DL, NL, TS Owner`s/User Manuals
Contents
1. SUPPORT ANGLE 3 X 2 GROOVE N CONCRETE FOR LENGTH OF RAMP SECTION BUMPERS NOT SHOWN FOR CLARITY CONTINUOUS 1 4 O de Alle 5 8 m 104 OR 110 FOR 66 OR 72 WIDE UNITS Manual No 4111 0025 15 March 2011 May 2012 INSTALLATION E O 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 5 used when dock edge is damaged there is no dock steel securely anchored into the concrete and the dock height is too low and leveler must be installed above this height to correct this situation Installation Steps 1 16 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 Review and follow formed angle installation instructions prior to leveler installation Page 18 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 At the points marked to each side of center measure and mark points 7 3 4 below dock level less height the unit is to be rais2. The use of the word CAUTION signifies possible hazard or unsafe practice which could result in personal injury IMPORTANT The use of the word IMPORTANT is to draw attention to a procedure that needs to be followed to prevent machine damage Manual No 4111 0025 March 2011 May 2012 SAFETY General Operational Safety Precautions Read and understand the operating instructions and become thoroughly familiar with the equipment and its controls before operating the dock leveler Never operate a dock leveler while a safety device or guard is removed or disconnected Never remove DANGER WARNING or CAUTION signs or decals on the equipment unless replacing them 457 get Do not activate the equipment until all unauthorized personnel in the area have been warned and have moved outside the operating Zone Remove any tools or foreign objects from the operating zone before starting Keep the operating zone free of obstacles that could cause a person to trip or fall SAFETY Operational Safety Precautions A Learn the safe way to operate this equipment Read and understand the manufacturer s instructions If you have any questions ask your supervisor 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
3. JO do usni 2219 19 9 Jaduing pue aje d aseq jo do SINN ZZ 99 404 OLL 70 SNONNILNOD LY Id 17 Manual No 4111 0025 March 2011 May 2012 INSTALLATION E O 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 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 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 3 Using a proper lifting device raise and position the formed angle to marked position slide formed angle against dock face 4 Mark along full length of back edge of formed angle Slide angle forward the width of brushing tool approximately 2 5 Place bushing tool on marked line at each end of formed angle to ensure proper alignment at both ends A Skil Roto Hammer 736
4. 1 2 Lift and secure leveler in full upright maintenance position to start Loosen jam nut A by turning the nut clockwise Once jam nut is loosened use an open faced wrench to hold the locknut B inside the spring body Tighten the hex bolt C by turning clockwise To start the top fender washer should be tightened until the washer is about one and a half inches from the underside of the linkage pin Tighten the jam but A by turning the nut clockwise until the jam nut is tight against the top fender washer Test leveler operation If spring tension is sufficient repeat the previous steps until desired tension is achieved Return leveler to stored position Manual No 4111 0025 March 2011 May 2012 5 DOTH 3630 Replacement Extension Spring Kits Includes all parts listed below Item Quantity Part Number Description 1 1 DOTH 3620 Bar Lip linkage 2 2 DOTH 2061 1 1 2 Shoulder Bolt 3 4 DOTH 2131 Nylon Lock Nut 4 2 DOTH 3621 Bar Base Linkage 5 1 DOTH 2347 Pin Linkage 6 2 DOTH 2390 Roll Pin 7 2 DOTH 2521 Spring Extension Reg Painted 8 4 DOTH 2209 Washer Fender Zinc Plated 9 2 DOTH 2045 HHCS Grade 5 Zinc Plated 10 2 DOTH 2130 Hex Nut Zinc Plated Grade 5 Mode Reference DL NL6630 NL6635 DL NL7230 NL7235 DL7820 25 NL7820 25 8421 25 4111 0025 March 2011 May 2012 Extension Spring Adjustment Instructio
5. OSHA lockout tagout procedures 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 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 Call 262 255 1510 for replacement placards warning labels or owner s user s manuals Ramp swings toward you Stand Clear Use maintenance strut while servicing Failure to do so will result in death or serious injury Refer to owner s user s manual for proper procedure Manual No 4111 0025 5 March 2011 May 2012 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 owner s user s company policies and operating conditions M
