User`s Manual - Curlin, Inc.
Contents
1. Lip Lip cylinder SA maintenance bar Leveler stored switch mounting bracket optional Top plate Maintenance strut E Main lift cylinders Safety stop velocity fuse Hydraulic power unit Maintenance strut Frame Lip keepers ramp stops 12 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K February 2013 2013 4Front Engineered Solutions Inc COMPONENTS AND SPECIFICATIONS continued Fig 16 Fig 17 n DANGER D Du RAISE DOCK LEVELER button A WARNING RAISE ae button 1 Ry BPA TED tawqay D TONS Lip Extend 1 button unit eee LIP EXTEND 2 unaq sapere button STOP GHH Kes O Pull to release 2 button O EM E 3 button unit Control Panel NEMA4 plastic enclosure automatic motor starter thermal overload 0 5A resettable c2. Fig 40 CB FU TO BE SUPPLIED BY OTHERS mE BCPD CB FU 3AMP MAX PANEL FLA 1 9A CONTACTOR SCCR 5KA M114 OL101 10 Cai 211 s MOT102 3i Fe LEVELER i 3 MOTOR 5131 Xo 1 8FLA 8 S NOTE 480V 3PH shown For other voltages reference schematic located inside control panel or consult factory 1111 1112 CB111 0 5 DOOR I L VEHICLE RESTRAINT 1 1 FACTORY JUMPER M114 1140 15 0101 1143 1 1 1 9599 LEGEND PANEL WIRING FIELD WIRING BY OTHERS SEE NOTE 1 NOTE TERMINALS WILL ACCEPT STRANDED WIRE ONLY WIRE COLOR GAUGE unless otherwise specified 208 600 14 BLK NOTES 120 16 RED 1 FIELD TERMINAL WIRING 90 DEGREE WIRE MIN 16AWG FOR SIGNAL WIRING MIN 24VAC 16 RED BLK 14AWG FOR INCOMING POWER SEE CHART IN PANEL FOR TORQUE REQUIREMENTS 216 un 2 DOOR INTERLOCK LEVELER WILL NOT OPERATE UNLESS DOOR IS FULLY RAISED DOOR SWITCH SUPPLIED BY OTHERS 24 0 18 BLU 3 VEHICLE RESTRAINT INTERLOCK LEVELER WILL NOT OPERATE UNLESS RESTRAINT 15 RAISED OR SWITCHED TO OVERRIDE 24V COM OVDC 18 BLU WHT 4 AFR LD SWITCH 625 040 SUPPLIED ON LEVELERS LOCATED ON LIP EXTENSION BAR ON LIP CYLINDER 12VAC VDC 18 VIO 12V COM 18 VIO WHT DRY UNPOWERED 18 YLW TOR F L A PANEL F L A O L SETTING CB FU MAX 11 2A 7 0AMPS 6 6 AMPS 11 2 AMPS 20A 36 37
3. Fig 52 DOCK GC 6363 eO mimummummmumumau 48 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K February 2013 2013 4Front Engineered Solutions Inc PARTS LIST CONTROL PANEL continued Optional 3 Button Control Panel Where Used Qty 120 1 60 208 1 60 240 1 60 208 3 60 240 3 60 480 3 60 575 3 60 Complete Control Panel Assy No 6012859 6012860 6012861 2012865 2012866 6012867 6012868 Kelley 6012876 6012877 6012878 6012879 6012880 6012881 6012882 SERCO CONTROL PANEL LABEL 6012851 KELLEY CONTROL PANEL LABEL 6012852 TRANSFORMER 200 600 23 110 50VA 6012567 HE MERCI CIRCUIT BREAKER 0 5A CONTACTOR 18A 120V COIL CONTACTOR 9A 1 N O 1 N C 120V 6012022 OVERLOAD RELAY 9 13A OVERLOAD RELAY 5 5 8A 6012559 OVERLOAD RELAY 2 5 4A 6012558 OVERLOAD RELAY 1 6 2 5A 6012557 E p TERMINAL 2 POLE PUSH BUTTON GREEN PUSH BUTTON BLUE PUSH BUTTON MUSHROOM RED MOUNTING COLLAR CONTACT BLOCK N O CONTACT BLOCK N C FUSE 1 2A 600V FUSE ATQR 1 4A 600V CC 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 2 99 ME EN M NH EG E NEN NN HE BEN 2 February 2013 6001947C Heavy Capacity Hydrau
4. BOCK S qo ac Where Used Qty 120 1 60 208 1 60 240 1 60 208 3 60 240 3 60 480 3 60 575 3 60 Complete Control Panel Assy No 6006420 6006421 6006421 6006423 6006423 6006425 6006426 Wem Part Description Pat J Ht C te PP SERCO CONTROLPANELLABEL 6006436 1 3 v 4 t KELLY CONTROL PANEL LABEL 6006453 3 3 v 4 t EL Q Fssmormownuy ew L sm Jo j 1 Femacworoncomcron seno j __ Femwcworoncomcron ER For 24V incoming power consult factory February 2013 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 47 02013 4Front Engineered Solutions Inc PARTS LIST CONTROL PANEL continued Optional 3 Button Control Panel
5. 15 Three Button Control 15 One Button Control 18 Planned 21 Troubleshooting Guide 24 Hydraulic Power Unit Adjustment 27 Hydraulic 28 Electrical Schematics 32 Optional Auto Return to Dock A R T D 34 A R T D Proximity Switch Adjustment 35 Parts List Dock Leveler 36 Hydraulic and Electrical 40 Control 47 Warranty EIE dis itu 53 Distributor Information 54 INTRODUCTION Welcome and thank you for choosing this dock leveler This manual covers Serco model HD and Kelley model HHC dock levelers It is equipped with the patented HYDRA MAX Lip Extension This User s Manual contains information that you need to safely install operate and maintain the dock leveler It also contains a complete parts list and information about ordering replacement parts Please keep and read this User s Manual bef
6. a Low fluid level in reservoir b Sequence valve set too high Lip hinge binding d Primary relief valve set too low a Sequence valve set too low SOLUTION a Check motor full load amperage and overload relay setting b Check for voltage at all three motor connections T1 T2 T3 in control panel a If a load was on the leveler remove the load and jog the RAISE button to unlock the leveler If no load was on the leveler adjust the needle valve to reduce drop speed See page 26 27 a Adjust flow needle valve for faster flow Turn counterclockwise to increase speed See page 26 27 a Check fluid level Add fluid if required and check for leaks See page 27 Fig 35 b Decrease sequence valve setting See page 26 27 Inspect hinge area for damage or trapped debris Lubricate hinge d Set primary relief valve to 1400 PSI See page 26 27 Note Requires use of pressure gauge or pump will be severely damaged a Turn clockwise to increase pressure so that the lip plate does not extend until the deck is fully raised See pages 26 27 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 25 02013 4Front Engineered Solutions Inc TROUBLESHOOTING GUIDE continued Before servicing the dock leveler read and follow the Safety Practices on Page 3 and the Operation section in this manual PROBLEM POSSIBLE CAUSE 10 Lip plate will not stay out falls a
7. 26 Check hydraulic fluid level Reference page 27 Fig 10 Remove shipping cotter pins Fig 11 3 8 side of pit to side of bumper mounting plate 1 4 w be 3 4 dia anchor Full length 1 of bumper Sun died mounting plate Downhill welds are by others not acceptable Vertical bumper mounting angle Laminated Bumper Fig 12 Warning and operating 79 Q instruction placard fj 10 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 2013 4Front Engineered Solutions Inc February 2013 A DANGER DO NOT WORK UNDER THE DOCK LEVELER RAMP OR LIP UNLESS BOTH MAINTENANCE STRUTS ARE SECURELY SUPPORTING THE LEVELER AND THE LIP MAINTENANCE BAR IS SUPPORTING THE LIP Before servicing the dock leveler read and follow the Safety Practices on page 3 and the operation section of this manual MAINTENANCE STRUTS AND LIP MAINTENANCE BAR 1 Toraise both maintenance struts and the lip maintenance bar two people are needed a Push hold the RAISE button on the control panel so leveler is fully raised and lip is extended The second person raises the maintenance struts into the locked vertical position See Fig 13 Pull out hitch pin and clevis pin from top hole of lip SERVICE TOOLS Fig 14 maintenance
8. A R T D units only 42 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K February 2013 Inc 2013 4Front Engineered Solutions PARTS LIST HYDRAULIC AND ELECTRICAL continued Fig 49 Dual Cylinder Single Button Control Remote Mount A R T D units only February 2013 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 43 2013 4Front Engineered Solutions Inc PARTS LIST HYDRAULIC AND ELECTRICAL continued Fig 50 Dual Cylinder 3 Button Control Remote Mount A R T D units only 99 2 d 44 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K February 2013 2013 4Front Engineered Solutions Inc PARTS LIST HYDRAULIC AND ELECTRICAL continued Model and Part Number x Ene 4 1 LIT ea OMNE o E Dre O N N 78 HOSE ASSY 3 8 X 16 30065 s as s 900 VELOCITY FUSE 10 GPM 313 239 60K SINGLE MAIN LIFT CYL 313 563 60K DUAL 80K MAIN LIFT CYL 313 563 x b 2 7 o _ O O Sl lt 2 C e S o O sa s sis lt lt lt Em 2013 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80 45 2013 4Front Engineered Solutions Inc PARTS LIST HYDRAULIC AND ELECTRICAL
