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HED Owner`s/User Manual

1. zi 30 HLONAT 803 jL3dONO NI OAN wun jeuosued esu JO Z Alene 10 duel Z4 JAQUS9 6 Xg uonejejsur jueunsn pe Buunp Buiddoup bua sed dures oL ued BuroeJq 1edoud suonisod eoa ered eseq Ul dij pue Jo pue sieduinq yoq snonunuoo A ddy ejejd Jo do ysni oj ejejd Jeduunq pue eseq jo do Tw SINA YO 99 03 OLL 80 701 47 E Eu Ad gt 25 lt SNONNILNOD lt lt 2 EE gt July 2015 INSTALLATION H E D Installation Instructions Flush Mount Bolt On Follow all safety precautions prior to installation A flush mount bolt on application is used when there is no steel on dock edge and the dock height is adequate Additional steel ramp plate and bolting is required with this type of installation Installation Steps T Remove all existing bumper material and protruding objects from dock edge Clean and sweep dock edge free of debris and flammable chemicals before installing unit At chosen location for Edge of Dock leveler locate the center of space and mark a point half of the base plate width to the
2. ueuw suondo pue eseud eues 1 YOOP SU3HLO A8 Q3TIVISNI dAVi3M0d A8 8313431 16 dAV33M0d S34IM M LINGNOD X314 SH3HLO A8 IN3IVAIO3 YO LAN 5133533435 e SYJHLO A8 SNOLLO3NNOO TV ASIMYSHLO 3LVOIQNI SSTINN SYSHLO A8 LINGNOD TV JSIMYJHLO Q3LVOIQNI SSJINN SYSHLO A8 SJAM I LYOHS 1 1 3503 LINDYIO HONVYE 30 ONU V3 WOWIXVM 3503 LINDYIO HONVYE 40 1 ONINALHOLL IVNINH3L 01 SHOLONGNOD ONIMIM 071313 30 9NU VS JYNLYYJdNAL SYOLONGNOD ONIMIM 071315 30 1 QVOTH3AO YOLOVINOD NO S3lV Id3AVN 335 3180 dH AJIAJ X900 LV 31V901 YOLOW Savi VIVO ALVIdSNVN SOLON 6 31801 SIYIM ASOLOV 3 l 61 1 53801 6 5 0 0350 JHL OL LXAN HOLIMS LOINNOOSIG 03503 31 001 NOWLOSLOUd 1 HONVYE 8043 035 38 53513 JHL Ydd 391A3Q LNIYYNONSAO HOLIMS LOANNOOSIG 193135 SHAHLO A8 JONAA IN3SMSODHJAO 9 HOLIMS L93NNOOSIQ HONVSB8 WO ZH 09 ISWHd A O9v 0cc GilddNS 010 uiui g 9JIM 1 4 ver A09 vel voe vote AO dH vH vii Manual No 4111 0027 Feb 2015 July 2015 37 TROUBLESH
3. 25 Install Control Panel and 26 Put New Dock Leveler Into Service 27 Operation Operating MSTUCHON a 28 Maintenance Penodi Maintenance a Vel ese 30 Adjustments Adjust Main 33 PAG 34 Electrical PF has euim suut ocu tna dms 36 PHASE Em 37 Troubleshooting BB iesu 38 Parts HE DOGE S etie 0 ere 40 a dated ev aso det edenda stra 43 Notes Customer rae Ree 45 Pici erigi eee ERE Back Cover 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 practice which could result in personal injury NOTICE
4. eunoeg ALON dV JO HI9N31 N04 11180800 N 3 0089 6 X 6 jIONV O3ASOJ NI 8 Manual No 4111 0027 Feb 2015 July 2015 21 INSTALLATION H E D Installation Instructions Ramp and Face Plate Follow all safety precautions prior to installation A ramp mount requiring a face plate application is used when there is no existing dock steel and the concrete at the dock edge has been damaged The dock height can be low high or adequate for this application however the face plate and ramp plate are required to rebuild the damaged concrete edge Installation Steps 1 10 22 Remove all existing bumper material and protruding objects from dock edge Clean and sweep dock edge free of debris and flammable chemicals before installing unit At chosen location for the face plate locate the center of space and mark a point half of the face plate width to the left and right Using a proper lifting device raise and position the face plate to marked position and push face plate against dock face Top of face plate should be flush with the top of dock floor Mark center of holes in face plate into dock face Drill 5 8 dia by 5 holes into dock face Install anchor bolts with washers per manufacturers specifications and tighten securely Place ramp plate to match each end of the face plate Leading forward edge of ramp plate should be flush with doc
5. jeuosued uone ejsu JO jueunsn pe 6uunp Buiddoup dwe ul ued BuroeJq Jedoud oe suonisod dij pue A jeunoeg SUNA ZL 99 404 ic 1 SuononJisul uonejejsur ees ejBue peuuo 5 OL esu Jo 2 JO dwel pseu eseq Jo ujBue pue sJeduunq 550102 pijam jddy ejejd Jo doi usnjj eq ejejd Jeduunq pue eseq jo do OLL 80 01 V NOLLOS t l dNVd 10 HION3 803 5mjA0089 C X JLIYOINOO NI XG SNONNILNOO Manual No 4111 0027 Feb 2015 July 2015 19 INSTALLATION H E D Installation Instructions Formed Angle Follow all safety precautions prior to installation A formed angle is used when there is no existing dock steel and concrete at the dock edge has been damaged The formed angle is required to rebuild the damaged concrete edge for a proper installation if the dock height is adequate Installation Steps ls 20 Remove all existing bumper material and protruding objects from dock edge Clean and sweep dock edge free of debris and flammable chemicals before ins
6. Lubricate the following areas with light weight machine oil Apply oil to each of the hoist and lip cylinder trunnions e Lubricate the following areas with white lithium grease A B Zerk fittings on both lip and platform hinge lines Manual No 4111 0027 Feb 2015 July 2015 MAINTENANCE M Reservoir N 3 in 76 5mm From Top of Reservoir P Breather Cap Q Fluid Level NOTICE A low fluid level or the use of hydraulic fluids not equivalent to the fluid types recommended will cause abnormal operation of the leveler and WILL void warranty e Check reservoir fluid level 1 Put the dock leveler platform at the full above dock position engage prop 2 Turn OFF all electrical power to the leveler 3 Measure fluid level The fluid level should be approximately 3 in 76 5 mm N from top of reservoir M with platform raised on the maintenance prop 4 Add hydraulic fluid if necessary Use only recommended fluid Reference page 30 5 Turn ON electrical power to the leveler 6 Return the platform to the stored position 31 5 This page intentionally left blank Manual No 4111 0027 32 Feb 2015 July 2015 Adjust Main Pressure Relief When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal inju
7. eunoeg 5 ALON HLIM HSATS 3lVid dvd 4000 JO 4904 V4l 40013 000 dO 401 HUM HSN Wid 4973 40 1 Wid 4OV4 V V a JO HION31 303 31389NOO NI jA0089 Z X amp gt Zn Manual No 4111 0027 Feb 2015 July 2015 23 INSTALLATION CHECK LIST 24 POWERAMP MCGUIRE DLM SYSTEMS INC Loading Dock Equipment E O D Installation Checklist Date Order No Serial Number Installer Customer Name Address City State Zip Phone 1 Unit is properly aligned and installed properly N 2 welding has been fully completed N 3 Welding slag has been removed N 4 Welds and other affected areas have been painted 5 Springs have been properly adjusted N 6 Unit 18 functioning properly without fault N I hereby certify that all installation and or repair work has been inspected and approved by Company Date Completed Name Signature A copy of this document must be signed and faxed to Systems Inc at 262 257 7399 to the attention Customer Service Technical Service To be placed in job folder Copy as needed Manual No 4111 0027 Feb 2015 July 2015 INSTALLATION Placard installation Instructions Owner is responsible for the installation and placement of product placards Make sure placard is in plain view of dock leveler opera