6. Model Deck Total Unit Comparative Industry Rating Width Width 66 20 000 72 25 000 30 000 N A for DL 78 78 Dimensions and Capacities Model Deck Total Unit I Width Width Comparative Industry Rating 66 20 000 72 25 000 30 000 78 35 000 N A for NL 84 84 Dimensions and Capacities Model Deck Total Unit Width Width Comparative Industry Rating 66 20 000 72 25 000 30 000 78 35 000 N A for 5 78 8 84 84 Manual No 4111 0025 March 2011 May 2012 INSTALLATION INSTALLATION DETAILS 8 C 11 5 FT CHANNEL MINIMUM BY OTHERS GREASE FITTINGS ON LIP HINGES CONTINUOUS WELD ACROSS TOP OF BUMPER BLOCKS AND BASE PLATE BUMP BLOCK ASSEMBLY ANCHOR BOLT 50 INCH ANCHOR BOLT PREFERRED GREASE FITTINGS ON BASE PLATE HINGES Only trained installation professionals with the Post safety warnings and barricade the work area at proper equipment should install this product dock level and ground level to prevent unauthorized use of the dock leveler before installation has been MORAN Failure to follow the installation instructions can DO NOT remove the shipping bands around the result in damage to dock leveler the facilities and dock leveler lip until instructed to do so or serious personal injury or death completed Manual No 4111 0025 9 March 2011 May 2012 INSTALLATION E O D Installation Instructions Flush Mount We
7. and the bump blocks 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 warpage but complete weld across the top 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 10 8 10 Installer must remove all welding slag and repaint welded areas Installer must adjust springs on all mechanical Edge of Dock levelers to provide desired tension for smooth operation Stand in front of leveler with the unit raised and secured in the maintenance position loosen jam nut on the underside of the linkage pin To start allow about 3 4 to 1 of threads between top of jam nut and linkage pin Using an open faced wrench hold locknut on inside of spring while tightening threaded bolt until washer on top side of spring closes up tight to jam nut Test operation of unit Further adjust spring tension if needed by advancing jam nut toward linkage pin and tightening threaded rod After desired unit operation is achieved tighten jam nut to outer washer on spring Springs must be adjusted alternately to have equal spring tension 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 Instal
8. crescent wrench on torsion tube assembly apply enough downward force to tube assembly until hex bolt can be removed Continue to apply downward force until flange on tube assembly has the next hole in series come into alignment with hex bolt hole Insert hex bolt B through the flange on the tube assembly and tighten nut until secure Test leveler operation If spring tension is sufficient repeat the previous steps until desired tension is achieved Return leveler to stored position 34 Manual No 4111 0025 March 2011 May 2012 5 CURRENT VS 2005 and Older Item Quantity Part Number Description Bar NL Extended Link Arm 1 1 DOTH 3730 pre 09 2005 NL SB Catch Assembly 2 1 DOTH 3744 pre 09 2005 Bar NL Extend Link Arm Du 09 2005 present NL SB Catch Assembly 09 2005 present Manual No 4111 0025 35 March 2011 May 2012 PARTS HANDLE OPTIONS ltem Quantity Part Number Description 1 1 DOTH 3752 NL Handle Assembly Tube 2 1 DOTH 3769 NL Handle Assembly Solid 3 1 DOTH 3691 Handle Assembly Formed 4 1 DOTH 3694 Handle Assembly 36 Manual No 4111 0025 March 2011 May 2012 OPERATING LINK OPTIONS Item Quantity Part Number Description 1 1 DOTH 3726 NL Operating Link Assembly 2 1 DOTH 3696 Operating Link Assembly 3 DOTH 3697 Operating Link Ass
9. of your body near moving parts wi Chock restrain all freight carriers Never remove the wheel chocks until loading or unloading is finished and truck driver has been given permission to drive away Do not use a broken or damage dock leveling device Make sure proper service and maintenance procedures have been performed before using 7 TE Make sure lip overlaps onto trailer at least 4 in 102 mm Keep a safe distance from both side edges Manual No 4111 0025 March 2011 May 2012 Operational Safety Precautions EE 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 Manual No 4111 0025 March 2011 May 2012 SAFETY SAFETY Maintenance Safety Precautions To put handle into maintenance prop position remove bolt and locknut at base of handle assembly Pull handle out of roller arm assembly and place into maintenance prop receiver if equipped Post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before installation has been completed Failure to follow the installation instructions can result in damage to dock leveler the facilities and or serious personal injury or deat
