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DM-Series

1. Lip hinge area inject grease into all the lip hinge grease fittings D Platform hinge area inject grease into all the platform hinge grease fittings E Lift arm roller bushing G Lift arm pivot K Lip assist pin 23 ADJUSTMENTS Adjust Lift Arm Spring and Lip Assist Spring Tension A Jam Nut B Adjustment Nut 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 Failure to do this C Lip Assist Spring D Lift Springs E Lift Spring Bolt F Hold Down Mechanism The platform 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 Failure to follow these instructions may result in serious personal injury or death may result in serious personal injury or death 24 4111 0005 Sept 2012 June 2010 ADJUSTMENTS NOTE Adjusting the tension of lift springs D usually 3 After lift spring adjustment is completed check requires that the lip assist spring C also be operat
2. A 2 55 1156 B 4 57 B 4 57 B 4 57 B 18 3 55 A 2 55 1 56 B 4 57 B 4 57 B 4 57 B 20 2 55 1 56 B 2 55 1 56 B 4 57 B 4 57 B 4 57 B 6 5 WIDE 16 2 55 1 56 B 2 55 1 56 B 457 B 57 B 2 2 58 B 18 2 55 1 56 B 4 57 B 4 57 B 57 B 2 2 58 B 20 2 55 1 56 B 4 57 B 457 B 2 58 B 2 2 58 B 7 0 WIDE 16 4 57 B 4 57 B 2 2 58 B 2 2 58 B 2 57 2 58 B 18 4 57 B 4 57 B 2 2 58 B 2 2 58 B 2 57 2 58 B 20 4 57 B 4 57 B 2 2 58 B 2 2 58 B 2 57 2 58 B 10 LON 6 0 WIDE 25K 30K 35K 40K 45 50K 16 8 57 B 8 57 B 4 57 4 58 B 8 58 B 8 58 B 18 8 57 B 8 57 B 4 57 4 58 B 8 58 B 8 58 B 20 8 57 B 8 57 B 4 57 4 58 B 8 58 B 8 58 B 6 5 WIDE 16 8 57 B 8 57 B 8 58 B 8 58 B 8 58 B 18 8 57 B 8 57 B 8 58 B 8 58 B 8 58 B 20 57 B 857 B 8 58 B 8 58 B 8 58 B 7 0 WIDE 16 4 4 58 B 4 57 4 58 B 8 58 B 8 58 B 8 58 B 18 4 4 58 B 4 57 4 58 B 8 58 B 8 58 B 8 58 B 20 4 4 58 B 4 57 4 58 B 8 58 B 8 58 B 8 58 B 4111 0005 Sept 2012 June 2010 PARTS Platform Components Sept 2012 June 2010 4111 0005 38 PARTS Toe Guard Weather Seal Optional 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 DKIT 9178 Full Range Toe Guard Assembly 5 D K 1 DKIT 917
3. 40 000 Ib 18 144 kg 45 000 Ib 20 412 kg 50 000 Ib 22 680 kg 5 us ee eee S CIR Comparative Industry Rating Call DLM for your specific needs INTRODUCTION Component Identification p a iL nf s d I BERIE 7 S 6 A Lip F Platform Release Ring Platform Maintenance Prop R Safety Leg Linkage B Lip Maintenance Prop G Ratchet Pawl M Hold Down Mechanism S Safety Leg Release Ring C Platform H Ratchet Bar N Safety Leg 2 used T Lift Arm Assembly D Lip Banger J Release Arm Spring P Lip Snubber Spring U Lift Main Spring E Lip Assist Spring K Main Frame Q Lip Shock Absorber Assembly 8 4111 0005 Sept 2012 June 2010 INSTALLATION Prepare Pit A Distance Pit Width B Distance Dock Floor to Pit Distance Pit Length D Distance Pit Corner to Corner Front and Rear Floor All Four Corners Both Sides of Pit Top Bottom and Both Sides 1 Before lowering the dock leveler into the pit the following must be performed Post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized 2 Remove all debris from the pit and sweep the pit use of the dock leveler before installation has been clean completed 3 Check the entire dock leveler pit for proper Failure to follow the installation instructions can construction according to approv
4. WARRANTY LIMITATIONS THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SYSTEMS INC AND 115 SUBSIDIARIES 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 INTERRUPTION OF BUSINESS OR LOSS OF GOODWILL PRODUCT SPECIFIC WARRANTY DM SERIES LEVELER In addition to the Standard Product Warranty provided with all DLM Products Systems Inc guarantees materials components and workmanship to be free of defects for the following extended periods e Structural Warranty For a period of ten 10 years from the date of shipment product will carry a prorated structural warranty This warranty specifically applies to the deck section lip section frame rear hinge assembly and front hinge assembly only This warranty covers structural repairs to or replacement of dock leveler in Systems Inc sole discretion and expense including reasonable labor materials freight and travel If Systems Inc determines replacement is necessary it will provide the original purchaser with a credit toward the purchase of the new replacement Systems Inc product in the amount equal to the original purchase price of the warranted product F O B point of manufacture disco
5. 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 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 transportation vehicle is positioned correctly in the dock opening and in contact with both bumpers there shall be a minimum of 4 00 inches 100mm overlap of the leveling device and the transportation vehicle at all times during the loading and unloading process 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 in
6. e Weld the front leveler frame shim stacks to the front pit curb steel if not done previously 24 When all welding has been completed remove all slag then paint all the welds and shims 16 25 Remove the lifting brackets from the platform side joists 26 Disengage the platform maintenance prop 27 Slowly walk out onto the platform to lower the platform until it is at the cross traffic stored position 28 Check operation of dock leveler by cycling the leveler at least four times When the platform is at full height lip will be fully extended eLip will begin to drop after full height is reached taking approximately 12 seconds to fully fold 29 Check below dock position by walking platform down before lip folds completely eLip will be over lip keepers Platform safety legs will be resting on frame 30 Check full below dock position by walking the platform down Pull and hold safety leg chain A before lip folds completely 31 11 the lip does not extend fully or lip folds too quickly see appropriate symptom in the Troubleshooting section 32 Install the dock bumpers as required 4111 0005 Sept 2012 June 2010 A Lip F Platform Release Ring B Lip Maintenance Prop G Ratchet Pawl C Platform H Ratchet Bar D Lip Banger E Lip Assist Spring J Release Arm Spring K Main Frame The DM series mechanical dock leveler uses large lift springs U to apply force to l