8. ysni eq Jeduunq pue eseq jo do xog OLL dO vOI uonounr Y O NIN L XC v l 1 VAIS MAITA ONY SNONNILNOO Manual No 4111 0027 Feb 2015 July 2015 13 INSTALLATION H E D Installation Instructions Ramp Mount Weld Bolt On Follow all safety precautions prior to installation A ramp mount weld on application is used when adequate dock steel is securely anchored in the concrete at the dock edge but the existing dock height is too low and the dock leveler must be installed above this height to correct this situation Installation Steps 1 Remove all existing bumper material and protruding objects from dock edge Clean and sweep dock edge free of debris and flammable chemicals before installing unit 2 Atchosen location for Edge of Dock leveler locate the center of space and mark a point half of the base plate width to the left and right 3 Atthe points marked to each side of center measure and mark points 7 3 4 below dock level less height the unit is to be raised to locate bottom of base plate This will locate the top of the base plate X above dock level 4 Using a proper lifting device raise and position the leveler base plate to marked position While holding base plate tight against dock face tack weld securely to dock steel on l
9. Note All adjustments should be made in small increments and should be charted to have reliable information when back tracking through adjustments Manual No 4111 0027 Feb 2015 July 2015 ADJUSTMENTS This page intentionally left blank Manual No 4111 0027 Feb 2015 35 July 2015 ELECTRICAL 1 Phase ueuw suondo pue eseud Jequunu eues 1 YOOP epi oJgd 5 A8 Q3TIVISNI 8 6 dAVii3MOd S34M M LINGNOD X313 SUGHLO AG TIVA Lid 40 X08 W3LNVIS JHL NO 96 TVNINH3L OL 17 0351 LON LOVINOD 4000 Jl Qasiva ATINI SI 4000 N3HM 035010 38 OL LOVINOD Q3SlVs ATINA LON 51 4000 N3HM N3dO 38 OL LOVINOO SU3HLO A8 LOVINOD 3000 0351 31 LOVLNOD 8008 Su3HL0 A8 LNFIVAINDA YO LAN 34MM SIN3S3ud3M 6 y 68 SYJHLO A8 SNOLLO3NNOO JAM TV ED LOVINOO GALVOIGNI SSTINA SYSHLO A8 LINGNOD gt 4000 31V9IQNI SSJINN SYSHLO A8 5386 7I 4000 GVSHYSAO 5 9NIQNnOND ONLLVY LNSYYND 1 LYOHS 3504 1 HONVYE 40 ONLLVY WAWIXVA 3503 LINOYIO H NVYE 30 1 300801 ONINALHOLL TWNINYAL SYOLONGNOD ONIMIM 01315 30 ONILVY JYNLVYSdWAL SYOLONGNOD ONIMIM 01315 30 JdL AVTSY QVOTH3AO X YOLOVLNOD NO SALVIdSNVN 33S as
10. the dock always e Ensure that no equipment material or people are on the dock leveler Return the dock leveler to its stored position at dock level Unsupported dock leveler ramps can lower unexpectedly Before allowing vehicle to leave the dock always e Ensure that no equipment material or people are on the dock leveler Return the dock leveler to its stored position at dock level SAFETY SAFETY INFORMATION Operation Read and follow all instructions and warnings in the owner s user s manual Use of dock leveler restricted to trained operators Always chock trailer wheels or engage truck restraint before operating dock leveler or beginning to load or unload Never use hands or equipment to move the ramp or lip Before activating dock leveler Ensure trailer is backed in against bumpers Remove any end loads if required Check trailer alignment to avoid lip interference If lip does not lower to trailer bed reposition vehicle Ensure that truck bed supports extended lip or the leveler frame Operation Read and follow all instructions and warnings in the owner s user s manual Use of dock leveler restricted to trained operators Always chock trailer wheels or engage truck restraint before operating dock leveler or beginning to load or unload Never use hands or equipment to move the ramp or lip Before activating dock leveler Ensure trailer is backed in against bumpe
11. the lip extends 5 Release the RAISE button to lower the platform As long as there is no transport vehicle present at the dock the platform will lower to the full below dock position as the lip folds NOTE transport vehicle is present the platform will lower until the lip rests on the transport vehicle bed See Operating Instructions in Operation section 6 Perform steps 4 amp 5 at least four times to purge any air that may be in the hydraulic system and to ensure proper operation Always stand clear of platform lip when working in front of the dock leveler Serious personal injury or death may result Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Manual No 4111 0027 Feb 2015 July 2015 INSTALLATION 27 OPERATION Operating Instructions DANGER Stay clear of dock leveler when transport vehicle is entering or leaving dock area DO NOT move or use the dock leveler if anyone is under or in front of leveler Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts Failure to follow these instructions will result in severe personal injury or death Only trained personnel should operate the dock leveler DO NOT use a broken or damaged dock leveler Make sure proper service and maintenance procedure have
12. Ae T V A 1 V STI 1 La vu vu 394m 4313431 5900 Q31V901 SOLON VH V1VQ ENT SOLON SU3HLO A8 Q3TIVISNI dAV43MOd Ad 15 0 0350 aud H 1 uiu g ONY 53188 335 M JIN HilNVIS 0350 JHL OL LX3N HOLIMS 193NNOOSIQ 03503 V 31V901 NOLLOALOYd 1 035 38 LSAW 53513 JHL Ydd 391430 LNIYYNOYSAO HOLIMS 193NNOOSIQ 193135 9 SU3HLO AG 39IA30 LN3NSf0H3AO 9 HOLIMS 193NNOOSIG 1 HONVSS WOU ZH 09 3SWHd A 08 8 5 YINOLSNI 3iVId3AVN YALYVLS 0 0350 NO 39VL 10A SSHOLVW JOVLIOA 3SVHd GilddNS YAWOLSNOD 38905 JAVA Feb 2015 July 2015 Manual No 4111 0027 36 ELECTRICAL 583010 A8 Lid 0 X08 f JilNViS JHL NO 66 OL IWNINYSL 0350 LON 19VLNOO 4008 dqasiva ATINA SI 4000 N3HM 035019 OL 19VINOO Q3SIV3 ATINA LON 51 4000 N3HM N3dO 38 OL A8 LOWLNOD 4000 0350 LOVLNOD 3000 19V1NO2 4000 4000 svea C e SU3HLO A8 Q3TIVISNI dAVH3MOd Ad 1 035070 089 uiui g 9JIM 1 4 3 Phase JIVId3AVN YALYVIS Q3S0 19N3 NO 39VL 10A SSHOLVN 39VL10A 3SVHd GillddNS YAWOLSNO JANS SIVAN
13. Check right hand end of base plate ensure that end is against dock steel and that the bottom of the base plate is even with the marks made previously Tack right hand end to dock steel Support unit until final welding is ready to complete 6 Position bump blocks out approximately 5 8 out from the edge of the inside flange of the bump block to the end of the base plate Position the top of the tread cover plate on the bump blocks to be flush with the top of the base plate Tack weld bump blocks to dock steel 7 Place steel ramp plate in position flush with top backside of base plate Mark along full length of back edge of ramp plate Slide ramp plate forward over dock leveler the width of bushing tool approximately 2 8 Place bushing tool on marked line at each end of ramp to ensure proper alignment at both ends and tack weld ramp plate to dock leveler to hold ramp plate in place while bushing A Skil Roto Hammer 736 or similar tool is recommended 18 9 Using the back edge of the ramp plate as a guide groove concrete approximately 3 4 deep by 2 wide and should be the entire length of ramp plate 10 Break tack welds holding ramp in place slide ramp plate back into position with the top of the ramp plate flush with the top of the base plate Tack weld each end and center of ramp plate to base plate 11 Drill 5 8 dia by 5 deep holes through ramp plate at back edge Install anchor bolts per manufacturers specificat