9. Voltage drop is more often a problem on single phase motors Verify the power supply wiring to the control panel is sized correctly b Measure for voltage at all three motor connections T1 T2 T3 in control panel The hydraulic fluid level should be checked when the leveler is resting on the maintenance strut with the lip pendant Add fluid if required and check for leaks See page 27 Fig 35 b Remove the hose from main lift cylinder and point free end into reservoir opening If no oil is pumped replace pump Check motor rotation and change electrical connections if necessary See motor name plate d Set primary relief valve setting to 1400 PSI See page 26 27 Note Requires use of pressure gauge or pump will be severely damaged 24 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 2013 4Front Engineered Solutions Inc February 2013 TROUBLESHOOTING GUIDE continued Before servicing the dock leveler read and follow the Safety Practices on Page 3 and the Operation section in this manual PROBLEM 5 Overload relay tripping 6 Leveler will not lower 7 Leveler floats down too slowly 8 Lip plate will not extend or extends too slowly 9 Lip plate extends too soon February 2013 POSSIBLE CAUSE Overload relay set too low b Loss of one phase Three phase only a Automatic safety stop velocity fuse is locked a Flow control requires adjustment
10. 2 2013 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80 39 2013 4Front Engineered Solutions Inc PARTS LIST HYDRAULIC AND ELECTRICAL Before doing any electrical work make certain the power is disconnected and properly tagged or locked off All electrical work must be done by a qualified technician and meet all applicable codes If it is necessary to make troubleshooting checks inside the control box with the power on USE EXTREME CAUTION Do not place your fingers or uninsulated tools inside the control box Touching wires or other parts inside the control box could result in electrical shock death or serious injury Fig 45 Single Cylinder Single and 3 Button Control Pit Mount A R T D units only 40 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 2013 4Front Engineered Solutions Inc February 2013 PARTS LIST HYDRAULIC AND ELECTRICAL continued Fig 46 Single Cylinder Single Button Control Remote Mount A R T D units only Fig 47 Single Cylinder 3 Button Control Remote Mount A R T D units only Conduit 1 2013 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80 41 2013 4Front Engineered Solutions Inc PARTS LIST HYDRAULIC AND ELECTRICAL continued Fig 48 Dual Cylinder Single and 3 Button Control Pit Mount
11. 36ames 6 Use class CC time delay fuses 32 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K February 2013 2013 4Front Engineered Solutions Inc ELECTRICAL SCHEMATIC Three Button Units with Optional A R T D Fig 41 CB FU TO BE SUPPLIED BY OTHERS LEVELER SUPPLY BCPD CB FU 3AMP MAX PANEL FLA 1 9A 011 2 CONTARTOR SCCR 5KA M115 OL101 1021 x 211 MOT102 7 0 Cae ay D LEVELER MOTOR 5131 Fes 1 8FLA 1 8A G g J Fu105 E BP 1051 1052 NOTE UE 19 24 4 H5 480V 3PH shown For other voltages t AD 480V XF110 reference schematic located inside 120V SEC SOVA control panel or consult factory 4 2 xi 1111 1112 CB111 0 5A 215 112 B1 DOOR I L VEHICLE RESTRAINT I L FACTORY JUMPER FACTORY JUMPER RED 115 1121 5 16 SUPP 1152 ONPI 1155 4 t Bl 1 1 Tue 919 LEGEND 2 3 1161 T L 1162 PANEL WIRING TBI TBI 5124 3 FIELD WIRING BY OTHERS SEE NOTE 1 1 NOTE TERMINALS WILL ACCEPT STRANDED 1 D 1 4 5011 WIRE ONLY I 1162 L e o z 1 1 WIRE COLOR GAUGE ARID unless otherwise specified 208 600VA
12. 42 3 0 34 3 8 29 44 2 0 3 2 0 4 24 12 19 17 16 2 0 2 0 4 1 3 1 31 41 2 5 47 21 54 0 0 1 6 2 0 12 24 10 26 08 28 0 0 2 5 4 7 19 53 15 57 13 6 0 x 2 0 0 1 3 5 01 3 5 01 3 5 01 35 x 2 0 14 0 6 2 07 65 06 6 6 05 67 4 0 14 50 11 47 0 9 45 0 7 43 40 0 6 78 0 4 76 0 4 7 6 0 3 7 5 2 6 0 3 0 66 2 3 5 9 1 8 5 4 1 5 54 S 6 0 2 1 9 3 1 6 8 8 43 85 11 83 gt gt 8 0 4 5 8 1 3 4 7 0 2 8 64 2 3 5 9 8 0 3 7 10 9 28 100 2 2 9 4 1 9 9 1 10 0 6 1 9 7 4 6 8 2 3 7 73 31 67 10 0 5 2 12 4 3 9 11 1 3 2 10 4 27 9 9 m 12 0 7 6 11 2 5 8 9 4 4 6 8 2 39 7 5 m 12 0 6 8 14 0 5 1 12 3 4 1 11 3 34 10 6 Leveler and lip grades minimum bend 18 lip Leveler and lip grades maximum bend 18 lip February 2013 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 5 2013 4Front Engineered Solutions Inc INSTALLATION PIT CHECK 1 Check entire dock leveler pit for proper construction according to certified pit drawings Check electrical service to assure it agrees with the phase and voltage of the hydraulic power unit and control panel supplied with the dock leveler See tag attached to motor and the wiring diagram located inside the control panel LEVELER CHECK PRIOR TO INSTALLATION 1 Visually check that all rear hinge pins c
13. February 2013 OPERATING INSTRUCTIONS 3 Button Controls INTRODUCTION This dock leveler is designed to span and compensate for space and height differences between a loading dock and freight carrier to allow safe efficient freight transfers The Hydraulic Dock Leveler with Three Button Control has a STOP button control to stop downward movement of the ramp and shuts off the RAISE and LIP EXTEND push button controls A valve will not allow the ramp to lower The STOP button must be out during normal use Pushing and holding the RAISE push button operates a hydraulic cylinder to raise the ramp Releasing the RAISE push button allows the ramp to lower When the dock leveler reaches its full raised position a second hydraulic cylinder extends the dock leveler lip The dock leveler with its lip extended settles onto the vehicle bed forming a bridge After loading pushing and holding the RAISE push button raises the ramp and the extended lip lowers to its stored position Releasing the RAISE push button allows the dock leveler to lower to its level stored position With the dock leveler in its stored position lip keepers support the dock leveler ramp at a position level with the dock floor The Hydraulic Dock Leveler with Three Button Control also has a LIP EXTEND push button control to extend the dock leveler lip before the ramp reaches its full raised position Releasing the LIP EXTEND push button allows the ramp to lower
14. Pilot operated check valve valve as leveler is lowering not closing b Lip cylinder damaged 11 Optional Auto Return To Dock a Proximity switch faulty or faulty not operating properly electrical connection b Proximity switch or lip target arm not properly adjusted HYDRAULIC POWER UNIT ADJUSTMENT A DANGER Be certain before climbing into the dock leveler pit or doing any maintenance or repair under the dock leveler that 1 BOTH MAINTENANCE STRUTS ARE SECURELY SUPPORTING THE DOCK LEVELER RAMP 2 The power is disconnected and properly tagged or locked out Before servicing the dock leveler read and follow the Safety Practices on page 3 and the Operation section in this manual Sequence valve Breather cap with dip stick Secondary relief valve SOLUTION a Remove and inspect for foreign matter Clean as required b Replace lip cylinder piston seal or replace cylinder 8 Check for 110V at terminal 2 in control panel b Check adjustment of proximity switch and lip target arm Refer to adjustment procedure on page 19 1 Solenoid valve 3 button unit only Place barricades on the dock floor around the dock rm leveler pit and in the driveway in front of the pit while installing maintaining or repairing the dock leveler N Shuttle z valve ER Primary relief Secondary valve relief valve Reservo
15. leveler 2 Continue to press the RAISE button The lip will automatically extend when the leveler is fully raised 3 When lip is fully extended release the RAISE button leveler will slowly float down to the vehicle s platform NOTE If an obstruction prevents the lip from deploying properly press the button to raise and retract the lip Restore the leveler to the safe dock level position with the lip in both lip keepers for endloading Before allowing vehicle to leave always return the dock leveler to its dock level stored position with the lip stored in both lip keepers See Fig 26 Failure to do so may leave the dock leveler in a position below the level of the dock floor This condition may result in unexpected drop of personnel or material handling equipment and could result in death or serious injury 1 Button Control Fig 26 Press to raise February 2013 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 19 2013 4Front Engineered Solutions Inc INSTRU CTIONS continued 1 Button Control 1 BUTTON UNIT continued Before allowing vehicle to leave always return the dock leveler to its dock level stored position with the lip stored in both lip keepers See Fig 29 Failure to do so may leave the dock leveler in a position below the level ofthe dock floor This condition may result in unexpe