7. 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 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 OPERATING INSTRUCTIONS For HM CM OM amp LM Dock Levelers Only PLACARD 1751 0877 MUST PLACED IN CLOSE PROXIMITY AND IN CLEAR 7 0000 VIEW OF THE LEVELER Failure io joios these instructions Gould ruh iri death or after serious injury har 1 Van riim g ds a J Bees Fe qvae mg 1 342 158 1508 or 5 4 J NE ru ad bte T f mu Em m Lar rag d amer oe r m 1ye PU NE p Er LET k ran mr tir 2 T ms TEL Dum ri 4 4111 0005 Sept 2012 June 2010 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 DANGER CRUSH HAZARD f t Maintenance prop must 0 r rep acemen S support leveler behind bar
8. 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 0005 Sept 2012 June 2010 General Information Congratulations on your choice of a DLM dock leveler This manual covers the DM series mechanical dock leveler Designed by DLM 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 To obtain maximum performance and longest possible use a simple program of preventive maintenance is recommended Once again thank you and congratulations on your purchase of a DLM mechanical dock leveler 4111 0005 Sept 2012 June 2010 INTRODUCTION Dock Leveler Stock Specifications DM Series 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 5 ft 6 ft 8 ft 10 ft 1424 mm 1828 8 mm 2438 mm 3048 mm Capacity CIR 25 000 Ib 11 340 kg 30 000 Ib 13 608 kg 35 000 Ib 15 876 kg
9. 012 June 2010 Service Dock Leveler Safely 7 0 322 A Lip Maintenance Prop B Platform Maintenance Prop 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 Failure to do this may result in serious personal injury or death The platform 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 Failure to follow these instructions may result in serious personal injury or death 4111 0005 Sept 2012 June 2010 ue 0 C MAINTENANCE AT pup E gt PT 2 a zt Prop Pin amp Clip Whenever maintenance is to be performed under the dock leveler platform support the platform with the platform maintenance prop B Put the platform maintenance prop in the service upright position so that the prop is cradled in the u bracket C Lock the platform maintenance prop in this position by inserting the prop pin and clip D or attaching an OSHA approved lockout d
10. 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 A 1751 0730 62 SAFETY INFORMATION n ides of moving dock level 8 Ne d Unsupported dock leveler ramps can lower unexpectedly P A e Before allowing vehicle to leave ihe dock always e Ensure no equipment material or people are on dock leveler e Return dock leveler to its stored position at dock level i Failure to follow posted instructions will result in death or serious injury Call 262 255 1510 for replacement placards warning labels or ov decal placed in same position on both sides 1751 0329 x2 decal placed in same position on both sides 00000 gt PSS 0 Ss RQ D D 7 LLLI OD 1 A N 4 1751 0330 2 decal placed in same position on both sides aN ADANGER 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 owner s user s manual for proper maintenance procedure 1751 0728 RevA ADANGER CRUSH HAZARD Do not work under dock leveler unless th
11. 1036 DLIP 1039 DLIP 1042 DLIP 1045 DLIP 1048 DLIP 1051 1 18 DLIP 1037 DLIP 1040 DLIP 1043 DLIP 1046 DLIP 1049 DLIP 1052 1 20 DLIP 1038 DLIP 1041 DLIP 1044 DLIP 1047 DLIP 1050 DLIP 1053 36 4111 0005 Sept 2012 June 2010 Platform Components PARTS 55 SEE CHART DOTH 2570 SPRING MAIN 6620 SEE CHART DOTH 2550 REG LIP SPRING ORANGE 56 SEE CHART DOTH 2574 SPRING MAIN 6635 B SEE CHART _DOTH 2546 HEAVY DUTY LIP SPRING GREEN 57 SEE CHART _ DOTH 2576 SPRING MAIN 6820 C SEE CHART _DOTH 2548 STANDARD LIP SPRING WHITE 58 SEE CHART DOTH 2578 SPRING MAIN 6835 6 LONG 6 0 WIDE 25K 30K 35K 40K 45 50K 16 4 55 A 4 55 B 4 55 B 1 55 2 56 B 1 55 2 56 B 18 4 55 A 4 55 B 2 55 1 56 B 1 55 2 56 B 1 55 2 56 B 20 4 55 A 4 55 B 4 55 B 1 55 2 56 B 1 55 2 56 B 6 5 WIDE 16 2 1 56 B 2 55 1 56 B 4 55 B 1 55 2 56 B 1 55 2 56 B 18 2 1 56 B 2 55 1 56 B 4 55 B 1 55 2 56 B 1 55 2 56 B 20 2 1 56 B 2 55 1 56 B 4 55 B 1 55 2 56 B 1 55 2 56 B 7 0 WIDE 16 1 2 56 B 1 55 2 56 B 4 55 B 2 2 56 B 2 55 2 56 B 18 1 2 56 B 1 55 2 56 B 2 55 2 56 B 2 2 56 B 2 55 2 56 B 20 1 2 56 B 2 55 2 56 B 2 55 2 56 B 2 2 56 B 2 55 2 56 B 8 LONG 6 0 WIDE 25K 30K 35K 40K 45 50K 16 3 55
12. 6 ft 1 DPLA 1211 Chain Hold Down Release 8 ft 1 DOTP 6924 Chain Hold Down Release 10 ft W 1 DOTP 1 Prop Maintenance 8432 0983 Keeper 16 Lip 20 Pit 8432 0984 Keeper 18 Lip 20 Pit X 2 8432 0985 Keeper 20 Lip 20 Pit 8432 0986 Keeper 16 Lip 24 Pit 8432 0987 Keeper 18 Lip 24 Pit 8432 0988 Keeper 20 Lip 24 Pit Y 1 DOTH 2356 Pin Clevis Z 1 DOTH 2405 Roller Hold Down Release Chain AA 1 DOTH 2375 Pin Cotter AB 1 DOTH 2563 Hold Down Assembly Complete 31 5 Ratchet Bar 1 DOTH 2564 Hold Down Assembly Complete 34 5 Ratchet Bar AD 1 DOTH 2222 Washer AE 1 DRFA 1205 Pin AH As Required 1 Provide dock leveler serial number platform size lip size and pit depth when calling or faxing orders 4111 0005 Sept 2012 June 2010 33 PARTS Platform Components 34 4111 0005 Sept 2012 June 2010 Platform Components PARTS Item Quantity Part Number Description A 1 oee Page 34 Platform Welded Assembly C DOTH 2424 Fitting Grease D 1 DOTH 2075 Cap Screw Lip Stop E 2 DOTH 2160 Nut Hex 5 8 11 F 1 DOTH 2131 Nut Nylon Lock G 2 DOTH 2214 Washer H 1 DOTH 2547 Spring Lip Maintenance Prop J 1 DOTP 2006 Prop Lip Maintenance K 1 DOTH 2062 Cap Screw L 1 See Page 34 Lip Welded