14. The use of the word NOTICE is to draw attention to a procedure that needs to be followed to prevent machine damage SAFETY INSTRUCTIONS Indicates a type of safety sign or separate panel on a safety sign where safety related instructions or procedures as described Manual No 4111 0027 Feb 2015 July 2015 SAFETY General Operational Safety Precautions Read and understand the s User s manual 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 placards or decals on the equipment unless replacing them a Do not start the equipment until all unauthorized personnel in the area have been warned and have moved outside the operating zone Remove any tools or foreign objects from the operating zone before starting Keep the operating zone free of obstacles that could cause a person to trip or fall Operational Safety Precautions 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 transport vehicle is entering or leaving area Do not move or use the dock leveling device if anyone is under or in front of it Keep hands and feet clear of p
15. left and right At the points marked to each side of center measure and mark points 7 1 2 below dock level for 74 ramp plate to locate position for bottom of base plate This position will place the top of the base plate 74 above the dock floor This position will vary with ramp plate thickness Mark line connecting these points and position support angles Position angles as shown in installation drawing provided Mark center of holes in each of the support angles At center marks drill holes 5 8 dia by 5 deep in concrete Install anchor bolts with washers through support angles into holes in concrete Tighten bolts until supportangles are secure Follow anchor manufacturers installation instructions for proper installation Using a proper lifting device raise and position the leveler base plate to marked position while resting on the support angles While holding base plate tight against dock face tack weld securely to support angles Drill 5 8 dia by 5 deep holes in concrete through holes in base plate and install anchor bolts with washers and tighten securely Position bump blocks out approximately 5 8 out from the edge of the inside flange of the bump block to the end of the base plate Position the top of the tread cover plate on the bump blocks to be 77 above dock level Note that this placement will vary with ramp plate thickness Mark centers of holes in bump block flanges Dril 5 8 dia by 5 deep hol
16. supported by maintenance prop If electrically powered turn off and 6 OSHA lockout tagout procedures Failure to follow posted instructions will result in death or serious injury Call 262 255 1510 for replacement placards waming labels or owner s user s manuals DANGER A DANGER CRUSH HAZARD DO NOT REMOVE hydraulic cylinder until leveler is safely supported by maintenance prop Refer to owner s user s manual for proper maintenance procedure Failure to comply will result in death or serious injury Ramp swings toward you Stand Clear Use maintenance strut while servicing Failure to do so will result in death or serious injury gt Decal 2 will have two positions one on outside of the left bumper and a PS 2 one on outside of the right bumper Decal 4 represents the placement of the serial tag E l Manual No 4111 0027 Feb 2015 5 July 2015 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
17. Contact manufacturer for any replacements Manufacturer s recommended periodic maintenance and inspection procedures in effect at the date of shipment shall be followed at all times Written documentation of maintenance replacement parts or damage should be retained In the event of damage notification to the manufacturer is required Loading dock equipment that has been structurally damaged or has experienced a sudden loss of main support while under load such as what might occur when a transport vehicle pulls out from under the leveling device shall be removed from service inspected by a manufacturer s authorized representative and repaired or replaced as needed before being placed back in service Any modifications 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 transport vehicles with air ride suspension systems shall have its air exhausted prior to performing loading and unloading operation t
18. DOTH 4202 Main Cylinder Pin DOTH 2358 Lower Cylinder Mount Assembly DOTH 4302 1 AL Hydraulc Power Unit 115V 1PH DOTH 2854 1 AL Hydraulic Power Unit 230V 1PH DOTH 2846 p a Hydraulic Power Unit 230V 3PH DOTH 2855 1 AL Hydraulic Power Unit 460V 3PH DOTH 2847 Motor Mount Bracket DOTH 4305 Manual No 4111 0027 Feb 2015 41 July 2015 5 This page intentionally left blank Manual No 4111 0027 42 Feb 2015 July 2015 DBBS 3550 Complete 18 Projection Bumper Assembly 6 Manual 4111 0027 Feb 2015 July 2015 QTY 1 PART NUMBER DOTH 3556 DOTH 3505 DOTH 2056 DOTH 2210 DOTH 2208 DOTH 2129 DKIT 3541 DESCRIPTION 18 Proj x 12 BB Weldment HED Rubber TUF Cord Hex HEad Cap Screw Washer Flat Zinc Plated Washer Flat Nylon Lock Nut Bumper with Hardware 18 1 2 sup NENNEN 5 43 MISCELLANEOUS This page intentionally left blank Manual No 4111 0027 44 Feb 2015 July 2015 MISCELLANEOUS NOTE The model serial number decal A is located on the right platform joist near the front lip of dock leveler When you receive your HED series Edge of Dock leveler write down the dock leveler model and serial number in the form provided This will help ensure safe keeping of the numbers in the event the model serial number decal A becomes lost or damaged Also write down Systems Inc s job number the company that installed the dock level
19. Depressing the raise button will return the platform and lip to the stored position Manual No 4111 0027 Feb 2015 July 2015 INTRODUCTION This page intentionally left blank Manual No 4111 0027 Feb 2015 9 July 2015 INSTALLATION INSTALLATION DETAILS GREASE FITTINGS ON LIP HINGES 8 C 11 54 FT CHANNEL MINIMUM BY OTHERS CONTINUOUS WELD ACROSS TOP OF BUMPER BLOCKS AND BASE PLATE BUMP BLOCK ASSEMBLY ANCHOR BOLT ANCHOR BOLT HOIST CYLINDER MOUNTING ANCHOR BOLT GREASE FITTINGS ON BASE PLATE HINGES Post safety warnings and barricade the work area at DO NOT grind or weld if hydraulic fluid or other dock level and ground level to prevent unauthorized use of the dock leveler before installation has been completed Failure to follow the installation instructions can result in damage to dock leveler the facilities and or serious personal injury or death 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 Only trained installation professionals with the proper equipment should install this product NOTICE DO NOT remove the shipping bands around th