10. 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 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 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 Apply continuous weld across top of each bumper and base plate to ramp plate Skip welding is acceptable to prevent warpage 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 Installer must remove all welding slag and repaint welded areas Installer must adjust main springs on all mechanical Edge of Dock levelers to provide desired tension for smooth operation Stand on ground in front of leveler with the unit raised and secured in the maintenance position loosen jam nut on the underside of the linkage pin To start allow about 3 4 to 1 of threads between top of jam nut and linkage pin Using an open faced wrench hold lo
11. serial number decal A becomes lost or damaged Also write down job number the company that installed the dock leveler and the original owners 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 0025 March 2011 May 2012 Dock Leveler Information Model Serial No DLM Job No Original Owner Information Name Address Installer Information Name Address Date of Installation 41 STANDARD PRODUCT WARRANTY SYSTEMS INC warrants that its products will be free from defects in design materials and workmanship for a period of one 1 year from the date of shipment 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 o
12. trailer alignment to avoid lip interference If lip does not lower to trailer bed reposition vehicle Ensure truck bed supports extended lip or leveler frame supports the ramp before driving on ramp OPERATION Read and follow all instructions and warnings in 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 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 truck bed supports extended lip or leveler frame supports the ramp before driving on ramp SAFETY SAFETY INFORMATION 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 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
13. 29 PARTS TS Series 30 Manual 4111 0025 March 2011 May 2012 PARTS ss st a T ss tip Pate amp ringeAssemby ___ bom _ T Cs Lip Pate amp Hinge assemby T Cs cener Pate amp Hinge Assembly Domaos 0 center at Hinge Assemy gt s ceterPiste amp ringeAssemby 0018403 T Cener Pate Hinge Assembly 2 C gt as vom Ts Ca Reno in 7 era ny buy Bumper Boss Sa ar Domes N N 4111 0025 34 March 2011 May 2012 PARTS DOTH 3618 Replacement Extension Spring Kits Includes all parts listed below Item Quantity Part Number Description 1 1 DOTH 3620 Bar Lip linkage 2 2 DOTH 2061 1 1 2 Shoulder Bolt 3 4 DOTH 2131 Nylon Lock Nut 4 2 DOTH 3621 Bar Base Linkage 5 1 DOTH 2347 Pin Linkage 6 2 DOTH 2390 Roll Pin 7 2 DOTH 2520 Spring Extension Reg Painted 8 4 DOTH 2209 Washer Fender Zinc Plated 9 2 DOTH 2045 HHCS Grade 5 Zinc Plated 10 2 DOTH 2130 Hex Nut Zinc Plated Grade 5 32 Model Reference DL6620 25 NLEG 20 25 DL7220 25 7220 25 Extension Spring Adjustment Instructions
14. 736 or similar tool 5 recommended Using the back edge of the ramp plate as a guide 10 11 12 13 14 groove concrete approximately 3 4 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 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 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 Apply continuous weld across top of each bumper and base plate to ramp plate Skip welding is acceptable to prevent warpage 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 Installer must remove all welding slag and repaint welded areas Installer must adjust main springs on all mechanical Edge of Dock levelers to provide desired tension for smooth operation Stand on ground in front of leveler with the unit raise
15. A ddy JO do usni 2219 13409 Jsdwng pue aseq jo 9 SINNA ZZ 99 404 OLL YO 01 ALIYVTI NMOHS LON SUAdWNE Vu HJONIT 403 31342 09 NI MOON 2 X I XC 1 SNONNILNOO Manual No 4111 0025 March 2011 May 2012 13 INSTALLATION E O 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 1 14 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 left and right At the points marked to each side of center measure and mark points 7 1 2 below dock level for 1 4 ramp plate to locate position for bottom of base plate This position will place the top of the base plate 1 4 above the dock floor This position will vary with ramp plate thickness Mark line connecting t