13. 8 4111 0005 Sept 2012 June 2010 TROUBLESHOOTING Platform rises to full height but lip does not fully extend Insufficient main spring tension Platform does not lower when operator walks out onto the platform Excessive main spring tension Lip folds too fast during normal walk down Disconnected worn or broken shock absorber Platform does not stay down teeth Damaged or worn hold down mechanism Lip does not fold after truck departs of lack of lubrication Excessive lip assist force 4111 0005 Sept 2012 June 2010 Insufficient lip assist force Damaged or worn Clean and inspect hold down mechanism hold down mechanism Insufficient lip assist force Entangled release chain Hemove cause of entanglement Dirt impacted in ratchet bar Lip hinge binding because Lip assist chain Connect or replace chain disconnected or broken Increase tension on main lift springs See Adjust Lift Arm Spring and Lip Assist Spring Tension in the Adjustments section Increase lip assist spring tension See Adjust Lift Arm Spring and Lip Assist Spring Tension in the Adjustments section Heduce main spring tension See Adjust Lift Arm Spring and Lip Assist Spring Tension in the Adjustments section Increase lip assist spring tension See Adjust Lift Arm Spring and Lip Assist Spring Tension in the Adjustments section Inspect shock absorber Connect or replace s
14. 9 Full Range Toe Guard Assembly 6 DKIT 9180 Full Range Toe Guard Assembly 8 DKIT 9181 Full Range Toe Guard Assembly 10 1 DKIT 9293 Brush Weather Seal Kit 6 amp 8 sides only DKIT 9292 T Rubber Weather Seal Kit 6 amp 8 sides only 4111 0005 Sept 2012 June 2010 39 NOTES This page intentionally left blank 40 4111 0005 Sept 2012 June 2010 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 DM series 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 DLM 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 or contact Systems Inc P O Box 309 Germantown WI 53022 Phone 800 643 5424 Fax 262 255 5917 4111 0005 Sept 2012 June 2010 Dock Leveler
15. Assembly 2 DPLA 2101 Pin Lip Hinge 6 ft wide M 2 DLPA 2102 Pin Lip Hinge 6 5 ft wide 2 DLPA 2103 Pin Lip Hinge 7 ft wide N 2 DOTH 2380 Pin Cotter Shock Absorber Assembly P 1 DOTH 2582 Shock Absorber Q 2 DOTH 2374 Pin Cotter H 2 DOTH 2210 Washer o 2 DOTH 2351 Bolt Clevis T 2 DOTH 2163 Nut Nylon Lock 1 DKIT 6465 Single Shock Absorber Assembly Includes Items P T Safety Legs Assembly U 1 DOTH 2423 Ring Chain V 1 DOTH 2412 Chain Safety Leg X 2 DOTH 2432 Spring Snap 3 16 in Y 1 DOTH 6231 Leg Left Safety Assembly with Spring Z 1 DPLA 2122 Pull Bar Rod Assembly Safety Leg AA 1 DOTH 2356 Pin Clevis AB 1 DOTP 6647 Rod Push AC 1 DOTH 2374 Pin Cotter AD 1 DOTH 6232 Leg Right Safety Assembly with Spring Lip Assist Assembly AE 1 DPLA 2130 Rod Lip Assist Adjuster 1 1 8 in x 34 in Heavy Duty Short AF 1 DOTH 2548 Spring STD Lip Assist DOTH 2546 opring HD Lip Assist AG 1 DOTH 2061 Bolt Shoulder AH 1 DOTH 2131 Nut Nylon Lock AJ 1 DOTH 2160 Nut Nylon Lock 5 8 11 UNC AK 2 DOTH 2449 Bearing Roller AL 2 DOTH 2211 Washer 5 8 1 5 16 in OD x 11 16 in ID AM 1 DOTH 6644 Spacer 1 1 4 in OD x 3 4 in ID x 1 in AN 1 DOTH 2076 Cap Screw 5 8 11 UNC x 3 1 2 in AO 1 DPLA 2126 Link Lip With Chain AP 2 DOTH 2131 Nut Nylon Lock 3 8 16 in AQ 2 DOTH 2061 Bolt Socket Head Shoulder AH As Required Continued on next page 1 Provide dock leveler serial number platform size and lip size when calling or faxing orde
16. DM Series Dock Leveler DLM Division of Systems Inc W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 257 5917 www docksystemsinc com techservices docksystemsinc com Printed in U S A Manual No 4111 0005 Copyright 2003 June 2010 Page Safety Recognize Safety Information ee eere 1 General Operational Safety Precautions 1 Operational Safety 2 Maintenance Safety Precautions eere 4 Safety DECALS Pee RE 5 Owner s User s Responsibilities 6 Introduction General qe Los eie autos vica soo Code RE 7 Dock Leveler Stock Specifications 7 Component Identification ccce 8 Installation Prepare ed SE 9 Prepare DOCK sn 10 Install DOCK e oe ooa re epe ooa pulse tienne 12 Operation Hle 17 Operating INSIFUCUHONS iiss rero ee re roe vw edere pc aoa dates 18 Ramp Loading Unloading Instructions 19 End Loading Unloading Instructions 20 Mai
17. Information Model Serial No DLM Job No Original Owner Information Name Address Installer Information Name Address Date of Installation 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 All 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 for all claims whether based on contract negligence or strict liability
18. K 50K 6 5 WIDE 20K 50K 6 5 WIDE 20K 50K 16 DRFA 1006 16 DRFA 1015 16 DRFA 1024 18 DRFA 1007 18 DRFA 1016 18 DRFA 1025 20 DRFA 1008 20 DRFA 1017 20 DRFA 1026 7 WIDE 20K 50K 7 WIDE 20K 50K 7 WIDE 20K 50K 16 DRFA 1009 16 DRFA 1018 16 DRFA 1027 18 DRFA 1010 18 DRFA 1019 18 DRFA 1028 20 DRFA 101 1 20 DRFA 1020 20 DRFA 1029 32 4111 0005 Sept 2012 June 2010 Frame Components PARTS Item Quantity Part Number Description A 1 DFRA Frame Welded Assembly see page 32 DFRA Frame Clean Sweep Welded Assembly Optional B 1 DOTH 2555 Spring Snubber C 1 DOTH 2416 Lap Link 3 16 x 1 0 in D 1 DPLA 2128 Chain Lip Assist Link E 1 DOTH 2421 Cold Shut Link 5 16 in 1 DFRA 0326 6 Foot Bolt Spring Adjuster amp Plate Spring Tensioner F 1 DFRA 0327 8 Foot Bolt Spring Adjuster amp Plate Spring Tensioner 1 DOTH 2222 Washer G 1 DOTP 6424 Lift Arm Short 25 1 DOTP 6423 1 Lift Arm Long 27 J 1 DOTH 2402 Roller Assembly Cam K AR DOTH J 1 Spring Lift 5 DOTH 2382 Pin Cotter 1 4 x 2 in M 3 9202 0002 Pin Rear Hinge N 1 DOTH 2061 Bolt Shoulder P 4 DOTH 2432 Spring Snap 3 16 in Q 1 DOTH 2423 Ring Chain S 1 DOTH 2131 Nut Nylon Lock T 1 DLPA 1210 Chain Release Pull U 1 DOTH 6929 Arm E Z Release 1 DPLA 1211 Chain Hold Down Release 5 ft V 1 DPLA 1211 Chain Hold Down Release
19. RTANT DO NOT remove the shipping bands B around the platform lip and leveler frame at this time The shipping bands are needed to hold the leveler together during the installation process 4111 0005 Sept 2012 June 2010 INSTALLATION 1 Remove any bumpers that may be banded or bolted 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 over tighten the lifting bracket hardware Over tightening 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 over tighten 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 4111 0005 Sept 2012 11 June 2010 INSTALLATION Install Dock Leveler Shim Stacking Methods PLACARD OOH 9 A Distance Leveler Frame H Distance Dock Floor to Pit Height Floor B Shim Locations Under Rear J Distance Top of