20. OOTING Before performing the detailed troubleshooting procedures check the following items first e sure the correct voltages are preset at the proper locations inside the control panels Motor overload device Reset overload relay three phase Determine cause tripped or fuse blown of overload Check voltage at starter or relay coil Platform does not rise Motor does not energize Motor starter three phase or motor relay single phase not energizing If voltage is present and starter or relay does not energize replace starter or relay f voltage is not present check all components in series with the starter or relay coil Check motor starter as follows Disconnect wires at load side of starter Energize the starter No voltage is present 3 Measure line to line voltage at line side of starter Three phase units only one line Measure line to line voltage at load side of starter Platform does not rise Line side and load side voltages should be Motor hums but does NOTE A motor that is approximately the same Replace starter if not run missing voltage on one line voltage values are considerably different from is said to be single phased one another Check all wiring to motor for high resistance or no connection Three phase units only Platform does not rise Phase reversed Motor runs in reverse Reverse any two legs at the branch circuit disconnect May have to
21. __ Division of Systems Inc DLM HED SERIES DOCK LEVELER Hydraulic EOD MANUFACTURING Dock Leveler Owner s User s Manual DLM Division of Systems Inc W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 255 5917 www docksystemsinc com techservices docksystemsinc com Printed in U S A Manual No 4111 0027 Copyright 2015 Feb 2015 July 2015 Table of Contents Page Safety Recognize Safety Information ccccseccecseeeeeseeeeeseeeesaaeeeseeeeeeseeeeesees 1 General Operational Safety Precautions 1 Operational Safety Precautions 2 2 Maintenance Safety Precautions 4 T a 5 Owner s User s 6 Introduction General Informoallon eee lees dees E 7 Dock Leveler Stock 7 7 8 Installation Inistallat rns eltallSz n a es S tese toten ues 10 El spn Mount Weld ON 12 Ramp Mount Weld Bolt On 14 16 Ramp Mount Weld On w Formed 9 18 ANOO 20 Face PIANC T 22 Installauon Check eae 24 Placard Installation
22. ation 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 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 ITS 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
23. been performed on leveler before using Transport vehicle wheels must be chocked unles the vehicle restraint is used Never remove the wheel chocks until loading unloading is finished and transport vehicle driver has been given permission to leave Make sure platform lip rests on the transport vehicle bed with at least 4 in 102 mm of overlap Maintain a safe distance from side edges of levele during the loading unloading process Failure to follow these instructions may result in serious personal injury or death 28 B in 127 mm Lo deme gc a Y The hydraulic Edge of dock leveler is designed to compensate for a maximum 5 in 127 mm of height difference between the loading dock and the transport vehicle bed DO NOT use the dock leveler if the transport vehicle bed is more than 5 in 127 mm higher or lower than the dock floor 5 in 127 mm Service height may vary with design specifications DO NOT overload the dock leveler DO NOT operate any equipment while under the influence of alcohol or drugs DO NOT leave equipment or material unattended on the dock leveler Failure to follow these instructions may result in personal injury and or damage to equipment Manual No 4111 0027 Feb 2015 July 2015 Operating Instructions 1 Make certain all equipment and personnel are clear of leveler before operation 2 The transport vehicle should be firmly against the
24. bump blocks and wheels chocked before operation of the leveler Figure 4 Manual No 4111 0027 Feb 2015 July 2015 OPERATION Always remove any end load while leveler is in stored position Figure 1 Depress and hold RAISE A button until leveler extends fully Figure 3 Release button Leveler will lower to transport vehicle bed Figure 4 To remove leveler from transport vehicle before departure operate leveler RAISE A button until lip clears transport vehicle bed folds up and returns Figure 2 then release button Leveler will then return to stored position Figure 1 A Raise Button 29 MAINTENANCE Periodic Maintenance A Lip Hinge Area B Platform Hinge Area C Platform Cylinder Trunnion D Lip Cylinder Before performing any maintenance under the dock leveler lock the electrical power source in OFF position and lock the maintenance prop in the service position using an approved locking device See Service Dock Leveler Safely in this section Failure to follow these instructions may result in serious personal injury or death NOTICE Use offluids that do nothave equivalent specifications to those in the following list will result in abnormal operation of the dock leveler and voiding of warranty 30 Trunnion To ensure normal operation of the dock leveler use only aircraft hydraulic fluid designed to meet or exceed mi
25. e dock leveler lip until instructed to do so Failure to follow these instructions may result in serious personal injury or death Manual No 4111 0027 10 Feb 2015 July 2015 INSTALLATION NOTICE DO NOT connect the dock leveler electrical wiring and ground connections until all welding has been completed DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler Always ground welding equipment to the dock leveler frame NEVER to the platform Failure to follow these instructions may damage the motor hoist cylinder wiring and or control panel lf the platform is raised using an external lifting device or the hydraulic system is opened to atmosphere air will enter into the hydraulic system Whenever this happens always cycle the leveler at least 4 times using the levelers own hydraulic power system before allowing the leveler to be put into service This is to make sure all air is purged from the hydraulic cylinders Failure to do this may result in serious personal injury or death Two people are required to engage the maintenance prop one person to operate the lifting device the other person to engage the maintenance prop Manual No 4111 0027 Feb 2015 11 July 2015 INSTALLATION H E D Installation Instructions Flush Mount Weld On Follow all safety precautions prior to installation A flush mount weld on application is used when an 8 8 Installer must remove a
26. e shooting section for further adjustment procedures 34 When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death Troubleshooting 1 Iflipopens as platform begins to rise turn sequence valve clockwise in 1 4 turn increments 2 If lip will not fully retract when recycling platform to stored position turn sequence valve clockwise in 1 8 turn increments
27. ection Equipment Required De energize equipment before working on or inside Do not open cover without appropriate PPE Refer to NFPA 70 for PPE requirements This panel may contain more than one power source Hazardous Voltage Will Cause Severe Injury or Death ALWAYS disconnect electrical power source and ground wire before welding on dock leveler DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler Always ground to the dock leveler frame Failure to follow these instructions may result in damage to dock leveler and or serious personal injury or death DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present Stray sparks can ignite spills or leaks near the work area Always clean up the oil leaks and spills before proceeding with grinding or welding Always keep a fire extinguisher of the proper type nearby when grinding or welding Failure to follow these instructions may result in serious personal injury or death ALWAYS stand clear of dock leveler lip when working in front of the dock leveler Failure to do this may result in serious personal injury or death Manual No 4111 0027 Feb 2015 July 2015 Safety Decals DANGER Unsupported dock leveler ramps can lower unexpectedly Before allowing vehicle to leave