16. DLM DL NL TS SERIES EOD Dock Leveler Owner s User s Manual DLM Division of Systems Inc W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 257 7399 www docksystemsinc com techservices docksystemsinc com Printed in U S A Manual No 4111 0025 Copyright 2011 March 2011 May 2012 Table of Contents Page Safety Recognize Safety Information 1 General Operational Safety Precautions 1 Operational Safety Precautions 2 Maintenance Safety Precautions 4 Sale DES pe 5 Owner s User s Responsibilities 6 Introduction Generalilnformalonza an He 8 Dock Leveler Stock Specifications 8 Installation Iastallallons PEAS aa 9 Fush Mount Weld 10 Ramp Mount Weld Bolt On 12 FIUSH MOUN BONON usa 14 Ramp Mount Weld w Formed 9 16 ee ehe 18 Ramp and FACE Plale sad 20 Installation Check VS ae 22 Operation Operating NSTIETONS DL u ed 23 Operating I
17. 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 2 All welding has been fully completed 3 Welding slag has been removed 4 Welds and other affected areas have been painted 5 Springs have been properly adjusted 6 Unit is functioning properly without fault 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 0025 March 2011 May 2012 OPERATION OPERATING INSTRUCTIONS FOR DL SERIES 1 With leveler in stored position back the truck into 4 position against the bump blocks Then actuate the leveler by placing the lifting hook into lip plate notch and manually lifting the hook until the lip plate section extends over the truck 2 Truck should be chocked before operation of leveler bed Lower lip to bed of the trailer 3 While standing behind the unit use lifting hook to 5 pull back and up on rivet OR engage on the notch until leveler is cocked When truck departs leveler automatically returns to stored position Only traine
18. aintaining updating and re training all operators on safe working habits and operation of the equipment regardless of previous experience should be done on a regular basis and should include an understanding and familiarity with all functions of the equipment Owner s user s shall actively maintain update and retrain all operators 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 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 mai
19. amaged 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 20 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 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 dock 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
20. 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 11 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 Apply a continuous fillet weld at the created joint between the face plate and ramp Skip welding should be the proper method used to avoid warpage and a complete weld must be achieved Manual No 4111 0025 March 2011 May 2012 INSTALLATION Va NOLLIA S d NV 405 MASINO NI pue Jo 310089 X 8 SSOJOE Alddy 3993 SPIS 6 5104 JOYDUE 81 341085 9 Wid 7 3094 9900 HIM HSN14 dAVE ae 40 3903 ONIGVST 80014 2000 40 dOL HUM HSNY 3094 30 dOl NOLLVAH TH 061 SNONNILNOD 21 Manual No 4111 0025 March 2011 May 2012 INSTALLATION CHECK LIST 22
21. cate the center of space and mark a point half of the base plate width to the left and right At the 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 above dock level 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 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 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 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 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
22. cknut on inside of spring while tightening threaded bolt until washer on top side sprint closes up tight to jam nut Test operation of unit Further adjust spring tension if needed by advancing jam nut toward linkage pin and tightening threaded rod After desired unit operation is achieved tighten jam nut to outer washer on spring Springs must be adjusted alternately to have equal spring tension 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 22 Manual No 4111 0025 March 2011 May 2012 INSTALLATION o io jeuosued 5 Buunp dwe ul ueo Buloesg 1099019 SuonIsod eoa Ul USYM dij pue woddns UONE E SUI p uuo E SU ALINVTI NMOHS LON SYAANNE NOLLOYS OSI JO Z L L dues ul lJ O L JO 804 11482NO9 NI ejd JA0089 Z Jo pue si duunq ujog 550 A ddy