20. Shim Vertical Supports Stack to Dock Floor C Shim Locations Under Lip K Shim Stack Keepers and Prop L Dock Leveler Frame D Dock Floor M Pyramid Preferred E Rear Pit Curb Angle N Stepped Acceptable F String P Offset Not Acceptable G Rear Hinge Frame Angle Q Straight Not Acceptable fo 12 4111 0005 Sept 2012 June 2010 NOTE DLM dock levelers are designed with a nominal 1 2 in 12 7 mm shimming distance to allow for pit inconsistencies Determine height of shim stack K for each shim location B by performing the following a Measure leveler frame height distance A b Measure dock floor to pit floor distance H at each shim location B Write down the dimensions obtained at each location c Subtract distance A from distance H to obtain the shim height Repeat for each shim location INSTALLATION 4 Put a 1 4 in 6 6 mm thick shim at locations C under lip keepers maintenance prop and safety legs Make sure shims are larger than frame angle iron so pyramid or stepped stacking method can be used 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 NOTE A 1 4 in 6 6 mm thick shim at locations C is used only as a starting point The final shim stack height will be determined after the dock level
21. cessary until a smooth transition is obtained 12 11 leveler cannot be squared and made level as instructed in steps 8 10 contact DLM Technical Services 4111 0005 Sept 2012 June 2010 DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present Stray sparks can ignite spills or leaks near the work area Always clean up the oil leaks and spills before proceeding with grinding or welding Always keep a fire extinguisher of the proper type nearby when grinding or welding Failure to follow these instructions may result in serious personal injury or death IMPORTANT Always ground welding equipment to the dock leveler frame NEVER to the platform 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 not to function correctly and shortening the lifespan of the affected components NOTE The illustration on the previous page shows a typical weld pattern The weld pattern will vary slightly depending on size of dock leveler 13 With the rear hinge frame angle F tight against the rear pit curb angle G weld the rear hinge frame angle F to the rear pit curb angle G using a 3 8 in 9 5 mm flare bevel skip weld each weld being 6 in 152 mm long Start at each en
22. ctice 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 0005 Sept 2012 June 2010 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 activate 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 before starting Keep the operating zone free of obstacles that could cause a person to trip or fall SAFETY Operational Safety Precautions A Learn the safe way to operate this equipment Read and understand the manufacturer s instructions If you have any questions ask your supervisor DANGER wor Stay clear of dock leveling device when freight carrier 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 freight carriers Never remove th
23. d 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 Alternate welding locations to distribute heat Welding sequentially from one end to the other may cause warping or distortion 4111 0005 Sept 2012 June 2010 INSTALLATION 14 Remove shipping bands at this time Allow platform to float Add Remove shims as necessary to bring platform level flush with floor Make sure all personnel are outside of the leveler operating zone and stand clear of the platform lip before removing the shipping bands Failure to do this may result in serious personal injury or death 15 Weld front of dock leveler frame B to shims located under the keepers then weld the shims to the front pit curb steel 16 Disconnect lifting device and chains from the lifting brackets Make sure all personnel are outside of the leveler operating zone and clear of the platform lip before activating the leveler Failure to do this may result in serious personal injury or death IMPORTANT When activating the leveler always pull AND hold the platform release ring until the platform is at the full raised position Releasing the ring while the platform is still rising may result in damage to the equipment 17 Pull and hold the release ring located in recess at rear of platform until the platform is fully raised Check for binding as platform rises 18 Slowly walk out
24. e distance from side edges of leveler during the loading and unloading process NEVER attempt to walk on an unsupported lip The dock leveler operation instructions are divided into the two methods of loading and NEVER allow untrained personnel to operate the unloading dock leveler e For ramp loading and unloading see Ramp NEVER attempt to lift any part of the leveler by Loading Unloading Instructions on page 19 hand e For end loading and unloading see End Loading Unloading Instructions on page 20 Failure to follow these instructions may result in serious personal injury or death 18 4111 0005 Sept 2012 June 2010 OPERATION Operating Instructions Continued Ramp Loading Unloading Instructions NOTE If end unloading is required see End Loading 7 Make sure that the lip is fully extended and Unloading Instructions on page 20 supported on the truck trailer along the entire width of the platform with at least 4 in 102 mm of lip 1 Check to make sure truck trailer is positioned contacting the truck bed squarely against dock bumpers 2 Instruct driver to remain at the dock until the loading or unloading process has been completed 3 Chock the truck trailer wheels or use truck restraint if present _ Tere 8 Proceed with loading or unloading NOTE If end loading is necessary see End Loading Unloading Instructions on page 20 4 Raise the platform by pulling and holding the pla