28. eft hand end of leveler Check right hand end of base plate ensure that end is against dock steel and that the bottom of the base plate is even with the marks made previously Tack right hand end to dock steel Support unit until final welding is ready to complete 5 Position bump blocks out approximately 5 8 out from the edge of the inside flange of the bump block to the end of the base plate Position the top of the tread cover plate on the bump blocks to be flush with the top of the base plate Tack weld bump blocks to dock steel 6 Place steel ramp plate in position flush with top backside of base plate Mark along full length of back edge of ramp plate Slide ramp plate forward over dock leveler the width of bushing tool approximately 2 7 Place bushing tool on marked line at each end of ramp to ensure proper alignment at both ends and tack weld ramp plate to dock leveler to hold ramp plate in place while bushing A Skil Roto Hammer 736 similar tool is recommended 14 8 Using the back edge of the ramp plate as a guide groove concrete approximately 3 4 deep by 2 wide and should be the entire length of ramp plate 9 Break tack welds holding ramp in place slide ramp plate back into position with the top of the ramp plate flush with the top of the base plate Tack weld each end and center of ramp plate to base plate 10 Drill 5 8 dia by 5 deep holes through ramp plate at back edge Install anchor bolts
29. er 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 Manual No 4111 0027 Feb 2015 July 2015 Dock Leveler Information Model Serial No DLM Job No Original Owner Information Name Address Installer Information Name Address Date of Installation 45 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 manufacturers recommendations and or specified design parameters and not otherwise have been subject to abuse misuse misapplication acts of nature overloading unauthorized repair or modification applic
30. es at center marks Reposition bump blocks insert anchor bolts with washers and tighten securely to dock face 10 Place steel ramp plate in position flush with top 16 11 12 13 14 15 16 17 18 19 backside of base plate Mark along full length of back edge of ramp plate Slide ramp plate forward over dock leveler the width of bushing tool approximately 2 Place bushing tool on marked line at each end of ramp to ensure proper alignment at both ends and tack weld ramp plate to dock leveler to hold ramp plate in place while bushing Skil Roto Hammer 736 or similar tool is recommended Using the back edge of the ramp plate as a guide groove concrete approximately 5 8 deep by 2 wide and should be the entire length of ramp plate Break tack welds holding ramp in place slide ramp plate back into position with the top of the ramp plate flush with the top of the base plate Tack weld each end and center of ramp plate to base plate Dril 5 8 dia by 5 deep holes through ramp plate at back edge Install anchor bolts per manufacturers specifications and tighten securely Weld anchor bolt nuts to ramp plate using a fillet weld all the way around the nut Cut off any portion of the anchor bolt exposed through the nut and plug weld around the top of the nut to the anchor bolt Ensure the top of the nuts are well rounded for smooth rollover Complete welding of tacked parts as follows A Appl
31. have to do this twice Check wiring to motor for high resistance Check for loose or corroded connections Check if gauge of Single phase units only wires to motor are of correct size and specification Platform does not rise for load requirement Replace if necessary Motor energizes but does not run Defective motor centrifugal Replace motor switch Defective motor capacitor Replace motor Line voltage to low Manual No 4111 0027 38 Feb 2015 July 2015 TROUBLESHOOTING Turn sequence valve clockwise approximately 1 4 turn and retest unit If the lip plate still will not retract repeat the above adjustment until unit operates properly Unit raises but the lip plate will not extend Unit raises but the lip plate will not retract The unit raises slowly the motor is extremely Check the fluid level in power unit reservoir if low add fluid and noisy and the hydraulic hoses are vibrating operate leveler several times to remove any air from the system Turn sequence valve clockwise in 1 2 turn increments until lip Lip Plate will not stay extended plate remains extended but is still yieldable to approximately thirty pounds of downward force The lip plate extends before the unit reaches Turn sequence valve clockwise in 1 2 turn increments until lip full dock height plate operates properly Check the motor for reverse polarity wiring Consult the wiring diagram located on the motor and reverse polarity according t
32. inch points Avoid putting any part of your body near moving parts tex Chock restrain all transport vehicles Never remove the wheel chocks until loading or unloading is finished and transport vehicle driver has been given permission to drive away AND Do not use a broken or damage dock leveling device Make sure proper service and maintenance procedures have been performed before using CM _ er Make sure lip overlaps onto transport vehicle at least 4 in 102 mm Keep a safe distance from both side edges Manual No 4111 0027 Feb 2015 July 2015 Do not use dock leveling device if transport vehicle is too high or too low Do not overload the dock leveling device Do not operate any equipment while under the influence of alcohol or drugs Do not leave equipment or material unattended on dock leveling device Manual No 4111 0027 Feb 2015 3 July 2015 Maintenance Safety Precautions DANGER Hydraulic and electrical power must be OFF when servicing the equipment For maximum protection use an OSHA approved locking device to lock out all power sources Only the person servicing the equipment should have the key to unlock the device Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the unit before maintenance is complete 4 DANGER Arc Flash and Shock Hazard PPE Personal Prot
33. ions and tighten securely Weld anchor bolt nuts to ramp plate using a fillet weld all the way around the nut Cut off any portion of the anchor bolt exposed through the nut and plug weld around the top of the nut to the anchor bolt Ensure the top of the nuts are well rounded for smooth rollover 12 Complete welding of tacked parts as follows A Apply continuous weld across top of each bumper and base plate to ramp plate Skip welding is acceptable to prevent warping but complete weld must be completed B Weld vertically along each end of base plate and on both inboard and outboard flanges of bump blocks C Fully plug weld all holes in base plate 13 Installer must remove all welding slag and repaint welded areas 14 Drill 5 8 dia by 5 deep holes in concrete through holes in lower cylinder mount and install anchor bolts with washers and tighten securely 15 Field mount control box to inside wall Field wire control box and hydraulic power unit per electrical schematic s provided Read and comply with all local electrical codes 16 Before install is complete installer must make a final operational check of dock leveler to verify all phases of install are correct Installer must complete sign and return the Installation Checklist upon completion Reference page 24 NOTICE Motor should NOT be wired in while welding Manual No 4111 0027 Feb 2015 July 2015 INSTALLATION