23. d and secured in the maintenance position loosen jam nut on the underside of the linkage pin To start allow about 3 4 to 1 of threads between top of jam nut and linkage pin Using an open faced wrench hold locknut on inside of spring while tightening threaded bolt until washer on top side of spring closes up tight to jam nut Test operation of unit Further adjust spring tension if needed by advancing jam nut toward linkage pin and tightening threaded rod After desired unit operation is achieved tighten jam nut to outer washer on spring Springs must be adjusted alternately to have equal spring tension 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 22 Manual No 4111 0025 March 2011 May 2012 INSTALLATION wun o 10 A nlu jeuosued 5 Buunp ul Ins i ueo USYM dij pue dwel SSI JO Z L L 10 Z aseq Jo SJadunq 550
24. d personnel should operate the dock leveler DO NOT use broken or damaged dock leveler Make sure proper service and maintenance procedures have been performed on leveler before using Truck trailer wheels must be chocked unless the truck restraint is used Never remove the wheel chocks until loading unloading is finished and truck driver has been given permission to leave Stay clear of dock leveler when freight carrier 15 entering or leaving dock area Make sure platform lip rests on the truck trailer bed with at least 4 in 102 mm of overlap Maintain safe distance from side edges of leveler during the loading unloading process Failure to follow these instructions may result in serious personal injury or death Manual No 4111 0025 March 2011 May 2012 DO NOT move or use the dock leveler if anyone is under or in front of leveler Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts Failure to follow these instructions may result in severe personal injury or death 23 OPERATION OPERATING INSTRUCTIONS FOR NL amp TS SERIES 1 Grasp the captured operating handle and raise to its full extended length Move handle toward you rotating center plate back past vertical Lip plate extend link arm will engage at this time RIVET 3 4 Push forward on operating handle against the rivet rotating leveler out onto truck Return handle to stor
25. ed position To remove leveler from truck repeat step number one until the lip clears the bed of the trailer Return leveler and handle to the stored position OR When the truck departs the unit will automatically return to the stored position 24 Manual No 4111 0025 March 2011 May 2012 PERIODIC MAINTENANCE When maintenance is to be performed in front of the dock leveler support the lip with the handle in the maintenance prop position OR by other means Put handle into maintenance prop position by removing bolt and locknut at base of handle assembly Pull handle out of roller arm assembly and place into maintenance prop receiver 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 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 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 increase wear and cause abnormal operation reference page 9 Manual No 4111 0025 March 2011 May 2012 MAINTENANCE Always post safety warnings and barricade the work area at dock level and ground level to prev
26. ed to locate bottom of base plate This will locate the top of the base plate X above dock level 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 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 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 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 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 5 recommended 9 10 11 12 13 14 15 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
27. eds Lubricated extended link arm lubrication 26 4111 0025 March 2011 May 2012 PARTS DL X Series gt Rivet rat a a C hok bomme 2 an xray Duty Bumper Sn ar Secondary Gussets Dormase Manual No 4111 0025 27 March 2011 May 2012 PARTS NL X Series 28 Manual No 4111 0025 March 2011 May 2012 3 5 Heel F RN 5 2 2 lt lt lt 6 5 Sy NX T Y SIZEICAPACITY 6620 25 6630 6635 7220 25 7230 7235 7820 25 7830 8420 25 8430 6620 25 6630 6635 7220 25 7230 7235 7820 25 7830 8420 25 8430 LL 6620 25 30 6635 7220 25 30 7235 7820 25 30 8420 25 30 A A A 6620 25 30 7220 25 6635 7230 7820 25 8420 25 7235 7830 35 8430 66 7220 30 78 84 35K Only 66 7220 30 66 7235 78 84 A A A A All All All oO N DESCRIPTION Lip Plate amp Hinge Assembly Lip Plate amp Hinge Assembly Lip Plate amp Hinge Assembly Lip Plate amp Hinge Assembly Lip Plate amp Hinge Assembly Lip Plate amp Hinge Assembly Lip Plate amp Hinge Assembly Lip Plate amp Hinge Assembly Lip Plate amp Hinge Assembly Lip Plate amp Hinge Assembly Center Plate amp Hinge Assembly Center Plate amp Hinge Assembly Center Plate amp Hinge Assembl