25. e equipment should have the key to unlock the maintenance prop Failure to follow these instructions may result in Always stand clear of the dock leveler lip when serious personal injury or death working in front of the dock leveler Failure to do this may result in serious personal injury or death Platform does not rise Heavy object s on platform Remove object s from platform For safety reasons the dock leveler is designed to lift only the platform s own Weight Disconnected or broken Connect or replace cable release cable Check for visible obstructions that could cause binding Check weather seal if equipped Dock leveler binds If no obstructions found call DLM Technical Services See inside back cover for phone number and address Platform rises slowly or Heavy object s on platform Remove object s from platform does not rise to the full raised position For safety reasons the dock leveler is designed to lift only the platform s own weight Check for visible obstructions that could cause binding Check weather seal if equipped Dock leveler binds If no obstructions found call DLM Technical Services See inside back cover for phone number and address Insufficient main spring tension Increase tension on main springs See Adjust Lift Arm Spring and Lip Assist Spring Tension in the Adjustments section Damaged or worn Clean and inspect hold down mechanism hold down mechanism 2
26. e wheel chocks until loading or unloading is finished and truck driver has been given permission to drive away E ee Do not use a broken or damaged dock leveling device Make sure proper service and maintenance procedures have been performed before using _ 0 17 Make sure lip overlaps onto trailer at least 4 in 102 mm Keep a safe distance from both side edges 4111 0005 Sept 2012 June 2010 SAFETY LE wer Do not use dock leveling device if freight carrier 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 0005 Sept 2012 June 2010 SAFETY Maintenance Safety Precautions 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 Stray sparks can ignite spills or leaks near the work area Always Always post safety warnings and barricade the clean up the oil leaks and spills before proceeding work area at dock level and ground level to prevent with grinding or welding unauthorized use of the unit before maintenance is complete 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
27. eath DO NOT activate the dock leveler until the truck trailer is positioned squarely against the bumpers and the truck wheels are chocked Never remove the wheel chocks until loading and unloading is finished and truck driver has been given permission to leave DO NOT use the dock leveler if the freight carrier is too high or too low NEVER use a fork truck or any other material handling equipment to lower the dock leveler DO NOT drive any equipment onto the dock leveler until platform lip is resting on the truck trailer with at least 4 in 102 mm of overlap in 305 mm Y o 0 La in 305 mm The DM series mechanical dock leveler is designed to compensate for 12 in 305 mm of height difference between the loading dock and the truck bed DO NOT use the dock leveler if the truck trailer bed is more than 12 in 305 mm higher or lower than the dock floor DO NOT overload the dock leveler DO NOT operate any equipment while under the influence of alcohol or drugs DO NOT leave store equipment or material unattended on the dock leveler Failure to follow these instructions may result in personal injury and or damage to equipment IMPORTANT When activating the leveler always pull AND hold the platform release ring until the platform is at the full raised position Releasing the ring while the platform is still rising may result in damage to the equipment Always maintain a saf
28. ed certified pit result in damage to dock leveler the facilities and drawings Make sure pit is square by making the or serious personal injury or death following measurements e Measure pit width distance A at both front and rear of pit Measure dock floor to pit floor distance B at all Only trained installation professionals with the four corners proper equipment should install this product e Measure pit length distance C at both sides e Measure corner to corner criss cross distance D at both sides Take measurements at dock IMPORTANT floor level and at pit floor level DO NOT remove the shipping bands around the 4 f any measurement is off by more than 1 8 in dock leveler lip until instructed to do so 3 18 mm contact DLM Technical Services before proceeding 4111 0005 Sept 2012 9 June 2010 INSTALLATION Prepare Dock Leveler A Lifting Bracket 2 used 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 the dock leveler and or serious personal injury or death 10 B Shipping Bands DLM dock levelers are designed with installation in mind Each unit is shipped with lifting brackets A fastened to the platform side joists IMPO
29. er is lowered into the pit IMPORTANT The minimum size of the shim that contacts the leveler frame i e the top shim of each shim stack must be at least 4 1 2 x 4 1 2 in 114 3 x 114 3 mm to support the full width of the frame rail and to provide a shelf for a fillet weld Use the thickest shim stock possible for stability and weld penetration purposes DO NOT use multiple Using an appropriate lifting device connected to the lifting brackets lower dock leveler into the pit so rear hinge frame angle G is tight against rear pit curb angle E across full width of the leveler frame Allow rear of dock leveler to rest on the rear shims while keeping the front of the dock leveler level with the dock floor layers of 1 8 in 3 18 mm or thinner shim stock 7 Add shims at front shim locations C so front of dock leveler will stay level with dock floor when leveler is resting fully on shims 2 Using the results obtained in step 1 create the individual shim stacks on the pit floor at locations B Build each shim stack K using the pyramid method M preferred or stepped method N with the top shim having a minimum size of 4 1 2 x 4 1 2 in 114 3 x 114 3 mm and each successive lower shim being larger so the shims can be welded together using a fillet weld DO NOT use offset method P or straight method Q NOTE To assist in obtaining an accurate measurement of distance J use a string F pulled tigh