16. 27 1 Xx Level with Door floor contact at this area area A gag cde UP 504 X lt lt lt lt 44 y oe lt AUN AR 54 lt ADA Shim under both subframe tubes Shim behind lip keepers if keepers project below pit floor and weld to front face of curb angle Shim under both maintenance struts See Fig 4 for all weld locations Shims 4 x 4 x height NOTE Shim under both subframe tubes Shim behind lip keepers if keepers project below pit floor and weld to front face of curb angle Shim under both maintenance struts See Fig 4 for all weld locations device Fig 9 Improper installation b Thesecond person positions the maintenance struts into their upright position See Fig 13 222 H XV lt NNNNNNM NNNN N c Electrical controls may now be released AAA AAT 17 Remove shipping cotter pins from telescopic toe guards if equipped See Fig 10 Proper installation PA PP AAA February 2013 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 9 2013 4Front Engineered Solutions Inc STALLATION continued Welding with dock leveler s power connected can damage electrical components If the dock leveler has previously been electri
17. 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 15 2013 4Front Engineered Solutions Inc OPERATING INSTRUCTIONS continued 3 Button Controls 3 BUTTON UNIT Always secure the vehicle with a vehicle restraint or wheel chocks before operating the dock leveler Do not operate dock leveler with anyone standing on or in front of it Do not drive on dock leveler or lip until it is fully extended and supported by the vehicle s platform Always keep hands and feet clear of all moving parts Always restore the leveler to its safe dock level position after servicing the vehicle Do not drive on leveler with STOP button pressed in Never use fork lift or other material handling equipment to lower the ramp and lip sections If equipped with Auto Return to Dock the dock leveler will automatically raise and return to dock level when the lip starts to retract RAISING LEVELER 1 Press the RAISE button on the control panel to raise the leveler See Fig 19 2 When the leveler is fully raised the lip will automatically extend To extend earlier press the LIP EXTEND button See Fig 20 3 When lip is fully extended release the RAISE button The leveler will slowly float down to the vehicle s platform Push the STOP button at any time to stop the leveler Pull the STOP button to release See Fig 22 NOTE If an obstruction prevents the lip from deploying properly push the STOP button Press the RAISE butto
18. Dock Levelers 60 80K Loosen threaded nut Using 3 16 allen wrench turn screw clockwise to increase relief pressure Relief pressure will be factory set at 1400 PSI and should not require adjustment Note a suitable hydraulic pressure gauge MUST BE USED when adjusting Ensure threaded nut is securely fastened to prevent screw from turning when complete Reference TSB2009 0722G for primary relief adjustment procedure Loosen locknut Turn the knob clockwise to decrease lowering speed Adjust the lowering speed to approximately equal the ramp raise speed Loosen threaded nut Using 3 16 allen wrench turn screw to adjust lip speed If the lip extends before the ramp is fully raised the valve should be turned clockwise Tightening the valve too far will cause very slow lip extension or no extension at all Ensure threaded nut is securely fastened to prevent screw from turning when complete No adjustment required Loosen threaded nut Using 1 4 allen wrench turn screw to adjust lip retraction speed If the lip is not closing fully when the lip is above the keepers turn the adjusting screw counterclockwise Ensure threaded nut is securely fastened to prevent screw from turning when complete If the lip is closing too forcefully turn the adjusting screw clockwise Fig 35 3 1 2 EET 5 27 02013 4Front En
19. Float speed controlled by flow control needle valve E au mde With leveler above dock height pump starts as above CERE Mere Rope 3 Solenoid valve shifts locking main cylinder in partial raised position Pressure increases sequence valve shifts and lip o dis fonte STOP Solenoid valve shifts stopping main cylinder and lip cylinder O Power cut off from motor control circuit 3 button unit Fig 19 RAISE Pump starts and shuttle valve shifts Main lift cylinder extends and lip cylinder retracts CSS Pilot check valve opens Fully Raised Pressure increases Sequence valve shifts Lip cylinder extends Stop Raise Sequence valve and shuttle valve return Top plate floats down forcing fluid to reservoir Float speed controlled by flow control in shuttle valve 1 button unit 14 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K February 2013 2013 4Front Engineered Solutions Inc Before operating the dock leveler read and follow the Safety Practices on page 3 Use by untrained people can result in death or serious injury Read and follow complete operating instructions DO NOT USE DOCK LEVELER IF IT APPEARS DAMAGED OR DOES NOT SEEM TO WORK PROPERLY Inform your supervisor immediately Always be certain that the vehicle wheels are chocked or that the vehicle is locked in place by a ve
20. HINGE PIN 6 586 0287 586 2333 LIP HINGE PIN 6 5 586 1495 586 2334 LIP HINGE PIN 7 586 0392 586 2335 1 23 1 LIP PLATE ASSY 6 X 18 3 0896 3 1602 1 LIP PLATE ASSY 6 X 20 3 0897 3 1603 LIP PLATE ASSY 6 6 X 18 3 3485 3 1621 1 LIP PLATE ASSY 6 6 X 20 3 3486 3 1622 1 LIP PLATE ASSY 7 X 18 3 0898 3 1604 1 LIP PLATE ASSY 7 X 20 3 0899 3 1605 DOCK GUARD LIP A replacement dock guard lip cannot be ordered for a leveler not originally equipped with this item 23 DGL LIP PLATE ASSY 6 X 18 3 1630 3 1636 DGL LIP PLATE ASSY 6 X 20 3 1633 3 1639 1 DGL LIP PLATE ASSY 6 6 X 18 3 1631 3 1637 1 DGL LIP PLATE ASSY 66 X 20 3 1634 3 1640 1 DGL LIP PLATE ASSY 7 X 18 3 1632 3 1638 1 DGL LIP PLATE ASSY 7 X 20 3 1635 3 1641 Model and Part Number REAR WEATHERSEAL ASSY RIGHT 8 8645 8 9374 8 8646 REAR WEATHERSEAL ASSY MIDDLE 8 9172 8 9172 8 0172 REAR WEATHERSEAL ASSY LEFT 8 8640 8 9375 8 8641 38 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K February 2013 02013 4Front Engineered Solutions Inc PARTS LIST DOCK LEVELER continued 60 000 Single Dual and 80 000 Ib Capacity Part Number DO NOT LIFT TRIP WARNING LABEL 138 837 138 837 138 837 138 837 TENSION BOLT ASSY 8 8010 2 PLAIN WASHER 5 8 BOLT SIZE 11 16 HOLE 234 131 Qty 27 2 28 1 29 1 30 1 1 31 2 2 a ES EN 2 _2_ 33 34 35 36 37 10
21. N15 J13 Texaco Aircraft Oil 1554 U S Oil Co Inc ZFI 5606 Low Temp Fig 32 Cleaning Location frequency Visually Inspect Replace damaged or worn Rear hinge pins 5 places a Pit quarterly 22 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K February 2013 2013 4Front Engineered Solutions Inc PLANNED MAINTENANCE continued Every 90 days quarterly inspect all safety labels and tags to ensure they are on the dock leveler and are easily legible If any are missing or require replacement please call 1 800 525 2010 or 972 466 0707 for replacements Fig 33 6008485 x2 SAFETY INSTRUCTIONS Locate at 138 837 x2 middle of leveler 921 075 reservoir should face center of leveler Optional ARTD Only 921 070 x2 DANGER 921 051 ins 6004906 921 050 921 027 3 921 023 921 052 DANGER OPERATIONS 6004905 921 093 1 Button 921 054 Er 921 147 WARNING AND OPERATION PLACARD MOUNTED ON WALL NEAR LEVELER February 2013 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 23 2013 4Front Engineered Solutions Inc TROUBLESHOOTING GUIDE Use the Troubleshooting Guide if ever the leveler fails to perform properly Find the condition that most c
22. RV2 N TI 1 29 2013 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80 2013 4Front Engineered Solutions Inc HYDRAULIC VALVE CROSS SECTION Fig 38 Lip cylinder extend Main cylinder Lip cylinder retract Sequence 422 One button unit Primary Relief valve RV1 1 400 PSI Needle valve Secondary relief valve RV2 T Lip cylinder Solenoid valve extend Lip cylinder A retract Main cylinder Sequence valve T Three button unit _ Needle valve Primary Relief valve RV1 1 400 PSI Secondary relief valve RV2 Eg JF 30 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80 February 2013 2013 4Front Engineered Solutions Inc ELECTRICAL SCHEMATIC A DANGER NOTE Before doing any electrical work make certain the power For 24V incoming power consult factory is disconnected and properly tagged or locked off All electrical work must be done by a qualified technician
