock leveler and the edge of the floor or sill of the transport vehicle Nameplates cautions instructions and posted warnings shall not be obscured from the view of operating or maintenance personnel for whom such warnings are intended Manufacturer s recommended periodic maintenance and inspection procedures in effect at time of shipment shall be followed and written records of the performance of these procedures should be kept Adock leveler that is structurally damaged or has experienced a sudden loss of support while under load such as might occur when a transport vehicle is pulled out from under the dock leveler shall be removed from service inspected by the manufacturer s authorized representative and repaired as needed before being placed back in service The owner shall see that all nameplates caution and instruction markings or labels are in place and legible and that the appropriate operating and maintenance manuals are provided to users Modifications or alterations of do
41. t all leveling feet are in contact with the floor of the pit Once all feet 4 are in contact with the floor Torque each shimless leveling leg to 25 40 ft lbs counterclockwise Weld all front shims solidly together and to the leveler subframe and to the front pit curb angle with 1 4 fillet welds Raise the dock leveler remove and discard the cotter pins from toe guards on both sides of the leveler Ensure telescopic toe guards optional move freely and do not bind See Fig 7 Store the dock leveler Perform the quarterly maintenance steps on page 19 in this manual Cycle the leveler four times going through the operational steps described on pages 14 18 Refer to all steps on pages 26 27 if any operational problems are encountered Mount the bumpers to the face of the dock See Fig 8 Improper installation of anchoring devices or installation into aged or unsound concrete could result in death or serious injury Fig 7 Remove shipping cotter pins Fig 8 3 8 side of pit to side of bumper mounting plate 14 Full length of bumper mounting plate Vertical down weld is not acceptable Vertical bumper 3 4 dia anchor bolt field neler supplie by others 31 Permanently mount the dock leveler warning and mounting angle operating placard on the wall near the dock leveler See Fig 9 Make sure the customer gets the user s manuals Laminated bumper and is properly t
42. t hinge bar 9 Check the full operation of the leveler Make any adjustments required Before making any adjustments to the leveler mechanisms be sure to clean lube per instructions on this page and page 20 and operate leveler several times 10 Lubricate the lip hinge tubes with molybdenum disulfide grease NLGI 2 Do not over grease Stop when grease begins to ooze out of the hinge tube ends Wipe off excess grease 11 Inspect dock bumpers Four inches 4 of bumper protection is required Worn torn loose or missing bumpers must be replaced November 2013 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame 19 2013 4Front Engineered Solutions Inc PLANNED MAINTENANCE continued Fig 30 2 Rear hinge pin aln Clean lip hinge area weekly Typ Legend Symbol Lubricate oil Light oil SAE 30 Lubricate grease Molybdenum disulfide NLGI 2 Cleaning Location frequency Visually inspect Replace damaged or worn ui DU Pivot points auc NE E QA Three sides aa A DANGER Clean gear Do not lubricate between the axle and brake band and brake drum rack 3 mo 20 2013 4Front Engineered Solutions Inc RAN SAT SN 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame E Hm p
43. t stay down on vehicle bed or in stored position November 2013 TROUBLESHOOTING GUIDE continued POSSIBLE CAUSE a Lip chain is disconnected b Lip hinge is binding a Lip spring requires more tension b Front of Hydra Shock is mounted in the cold weather position c Hydra Shock missing or damaged a Debris or corrosion in lip hinge b Lip spring is over tensioned a Safety legs or chain stuck or binding b Hold down binding or rack is bent c Main springs adjustment incorrect a Safety legs stuck in retracted position a Safety legs are engaging the frame b Hold down has insufficient float a Hold down requires adjustment or maintenance SOLUTION a Inspect and repair as required b Clean and lubricate the lip hinge a Adjust lip spring tension as shown on page 22 b Move the Hydra shock front mounting pin as shown on page 22 c Replace Hydra Shock a Clean and lubricate lip hinge b Adjust lip as shown on page 22 and lubricate mechanism a Inspect safety legs and lubricate or repair and required b Inspect hold down assy and adjust lubricate or replace as required Do not lubricate between the brake band and brake drum If rack is bent it must be replaced c Inspect main springs and adjust as required See page 23 a Inspect safety legs and lubricate or repair as required Check that return spring is properly installed a R