30. et go When the platform rises to approximately 2 3 inches 51 76 mm from its full raised height the snubber spring P and a chain pulls the lip link D forward This in conjunction with the lip assist spring E causes the lip linkage to push the lip out and up The lip assist spring also helps control the amount of time required for the lip to fully fold To lower the platform the operator walks out onto the platform The platform will lower until the extended lip rests on the truck bed If the lip did not fully extend or there is no truck at the dock the platform will lower until one of the following conditions occur e Lip is resting on lip keepers cross traffic position e Lip did not fully fold causing the platform to rest on safety legs below dock position e Lip did not fully fold and safety legs are retracted causing the platform to rest on the safety stops full below dock position The hold down ratchet assembly will keep the platform at the desired position until the platform release ring is pulled again 17 OPERATION Operating Instructions FUIT otay clear of dock leveler when freight carrier is entering or leaving dock area DO NOT raise or lower 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 d
31. evice and tagout device supplied by others Only the person servicing the equipment should have the capability to remove the lockout device The tagout device must inform that repairs are in process and clearly state who is responsible for the lockout condition If maintenance requires that the lip be in the extended position raise the lip by hand and support the lip with the lip maintenance prop A NOTE Make sure to disengage the lip maintenance prop and allow the lip to fold fully before disengaging the platform maintenance prop Refer to OSHA regulation 1910 147 21 MAINTENANCE Periodic Maintenance A Lip Hinge Grease Fittings B Lip Maintenance Prop Pivot C Lip Banger Pivots D Platform Hinge Area 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 Failure to do this may result in serious personal injury or death SDL E Lift Arm Roller Bushing F E Z Release Bellcrank Pivot G Lift Arm Pivot H Hold Down Pivot Pulley Ag gt A 2 IR m gt J Safety Leg Linkage Pivots K Lip Lift Assist Pin L Hold Down to Platform Pin The platform maintenance prop MUST be in the
32. hock absorber Clean and inspect ratchet bar and ratchet pawl teeth DO NOT lubricate the ratchet assembly Broken or damaged ratchet Replace ratchet assembly DO NOT lubricate the assembly teeth ratchet assembly Disconnected or broken Replace hold down pivot pins hold down pivot pins Clean and inspect hold down mechanism Inject grease into all of the lip hinge grease fittings See Periodic Maintenance in the Maintenance section Decrease lip assist spring tension See Adjust Lift Arm Spring and Lip Assist Spring Tension in the Adjustments section 29 TROUBLESHOOTING This page intentionally left blank 30 4111 0005 Sept 2012 June 2010 PARTS Hold Down Mechanism Item Quantity Part Number Description DOTH 2563 Hold Down Assembly Complete 31 5 Ratchet Bar DOTH 2564 Hold Down Assembly Complete 34 5 Ratchet Bar 1 1 DKIT 2575 Ratchet Bar and Pawl Assembly 31 5 Ratchet Bar DKIT 2576 Ratchet Bar and Pawl Assembly 34 5 Ratchet Bar C 1 1751 0043 Decal Warning D 1 DOTH 2559 Spring Release Arm 4111 0005 Sept 2012 31 June 2010 PARTS Frame Components BASE FRAMES ITEM QTY 6 LONG 8 LONG 10 LONG A 6 WIDE 20K 50K 6 WIDE 20K 50K 6 WIDE 20K 50K 1 16 DRFA 1003 16 DRFA 1012 16 DRFA 1021 18 DRFA 1004 18 DRFA 1013 18 DRFA 1022 20 DRFA 1005 20 DRFA 1014 20 DRFA 1023 6 5 WIDE 20
33. ift arm T The lift arm pushes against the underside of the platform C rolling on the cam not pictured forcing the platform to rise The force of the spring tension is just enough to lift the weight of the platform IMPORTANT When activating the leveler always pull AND hold the platform release ring until the platform is at the full raised position Releasing the ring while the platform is still rising may result in damage to the equipment To actuate the dock leveler platform the operator pulls and holds the platform release ring F located in the recess at the rear of the platform This causes ratchet pawl G to disengage from ratchet bar H With the ratchet pawl disengaged spring tension from lift springs U forces the platform to rise NOTE Hatchet pawl G and bar H are part of the hold down mechanism M 4111 0005 Sept 2012 June 2010 0 p S 4 7 60 p Si g A L 4 DIN P e OPERATION en Ws Se uel CASES L Platform Maintenance Prop R Safety Leg Linkage M Hold Down Mechanism N Safety Leg 2 used Ring P Snubber Spring Q Shock Absorber S Safety Leg Retract Pull T Lift Arm U Lift Springs The ratchet pawl disengages only when the platform release ring F is pulled AND held Spring tension from pawl spring J causes the ratchet pawl to engage the ratchet bar when the release ring is l
34. ion of the lip adjusted fthe lip folds before the platform can be walked If the platform does not rise fully and or lip does not down tension of lip assist spring C may be set extend fully the lift spring tension may be set too low too low If the platform cannot be walked down or is difficult to e f the lip does not fold fully or takes too long to walk down the lift spring tension may be set too high fold tension of lip assist spring C may be set too high 4 Adjust lip assist spring tension as follows If the platform does not rise fully on its own it may be necessary to use an external lifting device Use NOTE Use two turn increments when adjusting a lifting device with the appropriate lifting capacity lip assist spring C Check lip operation to safely raise the platform Make sure to engage after each adjustment Repeat until proper and lock the platform maintenance prop after raising operation is obtained the platform Failure to do this may result in serious personal injury or death a Loosen jam nut A b increase spring tension turn nut B clockwise IMPORTANT To decrease spring tension turn nut B When using an external lifting device to raise the counterclockwise platform make sure hold down mechanism F is disengaged Pull and hold platform release ring d Tighten jam nut during the lifting process to avoid shearing the ratchet pawl and ratchet bar teeth 5 Recheck operation of p