34. k face Mark along full length of back edge of ramp plate Slide ramp forward the width of bushing tool approximately 2 Place bushing tool on marked line at each end of ramp to ensure proper alignment at both ends A Skil Roto Hammer 736 or similar tool is recommended Tack weld ramp to face plate on each end to secure in place Using the back edge of the ramp plate as a guide groove concrete approximately 5 8 deep by 2 wide and should be the entire length of the lamp plate Break tack welds and slide ramp back until forward edge is flush with dock face Tack weld ramp on each end and center to face plate Drill 5 8 dia by 5 deep holes through ramp plate at back edge Install anchor bolts per manufacturers specifications and tighten securely Weld anchor bolt nuts to ramp plate using a 1 4 fillet weld all the way around the nut Cut off any portion of the anchor bolt exposed through he nut and plug weld around the top of the nut to the anchor bolt Ensure the top of the nuts are well rounded for smooth rollover 11 Apply a continuous filet weld at the created joint between the face plate and ramp Skip welding should be the proper method used to avoid warping and a complete weld must be achieved Manual No 4111 0027 Feb 2015 July 2015 INSTALLATION duueJ pue ujDue SSOJO snonunuoo Ajddy opis uoee 6 syoq soyoue 81
35. litary specification MIL H 5606G It is recommended that the following hydraulic fluids be used ULTRA VIS HVI 15 Aero Shell Fluid 4 or Fluid 41 Mobile Aero HFA MIL HS606A or Aero Texaco Aircraft Hydraulic Oil 15 or 5606 Exxon Univis J13 These fluid brands can be mixed together Mixing with fluids that do not meet or exceed MIL H 5606G may damage the equipment and WILL void warranty Use of hydraulic fluids with equivalent specifications to those listed here are acceptable Manual No 4111 0027 Feb 2015 July 2015 Periodic Maintenance FOLLOW ALL SAFETY PRECAUTIONS e Regular maintenance must be performed on a weekly and quarterly schedule Weekly Maintenance e Operate the dock leveler through the complete operating cycle to maintain lubrication NOTE To thoroughly inspect the platform hinge area put the platform in the full below dock position e Look for cracks or damage Repair or replace damaged or cracked parts as needed e 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 cause abnormal operation NOTICE Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler Quarterly Maintenance Follow weekly maintenance schedule in addition to the following e Platform hinge area apply oil to top of all platform hinges while platform is in stored position
36. ll welding slag and repaint wide minimum embed channel is securely anchored welded areas into the concrete at the dock edge and the dock height is adequate 9 Drill 5 8 dia by 5 deep holes in concrete through holes in lower cylinder mount and install anchor Installation Steps bolts with washers and tighten securely 1 Remove all existing bumper material and protruding objects from dock edge Clean and 10 Field mount control box to inside wall Field wire sweep dock edge free of debris and flammable control box and hydraulic power unit per electrical chemicals before installing unit schematic s provided Read and comply with all local electrical codes 2 At chosen location for Edge of Dock leveler locate the center of space and mark a point half of 11 Before install is complete installer must make a the base plate width to the left and right final operational check of dock leveler to verify all phases of install are correct Installer must 3 Using a proper lifting device raise and position complete sign and return the Installation Checklist leveler on dock face with the top of the base plate upon completion Reference page 24 being flush with the top of the embedded channel Position ends of base plate to match up with marks made previously TICE 4 Tack weld base plate to dock steel on left hand Motor should NOT be wired in while welding end of the leveler Check right hand end of base plate ensure that e
37. nd is against dock steel and that the top of the base plate is still flush with the top of the embedded channel Tack right hand end to dock steel 5 Position bump blocks out approximately 5 8 from the edge of the inside flange of the bump block to the end of the base plate This will allow for vertical welding of both the base plate and the bump block flange back to the dock steel Top of the bump block cover plate should be flush with the top of the embed channel Tack weld bump blocks to dock steel 6 Check the positioning of the base plate and the bump blocks 7 Complete welding of tacked parts as follows A Apply a continuous weld across top of each bumper and base plate to dock steel Skip welding is acceptable to prevent warping completed B Weld vertically along each end of base plate and on both inboard and outboard flanges of bump blocks C Fully plug weld all holes in base plate Manual No 4111 0027 12 Feb 2015 July 2015 INSTALLATION nun Anfu jeuosued JO jueugnsn pe Buunp ueo BuroeJq Jedoud oe suonisod ed Ul di pue Tv SIINA ZZ MO 99 404 eseq Jo pue sjeduunq 550102 pJ9 snonunuoo Ajddy Jeuueuo peppequue pue Jo doi
38. o The motor runs but the unit will not raise the diagram three phase only Check Fluid levels Check for voltage drop due to wrong size wiring Check fluid level Unit raises very slow x ry Make sure unit is well lubricated Unit raises but leveler shuts off during Check the overload relay located in the control box and adjust if operation cycle necessary Check fluid level in reservoir Fluid level should be three inches NOLTAISE 1O below the top of the reservoir with all cylinders fully extended Manual No 4111 0027 Feb 2015 39 2015 5 ITEM n d DESCRIPTION PART NUMBER 15 LIP PART NUMBER 17 LIP Manual 4111 0027 40 Feb 2015 July 2015 5 ITEM a DESCRIPTION PART NUMBER 15 LIP 6620 25 Center Plate amp Hinge Assembly DOTH 4200 6630 Center Plate amp Hinge Assembly DOTH 4208 6635 Center Plate amp Hinge Assembly DOTH 3231 7220 25 Center Plate amp Hinge Assembly DOTH 4212 7230 Center Plate 8 Hinge Assembly DOTH 4220 7235 Center Plate amp Hinge Assembly DOTH 4218 7820 25 Center Plate amp Hinge Assembly DOTH 4222 7830 Center Plate amp Hinge Assembly DOTH 4223 8420 25 Center Plate amp Hinge Assembly DOTH 3280 8430 Center Plate amp Hinge Assembly DOTH 3273 Base Plate amp Hinge Assembly Consult Factory 18 Projection Bumper Block DBBS 3550 Safety Strut Assembly DOTH 4325 Breather Vent Plug DOTH 2717 Upper Cylinder Pivot