23. and meet all applicable codes If it is necessary to make troubleshooting checks inside the control box with the power on USE EXTREME CAUTION Do not place your fingers or uninsulated tools inside the control box Touching wires or other parts inside the control box could result in electrical shock death or serious injury One Button Units Fig 39 NOTE 480V 3PH shown For other voltages PRIMARY FUSING AND DISCONNECT reference schematic located inside SUPELY BORD GB FU SAMP control panel or consult factory NOTE 480V 3PH 60Hz INCOMING POWER AND THE L1 L2 L3 LEVELER MOTOR CONNECT DIRECTLY TO THE CONTACTOR AND OVERLOADS DOCK LEVELER MOTOR 1HP FLA SEE TABLE L EGENI PBI LEGEND MOTOR F L A PANEL F L A O L SETTING CB FU SERCO KELLEY 600642 11 3 006421 6006462 6006421 6006462 6006423 6006450 6 1 6 AMPS Use class CC time delay fuses M DOCK LEVELE PB1 LEVELER RAISE DIRECT DEVICE CONNECTION EXTERNAL CONNECTIONS 95 796 INTERNAL WIRING R CONTACTOR February 2013 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 31 2013 4Front Engineered Solutions Inc ELECTRICAL SCHEMATIC One Button Units with Optional Interlock and A R T D
24. bar bracket and raise lip maintenance 9 bar See Fig 14 d Reinsertclevis pin through brackets and lip maintenance bar bracket Then reinsertthe hitch pin into the clevis pin e Release the RAISE button and leveler will lower to securely supported position resting on both maintenance struts 2 Tolowerboth maintenance struts fromtheir locked upright position two people are needed NOTE a Avoid pressing the RAISE button with lip maintenance bar in the raised position as this can damage the lip maintenance bar 2 b 2 a Push hold the RAISE button on the control panel b Pull out hitch pin and clevis pin from top hole on lip maintenance bar bracket and lower lip maintenance bar c Reinsert clevis pin through brackets and then put hitch pin in clevis pin to store d Liftupand then push backto lower both maintenance struts e Release the RAISE button It is important to always engage the lip maintenance bar lock pin when ever working under the leveler with the lip extended Any upward force on the lip could release the lip maintenance bar allowing the lip to fall February 2013 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 11 2013 4Front Engineered Solutions Inc COMPONENTS AND SPECIFICATIONS The main components of the dock leveler are shown below See the Parts List for specific part numbers Fig 15 80K leveler shown Lip plate ARTD sensor optional Lip hinge
25. continued Part Number 14 SOLENOID VALVE ASSY 3 BUTTON UNITS ONLY 313 546 313 546 313 546 313 546 5 A R T D BRACKET 328 554 328 554 328 554 328 554 A R T D BRACKET DGL 586 1953 A R T D CLAMP BRACKET 328 551 TARGET BRACKET 586 1838 PROXIMITY SWITCH 586 040 MAIN CYLINDER PIVOT PIN 586 1066 20 LIP CYLINDER PIVOT PIN 586 1063 1 OTTER PIN 6001832 22 SWIVELNUT TEE 313 105 23 FITTING ELBOW 313 106 24 FITTING O RING ELBOW 313 214 25 FITTING STREET ELBOW 313 102 gt gt ask 26 SWIVELNUT ELBOW 313 595 27 HEX BOLT 212 065 28 NYLOCK 5 16 18 212 065 29 CB 1 4 X 1 1 4 213 019 0 NYLOCK 1 4 213 502 HEX NUT 1 4 20 214 161 32 JUNCTION BOX 4 X 4 X 2 1 8 521 327 33 JUNCTION BOX COVER 521 328 34 FLAT WASHER 1 ID 234 161 234 161 234 161 234 161 35 HIRSCHMANN CORD SET 6001351 36 BRACKET WALL MOUNT 6000703 37 HOSE ASSY 1 4 X 20FT 9 HOSE ASSY 1 4 X 22FT 31649 HOSE ASSY 3 8 X 42 30060 30060 30060 30060 HOSE ASSY 3 8 X 36 30061 30061 30061 30061 46 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K February 2013 2013 4Front Engineered Solutions Inc HOSE ASSY 1 4 X 24FT 22 ES EH ES s ES ES PARTS LIST CONTROL PANEL Standard Control Panel Fig 51 D f O ENNAN QOO
26. 1 2013 4Front Engineered Solutions Inc 5 52 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80 February 2013 2013 4Front Engineered Solutions Inc LIMITED WARRANTY INFORMATION THIS LIMITED WARRANTY IS 4FRONT S SOLE AND EXCLUSIVE WARRANTY WITH RESPECT TO THE DOCK LEVELER AND IS IN LIEU OF ANY OTHER GUARANTEES OR WARRANTIES EXPRESS OR IMPLIED 4FRONT warrants that this DOCK LEVELER will be free from flaws in material and workmanship under normal use for a period of one 1 year from the earlier of 1 60 days after the date of initial shipment by 4FRONT or 2 the date of installation of the DOCK LEVELER by the original purchaser provided that the owner maintains and operates the DOCK LEVELER in accordance with this User s Manual Hydraulic Limited Warranty The hydraulic power unit and cylinders for this dock leveler are warranted to cover the cost of replacement costs only for an extended period of four 4 years beyond the base warranty period In the event that this DOCK LEVELER proves deficient in material or workmanship within the applicable Limited Warranty period owner shall so notify and 4 Front will at its option 1 Replace the DOCK LEVELER or the deficient portion s thereof without charge to the owner or 2 Alter or repair the DOCK LEVELER on site or elsewhere without charge to the owner This Limited Warranty does not cover any failure caused by improper installation abus
27. C 14 BLK 120VAC 16 RED NOTES 24VAC 16 RED BLK 1 FIELD TERMINAL WIRING 90 DEGREE WIRE MIN 16AWG FOR SIGNAL WIRING MIN NEUTRAL 16 WHT 14AWG FOR INCOMING POWER SEE CHART IN PANEL FOR TORQUE REQUIREMENTS GROUND GRN 24VDC 18 BLU DOOR INTERLOCK LEVELER WILL NOT OPERATE UNLESS DOOR IS FULLY RAISED DOOR SWITCH SUPPLIED BY OTHERS 24V COM 18 BLU WHT VEHICLE RESTRAINT INTERLOCK LEVELER WILL NOT OPERATE UNLESS RESTRAINT IS RAISED OR SWITCHED TO OVERRIDE 2 3 12VAC VDC 18 VIO 4 SWITCH 625 040 SUPPLIED ON HLR LEVELERS LOCATED ON LIP EXTENSION BAR ON LIP CYLINDER 12V COM 18 VIO WHT 5 SOLENOID VALVE 313 546 IS LOCATED ON TOP OF PUMP HOUSING AND IS WIRED INTO FRAME MOUNTED JUNCTION BOX DRY UNPOWERED 18 YLW CONTROL PANEL SERCO VOLTAGE 6012859 6012876 601286 601286 601286 6012866 6012880 601286 6012868 6012882 575 Use class CC time delay fuses 120 208 240 208 240 80 575 February 2013 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 33 2013 4Front Engineered Solutions Inc OPTIONAL AUTO RETURN TO DOCK A R T D OPERATIONS Use information in the section for those levelers equipped with the optional auto return to dock A R T D feature 1 Whenthelip 1 is extended the target bracket 2 rotates to the position shown 2 When the leveler floats down to the frame the lip will fall and cause the target bracket 2 on the lip
28. Heavy Capacity Hydraulic Dock Levelers 60 000 80 000 Ibs capacity This manual applies to hydraulic dock levelers manufactured beginning February 2013 with the serial numbers 61058683 and higher Do not install operate or service this product unless you have read and understand the Safety Practices Warnings and Installation and Operating Instructions contained in this manual Failure to do so could result in death or serious injury User s Manual Installation Operations Maintenance and Parts Part No 6001947C CONTENTS Introduction 2 Safety Signal Words 2 Safety Practices 3 Owner s Responsibilities 4 Ramp and Lip Grades 5 Installation 6 Service 11 Components and 12 Hydraulic System 14 Operating Instructions
29. SE button operates a hydraulic cylinder s to raise the ramp Releasing the RAISE button allows the ramp to lower When the dock leveler reaches its full raised position a second hydraulic cylinder s extends the dock leveler lip The dock leveler with its lip extended settles onto the vehicle bed forming a bridge After loading pressing and holding the RAISE button allows the ramp to raise The lip will retract as the dock leveler is raised Releasing the RAISE button lowers the ramp into its level stored position With the dock leveler in its stored position lip keepers support the dock leveler ramp at a position level with the dock floor February 2013 OPERATING INSTRUCTIONS continued 1 BUTTON UNIT Always secure the vehicle with a vehicle restraint or wheel chocks before operating the dock leveler Do not operate dock leveler with anyone standing on or in front of it Do not drive on dock leveler or lip until it is fully extended and supported by the vehicle s platform Always keep hands and feet clear of all moving parts Always restore the leveler to its safe dock level position after servicing the vehicle Never use fork lift or other material handling equipment to lower the ramp and lip sections If equipped with Auto Return to Dock the dock leveler will automatically raise and return to dock level when the lip starts to retract RAISING LEVELER 1 Press the RAISE button on the control panel to raise the