35. is 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 0788 Rev A DANGER CRUSH HAZARD Open the pin latch and insert through the maintenance 1751 0789 Ee completely Close the pin latch to secure prop Use every time dock leveler is serviced Failure to comply will result in death or serious injury DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is safely supported by maintenance prop Place barriers on driveway and dock floor to indicate 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 4111 0005 Sept 2012 5 June 2010 OWNER S USER S RESPONSIBILITIES 10 The owner user should recognize the inherent dangers of the interface between the loading dock and the transportation vehicle The owner user should therefore train and instruct all operators in the safe operation and use of the loading dock equipment in accordance with manufacturer s recommendations and industry standards Effective operator training should also focus on the owner s user s 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
36. latform and lip Readjust lift spring tension and lip assist spring tension until proper operation is obtained 1 Raise the platform and engage the platform maintenance prop Lock the maintenance prop in the service position using an appropriate locking device 2 Adjust tension of lift springs D as follows NOTE Use 1 2 turn increments when adjusting lift spring bolt E Check platform operation after each adjustment Repeat until proper operation is obtained To increase lift spring tension turn lift spring bolt E clockwise To decrease lift spring tension turn lift spring bolt E counterclockwise 4111 0005 Sept 2012 25 June 2010 ADJUSTMENTS Adjust Lip Stop Bolt 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 A result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler Failure to do this may result in serious personal injury or death The platform 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 A Platform D Lip Keeper Failure to f
37. ntenance Service Dock Leveler Safely seres 21 Periodic Maintenance eee a 22 Adjustments Adjust Lift Arm Spring and Lip Assist Spring Tension 24 Adjust LID 26 Troubleshooting ne 27 Parts Hold Down Mechanism 29 Frame Components TUS 30 Platform Components 32 Toe Guard Weather Seal Optional 35 Miscellaneous Customer Informations tu eras eme as 37 Lucie Back Cover 4111 0005 June 2010 Recognize Safety Information Safety Alert Symbol The Safety Alert Symbol identifies important safety messages on equipment safety signs in manuals or elsewhere When you see this symbol be alert to the possibility of personal injury or death Follow the instructions in the safety message DANGER 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 pra
38. ollow these instructions may result in B Jam Nut E Lip C Stop Bolt serious personal injury or death Check that lip E is fully resting on the lip keepers 4 Tighten jam nut B D and at the lowest part of the keeper cradle If lip is not resting properly in keepers perform the following 5 Disengage lip maintenance prop adjustment 6 Walk platform down to cross traffic stored position 1 Fully raise platform Manually raise the lip and engage lip maintenance prop not shown 7 Check lip position in both keepers Repeat procedure if necessary 2 Loosen jam nut B 3 Adjust stop bolt C as necessary Turn stop bolt in clockwise to allow lip to fold closer to platform A e Turn stop bolt out counterclockwise to hold lip further away from platform A 26 4111 0005 Sept 2012 June 2010 ADJUSTMENTS This page intentionally left blank 4111 0005 Sept 2012 27 June 2010 TROUBLESHOOTING Troubleshooting 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 The platform 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 th
39. onto the platform to lower the plattorm Allow the platform to lower to the cross traffic position Check for binding as platform lowers 19 11 binding occurs reposition leveler and or add or remove shims as necessary Raise and lower platform again If platform still binds contact DLM Technical Services for further instructions 20 Check that the leveler is flush with the dock floor and that the platform lip contacts both lip keepers evenly 21 Pull the release ring to raise platform Engage 15 INSTALLATION 0 066 0 PO DUR T U B ART A Safety Leg Chain Pull Ring B Platform Maintenance Prop C Shim Location Under Lift Arm Pivot D Prop Pin amp Clip the platform maintenance prop B in the service upright position and lock the maintenance prop at this position using an OSHA approved locking device D Engage lip maintenance prop 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 22 Install shims under lift arm at locations C using the pyramid shimming method The lift arm pivot must be solidly shimmed the entire length of the lift arm pivot Make sure the lift arm pivot is level from side to side 23 Finish weld all shims using a fillet weld eWeld all shims within each shim stack to each other then weld the shim stack to the leveler frame
40. rs 4111 0005 Sept 2012 June 2010 35 PARTS Platform Components Continued from previous page PLATFORMS ITEM QTY 6 Long 8 Long 10 Long A 6 0 Wide 6 5 Wide 7 0 Wide 6 0 Wide 6 5 Wide 7 0 FOOT 6 0 Wide 6 5 Wide 7 0 Wide 1 25K DPLA 1008 DPLA 1029 DPLA 1050 25K DPLA 1015 DPLA 1036 DPLA 1057 25K DPLA 1022 DPLA 1043 DPLA 1064 1 30K DPLA 1009 DPLA 1030 DPLA 1051 35K DPLA 1016 DPLA 1037 DPLA 1058 35K DPLA 1023 DPLA 1044 DPLA 1065 1 35K DPLA 1004 DPLA 1032 DPLA 1053 35K DPLA 1018 DPLA 1039 DPLA 1060 35K DPLA 1025 DPLA 1046 DPLA 1067 1 40K DPLA 1005 DPLA 1033 DPLA 1054 40K DPLA 1019 DPLA 1040 DPLA 1061 40K DPLA 1026 DPLA 1047 DPLA 1068 1 45K DPLA 1006 DPLA 1034 DPLA 1055 45K DPLA 1020 DPLA 1041 DPLA 1062 45K DPLA 1027 DPLA 1048 DPLA 1069 1 50K DPLA 1006 DPLA 1034 DPLA 1055 50K DPLA 1020 DPLA 1041 DPLA 1062 50K DPLA 1027 DPLA 1048 DPLA 1069 LIPS 167 25K 30K 35K 40K 45K 50K 6 0 1 16 DLIP 1000 DLIP 1003 DLIP 1006 DLIP 1009 DLIP 1012 DLIP 1015 1 18 DLIP 1001 DLIP 1004 DLIP 1007 DLIP 1010 DLIP 1013 DLIP 1016 1 20 DLIP 1002 DLIP 1005 DLIP 1008 DLIP 101 1 DLIP 1014 DLIP 1017 6 5 1 16 DLIP 1018 DLIP 1021 DLIP 1024 DLIP 1027 DLIP 1030 DLIP 1033 1 18 DLIP 1019 DLIP 1022 DLIP 1025 DLIP 1028 DLIP 1031 DLIP 1034 1 20 DLIP 1020 DLIP 1023 DLIP 1026 DLIP 1029 DLIP 1032 DLIP 1035 7 0 1 16 DLIP