39. o minimize transport vehicle bed drop Loading dock safety equipment should never be used outside of its intended use vertical working range or capacity Please consult the manufacturer if you have any questions as to the use vertical working range or capacity of the equipment Only properly trained and authorized personnel should operate the equipment When selecting loading dock safety equipment it is important to consider not only present requirements but also future plans and any possible adverse conditions environmental factors or usage Manual No 4111 0027 Feb 2015 July 2015 General Information INTRODUCTION Congratulations on your choice of a DLM Edge of Dock leveler This manual covers the HED series mechanical Edge of Dock levelers 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 Hydraulic Edge of Dock leveler The HED series Edge of Dock leveler comes equipped with an electrical control panel which allows push button operation of the dock leveler functions Each HED dock leveler unit and control panel has been factory pre wired and tested to ensure satisfactory operation To illu
40. per manufacturers specifications and tighten securely Weld anchor bolt nuts to ramp plate using a fillet weld all the way around the nut Cut off any portion of the anchor bolt exposed through the nut and plug weld around the top of the nut to the anchor bolt Ensure the top of the nuts are well rounded for smooth rollover 11 Complete welding of tacked parts as follows A Apply continuous weld across top of each bumper and base plate to ramp plate Skip welding is acceptable to prevent warping but complete weld must be completed B Weld vertically along each end of base plate and on both inboard and outboard flanges of bump blocks C Fully plug weld all holes in base plate 12 Installer must remove all welding slag and repaint welded areas 13 Drill 5 8 dia by 5 deep holes in concrete through holes in lower cylinder mount and install anchor bolts with washers and tighten securely 14 Field mount control box to inside wall Field wire control box and hydraulic power unit per electrical schematic s provided Read and comply with all local electrical codes 15 Before install is complete installer must make a final operational check of dock leveler to verify all phases of install are correct Installer must complete sign and return the Installation Checklist upon completion Reference page 24 NOTICE Motor should NOT be wired in while welding Manual No 4111 0027 Feb 2015 July 2015 INSTALLATION
41. ply continuous bevel weld SUPPORT across both bumpers and length of ANGLE base plate 2 X 2 GROOVE IN CONCRETE FOR LENGTH OF RAMP Manual No 4111 0027 Feb 2015 17 July 2015 INSTALLATION H E D Installation Instructions Ramp Mount Weld On w Formed Angle Follow all safety precautions prior to installation A ramp mount weld on used with a formed angle application is used when dock edge is damaged there is no dock steel securely anchored into the concrete and the dock height is too low and the leveler must be installed above this height to correct this situation Installation Steps 1 Remove all existing bumper material and protruding objects from dock edge Clean and sweep dock edge free of debris and flammable chemicals before installing unit 2 Review and follow formed angle installation instructions prior to leveler installation 3 At chosen location for Edge of Dock leveler locate the center of space and mark a point half of the base plate width to the left and right 4 Atthe points marked to each side of center measure and mark points 7 3 4 below dock level less height the unit is to be raised to locate bottom of base plate This Will locate the top of the base plate X above dock level 5 Using a proper lifting device raise and position the leveler base plate to marked position While holding base plate tight against dock face tack weld securely to dock steel on left hand end of leveler
42. priate PPE Refer to NFPA 705 for PPE requirements This panel may contain more than one power source Hazardous Voltage Will Cause Severe Injury or Death 26 WSs RR SSS WS SW SSS INN SSSR T Dy WE RSs NN e SZ SS Qy SSS 2 SN NS SESS 9 5 s 4 SSS eS OM a P SA 32 off CL A Disconnect Panel provided by others B Control Panel C Distance 48 in 14 630 mm Mount the push button control panel B so bottom of control panel to dock floor distance C is 48 in 1219 2 mm Install electrical disconnect panel A if not already installed Install and connect the control wiring Connect the dock leveler power cable to the field wires in the pit junction box Refer to the electrical drawings supplied with the dock leveler After all electrical connections have been made disengage the maintenance prop and lower the platform using the external lifting device connected to the platform lifting brackets Manual No 4111 0027 Feb 2015 July 2015 Put New Dock Leveler Into Service 1 Disconnect the external lifting device 2 Install the dock bumpers as required 3 Turn the main electrical power ON 4 Raise the leveler platform fully by depressing and holding the RAISE button NOTE The platform of a properly operating dock leveler will automatically stop rising when it reaches its full raised height at which point
43. rs Remove any end loads if required Check trailer alignment to avoid lip interference If lip does not lower to trailer bed reposition vehicle Ensure that truck bed supports extended lip or the leveler frame Supports the ramp before driving on ramp Stay clear of hinges and front and sides of moving dock leveler Never use damaged or malfunctioning dock leveler Report problems immediately to supervisor Maintenance Service Read and follow all instructions warnings and maintenance schedules in the owner s user s manual Maintenance Service of dock leveler restricted to trained personnel Place barriers on the driveway and on dock floor to indicate service work is being performed DO NOT ENTER PIT unless dock leveler is securely supported by maintenance prop If electrically powered turn off and use OSHA lockout tagout procedures Supports the ramp before driving on ramp Stay clear of hinges and front and sides of moving dock leveler Never use damaged or malfunctioning dock leveler Report problems immediately to supervisor Maintenance Service Read and follow all instructions warnings and maintenance schedules in the owner s user s manual Maintenance Service of dock leveler restricted to trained personnel Place barriers on the driveway and on dock floor to indicate service work is being performed DO NOT ENTER PIT unless dock leveler is securely
44. ry or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death The main pressure relief may need to increased if the platform does not rise or rises slowly and the system operates in pressure relief mode See Troubleshooting section The main pressure relief may need to be decreased if the pump motor loads down when platform reaches the full raised position See Troubleshooting section Manual No 4111 0027 Feb 2015 July 2015 ADJUSTMENTS C Reservoir D Main Pressure Relief A Motor B Breather Fill Cap To adjust the main pressure relief 1 Raise