44. ully retracted and clear of the vehicle walk forward to the front of the ramp The dock leveler will lower until the lip is resting in the lip keepers See Fig 21 Fig 21 e 16 6004758M CM WL and WS Series with HYDRA CAM Lip Extension SafeTFrame November 2013 2013 4Front Engineered Solutions Inc OPERATIONS BELOW DOCK LEVEL Use these instructions when the height of the vehicle is below the loading dock A WARNING Fig 22 _ E Always secure the vehicle with a vehicle restraint or wheel chocks before operating the dock leveler Do not operate dock leveler with anyone standing on or in front of it Do not lift the leveler lip by hand Always keep hands and feet clear of all moving parts Always restore the leveler to its safe dock level position with the lip supported in both lip keepers after servicing the vehicle 1 Toraise the leveler pull the hold down release ring at the rear of the leveler When the leveler is fully raised the lip will automatically extend See Fig 22 2 When the lip is fully extended walk forward to the front of the ramp Pull the safety leg release ring atthe front of the leveler The dock leveler will lower to the below dock position with the lip resting on the vehicle See Fig 23 STORING LEVELER 1 To return the leveler to the stored position gently pull the hold down release ring to raise the leveler from the vehicle floor
45. vicing the dock leveler read and follow the Safety Practices on page 3 and the Operating Instruction section in this manual NOTE Before making any adjustments to the leveler mechanisms be sure to clean lube per instructions on page 19 and 20 and operate leveler several times SOLUTION a Inspect release chain b Clean rack assy and lubricate Do not lubricate between the brake band and brake drum If rack is bent it must be replaced c Inspect brake band Adjust hold down if required as shown on pages 24 25 d Adjust spring tension if required as shown on page 23 a Clean rack assy and lubricate Do not lubricate between the brake band and brake drum If rack is bent it must be replaced b Adjust spring tension if required as shown on page 23 a Clean and lubricate lip hinge b Clean and lubricate rear hinge c Adjust lip spring as shown on page 24 and lubricate mechanism d Adjust hold down if required as shown on pages 24 25 e Adjust main springs as shown on page 23 November 2013 PROBLEM 4 Lip plate will not extend at all when leveler is raised 5 Lip falls before it can be walked down to the vehicle 6 Lip plate does not fall when leveler is in working range 7 Leveler will not travel below dock 8 Leveler travels below 2 1 2 below dock when lip is out of lip keepers 9 Leveler does not follow when vehicle floor moves down 10 Leveler will no
46. with the rear pit curb angle Repeat on each leg until all legs are in contact with the pit floor and the top frame angle is flush with the rear curb angle See Fig 3 NOTICE Therearedge ofthe dock leveler should be level or slightly 1 16 maximum below dock level The top surface of the dock leveler should be level and a smooth transition with the dock floor curb steel The front end should be level and parallel with the rear frame angle for proper operation Unequal shimming of the front supports may be required to obtain a level front edge Before welding the rear frame cover the weather seals with a sheet of steel to prevent setting fire to the weather seals Failure to do so may result in property damage 5 Verify placement of the leveler in the pit is such that the rear frame angle is touching the rear pit curb angle and the gaps along both sides of the leveler are equal 1 8 See Fig 4 NOTE If the pit is out of square the resulting gap between the rear frame and the rear curb angle should be shimmed as necessary at the weld locations Use steel shim s equal to the weld length and weld in place 6 Check the alignment of the top of the subframe and the top of the rear pit curb angle The top of the subframe should be flush with the top of the rear pit curb angle If a flush condition can not be achieved the frame should be a maximum of 1 16 lower than the curb angle Tack weld in four places min 3 8 one at o

User`s Manual - Curlin, Inc.

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