28. embly for all 35K units not shown 4 1 DOTH 2449 Roller Bearing Manual No 4111 0025 March 2011 May 2012 PARTS 3 PARTS DBBS 3500 Complete 15 Projection Bumper Assembly DKIT 3540 Bumper amp All Hardware weldment not included Item Quantity Part Number Description 1 1 DOTH 3537 12 BB Weldment 2 1 DOTH 3505 Rubber Tuf Cord 3 4 DOTH 2056 Hex Head Cap Screw 4 4 DOTH 2210 Wahser Flat Zinc Plated 5 4 DOTH 2208 Washer Flat 6 4 DOTH 2129 Nylon Lock Nut 2 DBBS 3506 15 Projection x 18 high option 38 Manual No 4111 0025 March 2011 May 2012 5 DBBS 3512 Complete 15 Projection Sliding Bumper Assembly Item Quantity Part Number Description 1 1 DOTH 3537 12 BB Weldment 2 2 DOTH 3514 Angle 12 BB Slide 3 2 DOTH 3515 Bar BB Sliding Stop 4 1 3517 12 Sliding BB Plate w Rubber N Manual No 4111 0025 39 March 2011 May 2012 MISCELLANEOUS This page intentionally left blank 40 Manual 4111 0025 March 2011 May 2012 MISCELLANEOUS NOTE The model serial number decal is located on the outboard side of the outer most LH gusset or base plate When you receive your DL NL or TS 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
29. ent 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 Securely block or support ramp and lip when in vertical position Lack of proper bracing can result in ramp dropping during maintenance causing personal injury or damage to unit Quarterly Maintenance Follow weekly maintenance schedule in addition to the following Lubricate the following areas with light weight machine oil Extend link arm pivots Lip linkage pivot Operating link pivots Torsion arm pivots Lubricate the following areas with white lithium grease Lip plate grease fittings Base plate grease fittings Note Failure to lubricate the dock leveler will cause abnormal operation of the leveler 25 TROUBLESHOOTING Unit does not operate Debris impacted on or Clean out debris on or around leveler properly around the leveler Insufficient lubrication Lubricate leveler Excessive weight on top of Remove weight from deck deck Main springs need more Adjust main spring tension as needed tension or less tension Damaged or missing parts Repair of replace as needed Extended link arm does Debris impacted in extended Clean out debris from extended link arm not latch out lip or unlatch Extended link arm ne
30. h 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 4 Manual No 4111 0025 March 2011 May 2012 Safety Decals A DANGER Unsupported dock leveler ramps can lower unexpectedly Before allowing vehicle to leave the dock always Ensure no equipment material people are on dock leveler Return dock leveler to its stored position at dock level Unsupported dock leveler ramps can lower unexpectedly Before allowing vehicle to leave the dock always Ensure no equipment material people are on dock leveler Return dock leveler to its stored position at dock level Failure to follow posted instructions will result in death or serious injury Decal 2 will have two positions one on the outside of the left bumper and one on the outside of the right bumper Decal 3 represents the placement of the serial tag left side of gusset OPERATION Read and follow all instructions and warnings in 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 ramp or lip Before activating dock leveler Ensure trailer is backed in against bumpers Remove any end loads if required Check
31. hese points and position support angles Position angles as shown in installation drawing provided Mark center of holes in each of the support angels At center marks drill holes 5 8 dial by 5 deep in concrete Install anchor bolts with washers through support angles into holes in concrete Tighten bolts until support angles 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 1 4 above dock level Note that this placement will vary with ramp plate thickness Mark centers of holes in bump block flanges 9 10 11 12 13 14 15 16 17 Drill 5 8 dia by 5 deep holes at center marks Reposition bump blocks insert anchor bolts with washers and tighten securely to dock face Place steel ramp plate in position flush with top backside of base plate Mark along full length of base edge of ramp plate Slide ram