45. strate which connections are to be made in the field at installation electrical drawings are included with each order or by contacting Systems Inc Technical Services Once again thank you and congratulations on your purchase of a DLM Hydraulic Edge of Dock leveler HED Series Edge of Dock levelers are available in the following sizes weight capacities and options Dimensions and Capacities Model Deck Total Unit Width Width Comparative Industry Rating Call Systems Inc to discuss available voltages phases and options to meet your specific needs Manual No 4111 0027 Feb 2015 July 2015 INTRODUCTION Component Identification A Lip Plate B Center Plate C Safety Prop E Hinge Area F Lip Cylinder THEORY The HED Edge of Dock leveler uses hydraulic pressure and single push button operation for ease of use Platform B is raised by depressing and holding the RAISE button J This activates an electric motor D which in turn drives a hydraulic pump The hydraulic pump forces oil into the platform cylinder G causing the platform to rise Hold J until lip fully extends D Powerpack Motor Pump Reservoir H G Main Hoist Cylinder H Bumper Blocks 2 used J Raise Button Releasing the raise button will allow the platform to float down to the bed of the transport vehicle The lip will stay extended until the platform reaches the full below dock position
46. talling unit At chosen location for the formed angle locate the center of space and mark a point half of the angle width to the left and right Using a proper lifting device raise and position the formed angle to marked position slide formed angle against dock face Mark along full length of back edge of formed angle Slide angle forward the width of brushing tool approximately 2 Place brushing tool on marked line at each end of formed angle to ensure proper alignment at both ends A Skil Roto Hammer 736 or similar tool is recommended Using the back edge of the formed angle as a guide groove concrete approximately 5 8 deep by 2 wide and should be the entire length of the formed angle Slide formed angle back until tight against dock face drill 5 8 dia by 5 deep holes through formed angle at back edge Install anchor bolts per manufacturers specifications and tighten securely Weld anchor bolt nuts to formed angle using a 1 4 fillet weld all the way around the nut Cut off any portion of the anchor bolt exposed through the nut and plug weld around the top of the nut to the anchor bolt Ensure the top of the nuts are well rounded for smooth rollover Drill 5 8 dia by 5 deep holes in dock face through holes in formed angle Install anchor bolts with washers and tighten securely per manufacturers specifications Manual No 4111 0027 Feb 2015 July 2015 INSTALLATION opis 6 syoq Jououe 81
47. the platform fully and engage the maintenance prop in the service position 2 Turn OFF all electrical power to the dock leveler Attach safety lockout and tagout devices 3 Loosen locking nut 4 Adjust hex adjusting screw in small 1 4 turn increments as follows Turn clockwise to increase pressure relief urn counterclockwise to decrease pressure relief 5 Tighten the jam nut 6 Turn ON electrical power to the dock leveler 7 Disengage the maintenance prop 8 Check leveler operation 9 Repeat steps 1 8 as necessary 33 ADJUSTMENTS Adjust Lip Function 1 Raise platform fully and engage the maintenance prop in the service position Allow platform to rest on the prop so the lip will fully fold until it contacts the lip stops 2 Turn OFF all electrical power to the dock leveler Attach safety lockout and tagout devices SEQUENCE VALVE ADJUSTABLE RELIEF VALVE SEQUENCE VALVE C2 OUTLET PORT TO LIP CYLINDER C1 OUTLET PORT TO MAIN CYLINDER Notes Relief valve is factory set at 1500 PSI This valve is main system relief Relief valve adjustment e Loosen nut e Turn screw clockwise to increase pressure Turn screw counter clockwise to decrease pressure e Tighten jam nut 3 Sequence valve is factory set at 750 PSI Turn clockwise to increase pressure turn counter clockwise to decrease pressure This valve normally should not need adjustment 4 See troubl
48. tions Suggested placement of placard is near control box attached to electrical conduit by using nylon tie If there is no control box present mount placard on wall to the immediate left of leveler at eye level gt TERRE TESTO X DU NNN ylon Tie lt SNZ NIS E es NN 2 p X 1 Manual No 4111 0027 Feb 2015 25 July 2015 INSTALLATION Install Control Panel and Wiring The electrical power must be OFF prior to electrical installation For maximum protection use an OSHA approved locking device to lock out all power sources Only the person installing the equipment should have the key to unlock the power source Failure to follow these instructions may result in serious personal injury or death DO NOT make any final electrical connections until all welding has been completed Failure to do this may result in serious personal injury or death All electrical work including the installation of the disconnect panel control panel and final connections to the pit junction box must be performed by a certified electrician and conform to all local and applicable national codes Always stand clear of platform lip when working in front of the dock leveler Serious personal injury or death may result 4 DANGER 4 Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De energize equipment before working on or inside Do not open cover without appro
49. working habits and operation of the equipment regardless of previous experience should be done on a regular basis and should include an understanding and familiarity with all functions of the equipment Owner s user s shall actively maintain update and retrain all operators on safe working habits and operations of the equipment The manufacturer shall provide to the initial purchaser all necessary information regarding Safety Information Operation Installation and Safety Precautions Recommended Initial and Periodic Inspections Procedures Planned Maintenance Schedule Product Specifications Troubleshooting Guide Parts Break Down Warranty Information and Manufacturers Contact Information as well as tables 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
50. y continuous weld across top of each bumper and base plate to ramp plate Skip welding is acceptable to prevent warping but complete weld must be completed B Weld bottom of base plate to support angles using a 4 fillet weld Installer must remove all welding slag and repaint welded areas Drill 5 8 dia by 5 deep holes in concrete through holes in lower cylinder mount and install anchor bolts with washers and tighten securely Field mount control box to inside wall Field wire control box and hydraulic power unit per electrical schematic s provided Read and comply with all local electrical codes Before install is complete installer must make a final operational check of dock leveler to verify all phases of install are correct Installer must complete sign and return the Installation Checklist upon completion Reference page 24 Manual No 4111 0027 Feb 2015 July 2015 INSTALLATION CONTINUOUS 1 4 2 1 32 a Junction Box 104 OR 110 FOR 66 OR 72 WIDE UNITS NOTICE Motor should NOT be wired in while welding Securely block or support ramp and lip when in vertical positions Lack of proper bracing can result in ramp dropping during adjustment or installation causing personal injury or damage to unit NOTE DESCRIPTION Top of base plate and bumper cover plate to be flush with top of ramp plate Ap

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