30. a 1 2 gap between the ends of the frame at the rear hinge assembly and the side curb angles If this is not the case the dock leveler will have to be positioned as required to accommodate dimensional discrepancies and any additional considerations e g conduit runs etc 13 Weld front frame to shims and shims to front curb angle with a minimum of 3 long 1 4 fillet welds on the front and sides 14 Remove shipping banding holding lip assembly closed Discard banding 15 If electrical power is available use the electrical controls to raise the ramp and lip to their full above dock position See operating instructions in this manual If electrical power is not available use a chain and load centering eyebolt A DANGER Hydraulic pressure must be maintained on the ramp to hold it in the raised position until the maintenance strut is in place DO NOT WORK UNDER THE DOCK LEVELER RAMP OR LIP UNLESS BOTH MAINTENANCE STRUTS ARE SECURELY SUPPORTING THE DOCK LEVELER 16 Two people are needed to place the dock leveler on the maintenance strut a One person must hold dock leveler in its highest position with electrical controls or other lifting IN STALLATION continued Fig 8 m Weld rear frame at Dosis 1 4 bevel locations Shims level 4 x 4 nm T with i 1 Do gd floor x height DUE ya gt Gap 1 2 1 v yyy 1
31. arm to activate the proximity switch 3 on the deck The motor will start and the leveler will raise 3 When raised above the lip keepers 4 the lip will fully retract and the target bracket will be forced away from the proximity switch The motor will stop and the leveler will float down until the lip rests in the keepers Fig 42 34 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80 February 2013 2013 4Front Engineered Solutions Inc OPTIONAL A R T D PROXIMITY SWITCH ADJUSTMENT A WARNING Be certain before climbing into the dock leveler pit or Before servicing the dock leveler read and follow the doing any maintenance or repair under the dock leveler Safety Practices on page 3 and the Operation section in that this manual 1 BOTH MAINTENANCE STRUTS ARE SECURELY SUPPORTING THE DOCK LEVELER Place barricades on the dock floor around the dock leveler 2 The power is disconnected and properly tagged pit and in the driveway in front of the pit while installing locked out maintaining or repairing the dock leveler Fig 43 Clamp bracket Switch bracket Proximity switch Lip arm Lip adjusting bolt 1 Theend ofthe proximity switch should be 1 16 1 5 mm 3 With the leveler raised and the lip fully retracted the above the end of the guard bracket as shown To adju
32. cally connected turn off power to control box Ground welder to dock leveler frame Failure to do so could result in product damage 18 Install shims under both ramp cylinder mounting pads to provide solid support to concrete Weld shims together and to lower cylinder mounting pad s using 1 long 1 4 fillet welds on three sides See Fig 7A 19 Remove lifting chain or other lifting devices 20 Read Safety Practices on page 3 and Operating instruction on pages 15 20 21 Connect electrical wiring and turn on power to dock leveler control panel See Fig 3 22 Two people are needed to store the maintenance struts a Press RAISE button on the control panel and hold b The second person lowers both maintenance struts c First person can now release RAISE button and leveler will float down Keep hands fingers and head away from the lip when the RAISE button is released The lip and dock leveler are free to move downward when hydraulic pressure is removed from cylinders 23 Mount dock bumpers to face of dock Downhill welds are not acceptable See Fig 11 24 Permanently mount the laminated dock leveler warning and operating placard on the wall near the dock leveler controls See Fig 12 Make sure the customer gets the User s Manual and is properly trained 25 Operate the dock leveler four times through the complete cycle to check operation Read Safety Practices on page 3 and Operating Instructions on pages 15 20
33. cted drop of personnel or material handling equipment and could result in death or serious injury STORING LEVELER 1 To return the leveler to the stored position press the RAISE button As the leveler raises the lip will retract When the lip is fully retracted release the RAISE button The leveler will float down to the stored position See Fig 28 BELOW DOCK ENDLOADING 1 Press the RAISE button until leveler is fully raised and the lip starts to extend When the lip has extended 2 to 3 inches to clear the front of the keepers release the RAISE button Leveler will float down for endloading See Fig 30 AUTO RETURN TO DOCK A R T D OPTIONAL The A R T D automatically resets the leveler whenever a vehicle just pulls away from the loading dock with the lip resting on the vehicle This is how it works 1 Ifthe vehicle pulls away the leveler will float down to the lowest position and the lip will fall The leveler will automatically raise retract the lip then float down to the stored position See Fig 31 20 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 2013 4Front Engineered Solutions Inc Fig 28 Release to Lower e eit Float down Fig 29 Press to raise Release to lower 8 Fig 30 Press to raise 2013 To ensu
34. ds See page 23 Replace as necessary 2 Clean out the inside of the pit area If washing out take care not to spray any electrical parts 3 Inspect and lubricate all mechanical pivot points on the leveler with S A E 30 oil Cycle the leveler when lubricating 4 Inspect the hydraulic cylinders and hoses for any fluid loss and check the reservoir level Add fluid as required See Hydraulic Fluid Level on page 27 5 Inspect all welds under the leveler for fatigue or failure particularly the lip plate hinge and top plate beams and front hinge bar If cracks are discovered contact your authorized Serco distributor 6 Check the full operation of the leveler Make any adjustments required 7T Lubricate the lip hinge tubes with a molybdenum disulfide NLGI 2 grease Do not over grease Stop when grease begins to ooze out of the hinge tube ends Wipe off excess grease 8 Inspect dock bumpers Six inches 6 of bumper protection is required Worn torn loose or missing bumpers must be replaced February 2013 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 21 2013 4Front Engineered Solutions Inc PLANNED MAINTENANCE continued Hydraulic Fluid An all weather hydraulic fluid with a viscosity of 15 CSt at 40 C 100 F such as Legend Shell Tellus T 15 Symbol Lubricate oil Light oil SAE 30 Lubricate grease Molybdenum disulfide NLGI 2 Mobil Aero HFA 49011 Exxon Univis HV13
35. e improper operation negligence or failure to maintain and adjust the DOCK LEVELER properly Parts requiring replacement due to damage resulting from vehicle impact abuse or improper operation are not covered by this warranty 4AFRONT DISCLAIMS ANY RESPONSIBILITY OR LIABILITY FOR ANY LOSS OR DAMAGE OF ANY KIND INCLUDING WITHOUT LIMITATION DIRECT INDIRECT CONSEQUENTIAL OR PUNITIVE DAMAGES OR LOST PROFITS OR LOST PRODUCTION arising out of or related to the use installation or maintenance of the DOCK LEVELER including premature product wear product failure property damage or bodily injury resulting from use of unauthorized replacement parts or modification of the DOCK LEVELER 4FRONT s sole obligation with regard to a DOCK LEVELER that is claimed to be deficient in material or workmanship shall be as set forth in this Limited Warranty This Limited Warranty will be null and void if the original purchaser does not notify 4FRONT s warranty department within ninety 90 days after the product deficiency is discovered THERE ARE NO WARRANTIES EXPRESS OR IMPLIED WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF INCLUDING BUT NOT LIMITED TO A WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE ALL OF WHICH 4FRONT HEREBY DISCLAIMS February 2013 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 53 2013 4Front Engineered Solutions Inc Please direct questions about your leveler to your local distributor