41. 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 Failure to follow these instructions may result in serious personal injury or death 22 4111 0005 Sept 2012 June 2010 Regular maintenance must be performed on a weekly and quarterly schedule MAINTENANCE Weekly Maintenance Quarterly Maintenance Operate the dock leveler through the complete e Lubricate the following areas with light weight operating cycle to maintain lubrication NOTE To thoroughly inspect the platform hinge area position the platform in the full below dock position Inspect the platform 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 increase wear and cause abnormal operation IMPORTANT Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler DO NOT lubricate the hold down ratchet bar and pawl 4111 0005 Sept 2012 June 2010 machine oil B Lip maintenance prop pivot C Lip banger pivots F E Z release bellcrank pivot H Hold down pivot pulley J Safety leg linkage pivots L Hold down to platform pin Lubricate the following areas with white lithium grease A
42. sition 4 f truck trailer bed is at or above dock floor level leave leveler at the cross traffic position and proceed with loading or unloading When finished perform steps 9 and 10 If truck trailer bed is below the dock floor level perform steps 5 10 5 Pull and hold the platform release ring A until the platform is at the fully raised position 20 6 Slowly walk the platform down allowing enough time for the lip to fold Just before the platform reaches the cross traffic position pull and hold the safety leg retract pull ring B located in a recess at front of the platform The platform will continue lowering to the full below dock position End Loading Unloading Platform at Below Dock Position 7 Proceed with loading or unloading NOTE When end unloading is finished and additional access lo the truck trailer requires that the platform lip be extended see Ramp Loading Unloading Instructions on page 19 for further instructions When loading or unloading is finished raise the platform to the full raised position by pulling and holding the platform release ring Slowly walk the platform down allowing enough time for the lip to fold The platform will lower to the cross traffic position lip engages in the lip keepers Remove chocks from truck trailer wheels or release truck restraint if used 10 Indicate to the driver that the truck may leave the dock 4111 0005 Sept 2
43. spection 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 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 transportation 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
44. t across the pit opening directly over the shim locations 3 Verify that each shim stack is at the correct height by measuring distance J top of shim stack K to dock floor Distance J must equal the dock leveler height A 4111 0005 Sept 2012 13 June 2010 INSTALLATION am 722 3 8 6 9 5 152 A Front of Dock Pit B Dock Leveler Frame C Side Pit Curb Angle D Gap 3 4 in 19 mm Minimum 8 With rear hinge frame angle F tight against rear pit curb angle G perform check the following ePry between the platform and rear hinge frame angle at locations E to make sure rear edge of platform is parallel to the rear hinge frame angle F Gap D must exist equally along both sides of leveler so weather seal if equipped will not bind during dock leveler operation 9 If gap D cannot be obtained equally at both sides of leveler grind or add material at the rear edge of rear hinge frame angle F as needed 14 E Pry Locations F Rear Hinge Frame Angle To Fit Spacing 00 SN G Rear Pit Curb Angle H Flare Bevel Weld Typical 10 Allow the dock leveler to rest fully on the shim stacks Make sure the leveler is in the cross traffic stored position with lip resting on lip keepers 11 Check that a smooth and level transition exists between the dock floor and the dock leveler platform Add or remove shims as ne
45. tform release ring A 5 Hold the release ring until the platform is at the fully raised position and lip is fully extended 9 When the loading or unloading process has been completed return platform to cross traffic stored position as follows a Raise the platform to the full raised position by pulling and holding the platform release ring A b Lower platform by slowly walking out onto the platform allowing time for the lip to fully fold and clear the truck trailer Continue walking out on platform until platform lowers to the cross traffic 6 Walk out onto the platform The platform will lower position lip engages in the lip keepers until the lip rests on the truck trailer bed 10 Remove chocks from truck trailer wheels or release truck restraint if used 11 Indicate to driver that truck may leave the dock 4111 0005 Sept 2012 19 June 2010 OPERATION Operating Instructions Continued End Loading Unloading Instructions NOTE End loading or unloading can be done with the dock at the cross traffic position or below dock position depending on the height of the truck trailer bed 1 Check to make sure truck trailer is positioned squarely against dock bumpers 2 Instruct driver to remain at the dock until the loading or unloading process has been completed 3 Chock the truck trailer wheels or use truck restraint if present oC ete End Loading Unloading Platform at Cross Traffic Po
46. unted on a ten year straight line basis by the number of years of use prior to replacement

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