32. ior to performing loading and unloading operation to minimize trailer bed drop Loading dock safety equipment should never be used outside of its intended use vertical working range or capacity Please consult the manufacturer if you have any questions as to the use vertical working range or capacity of the equipment Only properly trained and authorized personnel should operate the equipment When selecting loading dock safety equipment it is important to consider not only present requirements but also future plans and any possible adverse conditions environmental factors or usage Manual No 4111 0025 March 2011 May 2012 NOTES This page intentionally left blank Manual No 4111 0025 7 March 2011 May 2012 INTRODUCTION General Information Congratulations on your choice of a DLM Edge of Dock leveler This manual covers the DL NL TS 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 mechanical Edge of Dock leveler DL NL TS Series Edge of Dock levelers are available in the following sizes weight capacities and options Dimensions and Capacities
33. lation Checklist upon completion Reference page 22 Manual No 4111 0025 March 2011 May 2012 INSTALLATION x Z IN aseq JO pue SJadunq ujoq 550 Alddy o Anfu euosJad Buunp ueo yoe suonisod Jeo JO do usni 0 2219 pue aje d aseq jo 9 USYM uoddns 10 Tv SUNN ZZ 40 99 404 OLL 4O HOL 8 8 G G 1 SNONNILNOO 11 Manual No 4111 0025 March 2011 May 2012 INSTALLATION E O 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 12 Remove 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 lo
34. ld On Follow all safety precautions prior to installation A flush mount weld on application is used when an 8 wide minimum embed channel is securely anchored into the concrete at the dock edge and the dock height is adequate 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 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 Using a proper lifting device raise and position leveler on dock face with the top of the base plate being flush with the top of the embedded channel Position ends of base plate to match up with marks made previously Tack weld base plate to dock steel on left hand end of the leveler Check right hand end of base plate ensure that end 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 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 Check the positioning of the base plate
35. ns l 2 Lift and secure leveler in full upright maintenance position to start Loosen jam nut A by turning the nut clockwise Once jam nut is loosened use an open faced wrench to hold the locknut B inside the spring body Tighten the hex bolt C by turning clockwise To start the top fender washer should be tightened until the washer is about one and a half inches from the underside of the linkage pin Tighten the jam but A by turning the nut clockwise until the jam nut is tight against the top fender washer Test leveler operation If spring tension 15 not sufficient repeat the previous steps until desired tension is achieved Return leveler to stored position 33 PARTS DOTH 3675 Torsion Spring Kit Includes all parts listed below Item Quantity Part Number Description 1 1 DOTH 3305 L amp R Gusset Assembly w Bearing 2 1 DOTH 3327 HL Model Gusset w Guide 3 1 DOTH 3679 HL Torsion Tube Assembly 4 1 DOTH 3676 HL Torsion Bar Assembly 5 1 DOTH 2509 Spring Torsion 6 1 DOTH 3316 Bar Pivot 7 3 DOTH 2033 HHCS Grade 2 Zinc Plated 8 1 DOTH 2121 Nylon Lock Nut 9 1 DOTH 3682 HL Plate Locking Torsion 10 2 DOTH 3617 Bar 6630 L Linkage 11 2 DOTH 2061 1 1 2 Shoulder Bolt 12 2 DOTH 2136 Center Locknut Torsion Spring Adjustment Instructions 1 2 3 Lift and secure leveler in full upright maintenance position to start Remove nut A from hex bolt B Place
36. nstructions NL amp 15 24 Maintenance Periodic Maintenance 25 Troubleshooting TLOUBIESNOOUNG ze Lee 26 Parts DIER SEES 27 SES 28 T S SOI O lese 30 Extension Spring Components 32 Torsion Spring Components 34 Current vs 2005 and Ode 35 Harde aars 36 Operating Link OPIONS yu u ee 37 Bumper Components a 38 Sliding Bumper Components 39 Notes Customer Information a 41 War niy 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 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