36. engaged The dock leveler should never be used outside the manufacturer s labeled rated capacity It must also be compatible with the loading equipment and other conditions relating to the dock 4 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 2013 4Front Engineered Solutions Inc February 2013 RAMP AND LIP GRADES Fig 1 Leveler grade Lip grade Leveler and lip grades Leveler and lip grades Vehicle bed for each dock leveler length Vehicle bed for each dock leveler length position position 6 Leveler 8 Leveler 10 Leveler 12 Leveler 6 Leveler 8 Leveler 10 Leveler 12 Leveler from dock from dock in Leveler Lip Leveler Lip Leveler Lip Leveler Lip in Leveler Lip Leveler Lip Leveler Lip Leveler Lip 16 0 7 1 3 5 16 0 7 6 04 15 0 8 1 44 67 31 15 0 86 14 72 0 0 xX 14 0 7 6 39 63 27 14 0 82 1 0 68 04 5 12 0 109 73 83 47 66 3 0 55 1 9 12 0 11 8 46 89 1 7 72 00 60 1 2 10 0 9 4 5 8 71 35 57 21 48 12 10 0 103 3 7 7 05 62 10 52 20 B 8 0 7 8 4 2 59 23 47 1 1 40 04 5 8 0 8 7 1 5 66 0 6 53 1 9 44 28 2 2 6 0 6 3 2 7 47 1 1 38 02 32 04 lt 6 0 7 2 0 0 54 18 43 2 9 36 3 6 4 0 47 1 1 36 00 29 07 24 12 40 5 6 1 6
37. er which can result in death or serious injury The maximum uncontrolled drop of this hydraulic dock leveler from any position is 4 inches Visually check that the lip is supported by the vehicle bed or the ramp is supported by both front lip keepers before driving or walking on the ramp Always return the dock leveler to its dock level stored position before allowing the vehicle to leave the dock If the vehicle pulls away before the dock leveler is stored the lip will fall to its pendant position and may not be supported by the lip keepers In addition failure to properly store the dock leveler may leave the leveler in a position below the level of the dock floor These conditions may result in unexpected drop of personnel or material handling equipment and result in death or serious injury Before pressing button ensure lip avoids contact with vehicle sides and cargo If lip does not lower to vehicle platform reposition the vehicle Before chocking wheels or engaging vehicle restraint dump air from air ride suspensions and set parking brakes 18 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 2013 4Front Engineered Solutions Inc INTRODUCTION This dock leveler is designed to span and compensate for space and height differences between a loading dock and freight carrier to allow safe efficient freight transfers This dock leveler uses a push button control to position the ramp Pushing and holding the RAI
38. gineered Solutions Inc HYDRAULIC SCHEMATIC Fig 36 60 000 Ibs capacity configuration shown single main cylinder p MAIN CYLINDER iaa VELOCITY FUSE LIP h CYLINDER C2 C3 C1 6 6 SAE 6 SAE S PC1 cv2 sv THREE BUTTON 1 PORT UNITS ONLY CT H LP ADJUST SEQUENCE VALVE NEEDLE O 1 VALVE V1 2 5 1400PSI p RV2 N J 2 0 Hel 28 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80 02013 4Front Engineered Solutions Inc February 2013 HYDRAULIC SCHEMATIC Fig 37 60 000 dual and 80 000 Ibs capacity configuration shown dual lip and main cylinders HH MAIN ens LIP CYLINDERS i VELOCITY CYLINDERS FUSE L 4 2 C1 N 6 SAE 6 SAE 6 SAE 2 i SV BUTTON A PORT UNITS ONLY ft X LIP ADJUST SEQUENCE Q NEEDLE VALVE PC1 Q RV1 1400PSI
39. hicle restraining device and the brakes set before loading or unloading Visually inspect vehicle restraint to make sure it is properly engaged Vehicles pulling away unexpectedly can cause uncontrolled drop of the dock leveler which can result in death or serious injury The maximum uncontrolled drop of this hydraulic dock leveler from any position is 4 inches Visually check that the lip is supported by the vehicle bed or the ramp is supported by both front lip keepers before driving or walking on the ramp Always return the dock leveler to its dock level stored position before allowing the vehicle to leave the dock If the vehicle pulls away before the dock leveler is stored the lip will fall to its pendant position and may not be supported by the lip keepers In addition failure to properly store the dock leveler may leave the leveler in a position below the level of the dock floor These conditions may result in unexpected drop of personnel or material handling equipment and result in death or serious injury Before pressing button ensure lip avoids contact with vehicle sides and cargo If lip does not lower to vehicle platform reposition the vehicle Before chocking wheels or engaging vehicle restraint dump air from air ride suspensions and set parking brakes Never drive on dock leveler with STOP button pressed in Failure to follow these instructions could result in death or serious injury to operators and or bystanders
40. ice vehicles outside its intended working range which is 12 above and 12 below dock on 6 and 8 long levelers 15 above and 12 below dock on 10 long levelers and 16 above and 12 below dock on 12 long levelers Do not operate the dock leveler when anyone is in front of it unless they are securing the maintenance struts Stay clear of the dock leveler when it is moving KEEP HANDS CLEAR OF HINGES AT ALL TIMES Do not use hands to position dock leveler ramp or lip or to store dock leveler Do not use the dock leveler if it appears damaged or does not operate properly Inform your supervisor immediately Do not stand in the driveway between the dock leveler and the backing vehicle Chock vehicle wheels or lock vehicle into place with vehicle restraining device and set brakes before loading or loading Visually check that the lip is supported by the vehicle bed or the lip is supported by both lip keepers before driving on the ramp Store dock leveler to dock level with lip in both lip keepers after use Move all equipment material or people off the dock leveler and store the dock leveler after use Do not use a forklift or other material handling equipment to lower the ramp SAFETY PRACTICES OPERATION continued Before chocking wheels or engaging vehicle restraint dump air from air ride suspensions and set parking brake Ensure lip avoids contact with vehicle sides and cargo If lip does not lower to vehicle bed re
41. ir 26 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K February 2013 2013 4Front Engineered Solutions Inc HYDRAULIC POWER UNIT ADJUSTMENT continued Description Primary Relief Valve RV1 Controls maximum pressure in the hydraulic system and protects the other components from excessive force Flow Control Needle Valve Controls the lowering speed of the ramp plate and directs fluid to the cylinders when the pump is running and Controls retraction extension lip plate Solenoid Valve Stops the fall of the top plate when either the LIP EXTEND or LEVELER STOP button is pushed Secondary Relief Valve RV2 Controls the force and speed of lip retraction when the power unit is running Does not affect speed of lip closing when power unit is not running HYDRAULIC FLUID LEVEL The hydraulic fluid level should be checked when the leveler is resting on the maintenance strut with the lip pendant If the leveler is equipped with A R T D allow the deck to descend to the maintenance struts and the lip to fall pendant then push the E STOP before the A R T D initiates The fluid level in reservoir should register below the MAX oil limit within the hatched markings near centerline of the tank See Fig 41 If the level is low or not visible on the dipstick add fluid to the desired level using an approved oil from the list on page 16 February 2013 6001947C Heavy Capacity Hydraulic
42. ition from the dock to the dock leveler Add or remove shims as required NOTICE The rear edge of the dock leveler should be level or slightly 1 16 maximum below dock level Shim the front end of the dock leveler LEVEL with the dock floor See Fig 8 and 9 Add or remove shims as required 11 Check the alignment of the dock leveler with the sides of the pit See Fig 7 NOTICE Welding with the dock leveler s power connected can damage electrical components If the dock leveler has previously been electrically connected turn off power to control box Ground welder to dock leveler frame Failure to do so can result in product damage Be certain that the rear frame angle is held tightly against the rear pit curb angle before welding If front and rear pit curb angles are not parallel do not attempt to shim dock leveler supports to match pit angles The front supports and rear frame angle must be parallel for proper operation of the dock leveler Add or subtract shims as required 12 Weld rear frame angle to the rear pit curb angle See Fig 8 Fig 7 1 2 Rear Rear pit frame curb angle angle Fig 7A Pit side curb angle Weld 4 x 4 shim 8 6001947 Heavy Capacity Hydraulic Dock Levelers 60 80K February 2013 2013 4Front Engineered Solutions Inc If the pit width conforms to the certified pit drawing there will be
43. lic Dock Levelers 60 80K 49 2013 4Front Engineered Solutions Inc PARTS LIST E CONTROL PANEL continued Optional Interlockable and A R T D 1 Button Control Panel Fig 53 IL DOGK I Y i eF 50 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K February 2013 2013 4Front Engineered Solutions Inc PARTS LIST CONTROL PANEL continued Optional Interlockable and A R T D 1 Button Control Panel Where Used Qty 120 1 60 208 1 60 240 1 60 208 3 60 240 3 60 4803 60 575 3 60 Complete Control Panel Assy No 6012848 6012853 6012854 3012855 3012856 3015857 6012858 Epp EEN BE Part Description Parts SERCO CONTROL PANEL LABEL KELLEY CONTROL PANEL LABEL TRANSFORMER 200 600 23 110 50VA CIRCUIT BREAKER 0 5A CONTACTOR 18A 120V COIL CONTACTOR 9A 1 N O 1 120V OVERLOAD RELAY 9 13A OVERLOAD RELAY 5 5 8A OVERLOAD RELAY 2 5 4A OVERLOAD RELAY 1 6 2 5A 6012557 TERMINAL 2 POLE PUSH BUTTON BLUE 1 CONTACT BLOCK N O 1 FUSE 1 2 600V o FUSE ATQR 1 4A 600V CC 1 1 1 1 1 e February 2013 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 5
44. losely matches your situation and make the recommended adjustments Observe all safety warnings before attempting any maintenance procedure PROBLEM 1 Leveler does not raise Motor is silent b Electrical connections incorrect or broken 2 Leveler does not raise motor starts then stops motor starter relay chatters tripping b Voltage drop due to undersized wiring run a long distance from the power source 3 Leveler does not raise Motor hums a Voltage drop b Loss of 1 phase Three phase only 4 Leveler does not raise Motor runs b Pump not running or pressure insufficient c Pump running in reverse d Primary relief valve setting too low POSSIBLE CAUSE a No electrical power to control panel Overload relay main circuit breaker or leveler control circuit breaker Low fluid level in reservoir Before servicing the dock leveler read and follow the Safety Practices on Page 3 and the Operation section in this manual SOLUTION a Check that voltage is present at terminal connections to the control panel b Check that wiring matches the wiring diagram a Verify overload relay is set to approx 15 above FLA indicated on motor nameplate b Check voltage when motor is started Voltage drop is more often a problem on single phase motors Verify the power supply wiring to the control panel is sized correctly a Measure voltage when motor is started
45. n to raise and retract the lip Restore the leveler to the safe dock level position with the lip in both lip keepers for endloading 16 2013 4Front Engineered Solutions Inc 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K Before allowing vehicle to leave always return the dock leveler to its dock level stored position with the lip stored in both lip keepers See Fig 23 Failure to do so may leave the dock leveler in a position below the level of the dock floor This condition may result in unexpected drop of personnel or material handling equipment and could result in death or serious injury Fig 20 Press to raise Press to extend 2 Lip extend 7 February 2013 INSTRU CTIONS continued 3 BUTTON UNIT continued STORING LEVELER 1 To return the leveler to the stored position press the RAISE button As the leveler raises the lip will retract When the lip is fully retracted release the RAISE button The leveler will float down to the stored position See Fig 23 BELOW DOCK ENDLOADING 1 Press the RAISE button until leveler is about 6 above dock Press the LIP EXTEND button until the lip has extended 2 to 3 inches to clear the front of the keepers and release the button Leveler will float down for endloading See Fig 24 AUTO RETURN TO DOCK A R T D OPTIONAL The A R T D automaticall
46. ontrol circuit breaker UL or cUL approved Auto Return to Dock Proximity Switch NEMA 6P normally open with LED pilot light Motor NEMA Standard T E N V 48YZ frame 1 h p single or three phase or 24V DC Pump Fixed displacement gear pump 2 gpm primary relief valve factory set at 1400 psi February 2013 Hydraulic Fluid An all weather hydraulic fluid with a viscosity of 15 CSt at 40 100 F such as Shell Tellus T 15 Mobil Aero HFA 49011 Exxon Univis HV13 N15 J13 Texaco Aircraft Oil 1554 U S Oil Co Inc ZFI 5606 Low Temp 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 13 2013 4Front Engineered Solutions Inc HYDRAULIC SYSTEM OPERATION Fig 18 The following describes the operation of the hydraulic system when the control is activated 4 A y RAISE Pump starts Main lift cylinder extends and lip cylinder retracts Fully Raised om DOCK LEV Pressure increases ff Sequence valve shifts bo Ae Lip cylinder extends Stop Raise Sequence valve resets ae Deck floats down forcing fluid to reservoir ge NC
47. or to 4Front Engineered Solutions Inc Corporate Head Office Your local 4Front Engineered Solutions Inc distributor is 1612 Hutton Dr Suite 140 Carrollton TX 75006 Tel 972 466 0707 Fax 972 323 2661 2013 4Front Engineered Solutions Inc Part No 6001947C
48. ore using your new dock leveler SAFETY SIGNAL WORDS You may find safety signal words such as DANGER WARNING or CAUTION throughout this Owner s Manual Their use is explained below This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible death or injury Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury 2 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 2013 4Front Engineered Solutions Inc Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury NOTICE Notice is used to address practices not related to personal injury February 2013 Read these Safety Practices before installing operating or servicing the dock leveler Failure to follow the Safety Practices could result in death or serious injury If you do not understand the instructions ask your supervisor to explain them to you or contact your local authorized distributor OPERATION Use restricted to trained operators Follow the procedures on the placard posted near the dock leveler Do not operate the dock leveler with equipment material or people on the ramp or lip Do not use this unit to serv
49. otter pins and kliprings are in place 2 Visually check that the lip pin retainers are in place on both ends of the lip rod 3 Visually check that both the maintenance bar and both maintenance struts are undamaged and pins securely attached INSTALLATION OF DOCK LEVELER Place barricades around pit on dock floor and drive while installing maintaining or repairing dock leveler Power to control box must be from fused disconnect supplied by others Fuse size for a time delay type fuse can be no greater than 225 of motor FLA Before doing any electrical work make certain the power is disconnected and properly tagged or locked out All electrical work must be done by a qualified technician and must meet all applicable codes If it is necessary to make troubleshooting checks inside the control panel with the power on USE EXTREME CAUTION Do not place fingers or uninsulated tools inside the control panel Touching wires or other parts inside the control panel could cause electrical shock death or serious injury 1 Mountand wire control panel See wiring diagram located insidethe control panel and wiring diagrams in this manual See Fig 2 2 4 x 4 shims are to be placed under each of the rear upright supports under the hydraulic cylinder mount s under both ofthe front lip keepers and both maintenance struts and behind the rear frame to the back of the pit wall See Fig 4 Fig 2 aN ES k Push button 48 cont