37. ntenance personnel for whom such warnings are intended for Contact manufacturer for any replacements Manufacturer s recommended periodic maintenance and inspection procedures in effect at the date of shipment shall be followed at all times Written documentation of maintenance replacement parts or damage should be retained In the event of damage notification to the manufacturer is required Loading dock equipment that has been structurally damaged or has experienced a sudden loss of main support while under load such as what might occur when a transport vehicle pulls out from under the leveling device shall be removed from service inspected by a manufacturer s authorized representative and repaired or replaced as needed before being placed back in service Any modifications 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 pr
38. or similar tool is recommended 6 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 7 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 8 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 18 Manual No 4111 0025 March 2011 May 2012 INSTALLATION SPIS 6 5104 JOYDUE 81 9 ALON MATA 061 EE Va de JO HJ NIT 40 31399N09 N JA00Y9 GINNOL NI 8 May 2012 INSTALLATION E O 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 d
39. p plate forward over dock leveler the width of brushing 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 A 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 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 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 Apply continuous weld across top of each bumper and base plate to ramp plate Skip welding is acceptable to prevent warpage but complete weld must be completed B Weld bottom of base plate support angles using a 1 4 fillet weld Installer must remove all welding slag and repaint welded ares Ins
40. taller must adjust main springs all mechanical edge of dock levelers to provide desired tension for smooth operation Stand on ground in front Manual No 4111 0025 March 2011 May 2012 INSTALLATION of lever with the unit raised and secured in the maintenance position loosen jam nut on the underside of the linkage pin To start allow about 3 4 to 1 of threads between top of nut and linkage pin Using an open faced wrench hold locknut on inside of spring while tightening threaded bolt until washer on top side of spring closes up tight to ram nut Test operation of unit Further adjust spring tension if needed by advancing jam nut toward linkage pin and tightening threaded rod After desired operation base piate and b mpef is achieved tighten jam nut to outer washer on 1 cover plate to be flush with top of spring Springs must be adjusted alternately to EU AN have equal spring tension ie rn p base plate 18 Before install is complete installer must make a final operation check of dock leveler to verify phases of install are correct Installer must complete sign and return the Installation Checklist up on completion reference page 22 Securely block or support ramp and lip when in vertical positions Lack of proper bracing can result ramp dropping during adjustment or installation causing personal injury or damage to unit
41. therwise 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 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
42. y Center Plate amp Hinge Assembly Center Plate amp Hinge Assembly Center Plate amp Hinge Assembly Center Plate amp Hinge Assembly Center Plate amp Hinge Assembly Center Plate amp Hinge Assembly Center Plate amp Hinge Assembly Base Plate amp Hinge Assembly Hinge Pin Hinge Pin Hinge Pin Hinge Pin Hinge Pin Hinge Pin Rivet Button Rivet Flat Extra Hvy Duty Bumper Blocks Spring Linkage Assy X Regular Spring Linkage Assy X Hvy Duty Spring Linkage Assy 3 Spring X Gusset Secondary Gussets NL Roller Arm Assembly Open Operating Link Assembly NLIII Operating Link Assembly NL Pipe Handle Assembly NLIII Hanlde Assembly Extend Link Arm Extend Link Arm Stop Pivot Block Shoulder Bolt Locknut Lip Stop Handle Holder PART NUMBER 1 DOTH 4047 DOTH 4049 DOTH 4051 DOTH 4053 DOTH 4055 DOTH 4057 DOTH 4058 DOTH 3924 DOTH 3156 DOTH 3159 DOTH 4062 DOTH 4063 DOTH 4064 DOTH 4065 DOTH 4066 DOTH 3258 DOTH 4067 DOTH 3923 DOTH 3242 DOTH 3241 5 Consult Factory DOTH 3104 DOTH 4312 DOTH 3122 DOTH 4313 DOTH 3946 DOTH 3920 DOTH 2400 DOTH 2398 DBBS 3500 DOTH 3618 DOTH 3630 DOTH 3626 DOTH 3589 DOTH 3319 DOTH 3834 DOTH 3696 DOTH 3697 DOTH 3833 DOTH 3694 DOTH 3585 DOTH 3586 DOTH 3316 DOTH 2061 DOTH 2136 DOTH 3734 DOTH 3695 LIP PARTS PART NUMBER 17 LIP DOTH 4048 DOTH 4050 DOTH 4052 DOTH 4054 DOTH 4056 DOTH 3167 DOTH 4059 DOTH 4060 DOTH 3155 DOTH 4061
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