50. position vehicle INSTALLATION MAINTENANCE AND SERVICE Place barricades on the dock floor around the dock leveler pit and in the driveway in front of the pit while installing maintaining or repairing the dock Do not operate the dock leveler when anyone is standing in front of the dock leveler unless they are securing the maintenance struts Do not enter pit or do any maintenance or repair under dock leveler unless leveler is securely supported by both maintenance struts Disconnect the power and properly tag or lock out before climbing into the pit or doing any maintenance or repair under the leveler All electrical troubleshooting or repair must be done by a qualified technician and must meet applicable codes Disconnect the power and properly tag or lock out before doing any electrical work If it is necessary to make troubleshooting checks inside the control box with the power on USE EXTREME CAUTION Do not place fingers or uninsulated tools inside the control box Touching wires or other parts inside the control box could result in electrical shock death or serious injury February 2013 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 3 2013 4Front Engineered Solutions Inc OWNER S RESPONSIBILITIES The owner s responsibilities include the following The owner should recognize the inherent danger of the interface between dock and transport vehicle The owner should therefore train and instr
51. r swing into people causing death or serious injury 6 Place the dock leveler into the pit Leave room between the rear of the dock leveler frame and the rear of the pit so that electrical wires can be connected 7 Connectthe electrical wiring to the dock leveler junction box See Fig 3 and applicable wiring schematic February 2013 IN STALLATION continued Fig 4 Shim to the back of pit wall Fig 5 Dock floor Rear pit curb angle 23 to string line Y Pit floor La Fig 6 0 load centering 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 7 2013 4Front Engineered Solutions Inc STALLATION continued 8 Move the dock leveler back to the rear pit angle With the rear leveler angle touching the rear pit angle square up the sides of the pit to the sides of the leveler The gap should be even on both sides See Fig 7 NOTE If the pit is out of square the resulting gap between the rear frame and the rear curb angle should be shimmed as necessary at the weld locations Use steel shim s equal to the weld length and weld in place NOTICE Route power cord clear of edges and resting surfaces so that it is not damaged during lifting and placement 9 Shim the front end of the leveler per Fig 8 so it is level with dock floor 10 Check to confirm that the shimmed height of the rear of the dock leveler frame is properfor a smooth trans
52. re the proper operation of your dock leveler perform the following planned maintenance procedures ADANGER Be certain before climbing into the dock leveler pit or doing any maintenance or repair under the dock leveler that 1 THE MAINTENANCE STRUT IS SECURELY SUPPORTING THE LEVELER See page 13 14 2 The power is disconnected and properly tagged or locked out Before servicing the dock leveler read and follow the Safety Practices on page 3 and the operation section of this manual Place barricades on the dock floor around the dock leveler pit and in the driveway in front of the pit while installing maintaining or repairing the dock leveler WEEKLY 1 Cleanthe upper portion of the lip plate hinge with a brush and blow away all dirt and debris This will ensure proper lip plate operation 2 Inspect for debris in rear hinge area of the leveler and between the sides and curb angles to ensure smooth operation Clean as required 3 Checkthe full operation of the leveler to ensure there is no hesitation in the hydraulic system Any loss of fluid will affect the safety valve operation 4 Inspect the operation of the telescopic toe guards to ensure they are not distorted or binding when the leveler is operating 5 Clean away any debris from the rear hinge area of the leveler and between the sides and curb angles to ensure smooth operation PLANNED MAINTENANCE QUARTERLY 1 Inspect all warning labels and placar
53. rol panel May be different depending on owner s requirement Om 6 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K February 2013 2013 4Front Engineered Solutions Inc 3 Stack shims so the dimension from the top of the shims to the top of the dock floor is 23 at the back of the pit and 23 1 2 at the front of the pit See Fig 5 Before installing the dock leveler read and follow the Safety Practices on page 3 Failure to follow the safety practices could result in death or serious injury 4 Remove shims from pit and weld in place on the bottom of the dock leveler frame under the corresponding upright support Weld shims needed behind the rear frame to contact the back pit wall using 1 welds See Fig 4 5 Screw in two 3 4 10 load centering eye bolts into the top of the top plate Place a chain or other suitable lifting device through the eye bolts The dock leveler should not be lifted in any other manner when placed into the pit See Fig 6 Inadequate lifting equipment or practices can cause a load to fall unexpectedly Make sure the lifting chain or other lifting devices are in good condition and have a rated capacity of at least 3500 Ibs for the lifting angle used Never allow anyone to stand on or near the dock leveler when it is lifted or placed into the pit Stand clear of the dock leveler when it is placed into the pit Failure to follow this warning can allow the dock leveler to fall tip o
54. st clearance between the proximity switch and the target the proximity switch turn the nuts and secure when the bracket should be approximately 3 8 10mm To adjust February 2013 desired position is achieved The target bracket should rotate easily by hand yet must be held firmly to the lip arm by the clamp bracket Adjust the clamp bolt as required Proper clamping should be achieved by turning the nut 1 2 turn more than required to prevent the bolt from being loose the target clearance loosen the two locking nuts and turn the adjusting bolt Secure the nuts when the desired position is achieved Restore the electrical power and operate the dock leveler If the lip does not close fully and store properly in the lip keepers adjust the bolt to decrease the target clearance If the motor does not stop when the lip is fully closed adjust the bolt to increase the target clearance 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 35 2013 4Front Engineered Solutions Inc PARTS LIST DOCK LEVELER 60 000 Single Dual and 80 000 Ib Capacity A WARNING NOTE To ensure proper function durability and safety of the Left hand side toe guard removed for clarity product only replacement parts that do not interfere with the safe normal operation of the product must be used Incorporation of replacement parts or modifications that weaken the structural integrity of the product or in a way Note For installa
55. tion of rear weatherseal lift alter the product from its normal working condition at rear with 3 4 eyebolt to clear backframe the time of purchase from 4Front Engineered Solutions Inc could result in product malfunction breakdown premature wear death or serious injury Note Rubber overlaps slotted hinge Fig 44 3 4 between rubber Right Note Install self tapping screws item 6 with hex socket driver Hold back rubber for access 36 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K February 2013 2013 4Front Engineered Solutions Inc PARTS LIST DOCK LEVELER continued 60 000 Single Dual and 80 000 Ib Capacity Part Number ismi 152 324 7FT 152 324 9 152 324 11FT 152 325 5FT 152 325 7FT 152 325 9FT 152 325 11FT SELF TAPPING SCREW STS 12 14 X34 TEKS 215 702 6 215 702 8 215 702 8 215 702 14 SAFETY LABEL ENTERING PIT 921 070 SAFETY LABEL OPTIONAL A R T D 921 075 February 2013 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 37 2013 4Front Engineered Solutions Inc PARTS LIST DOCK LEVELER continued 60 000 Single Dual and 80 000 Ib Capacity Capacity and Part Number Part Description 60 000 80 000 LIP
56. uct operators in the safe use of dock leveling devices When a transport vehicle is positioned as closely as practicable to a dock leveling device there shall be at least 4 of overlap between the front edge of the lip and the edge of the floor or still of the transport vehicle Nameplates cautions instructions and posted warnings shall not be obscured from the view of operating or maintenance personnel for whom such warnings are intended Manufacturer s recommended periodic maintenance and inspection procedures should be kept Dock leveling devices that are structurally damaged or have experienced a sudden loss of support while under load such might occur when a transport vehicle is pulled out from under the dock leveling device shall be removed from service inspected by the manufacturer s authorized representative and repaired as needed before being placed back in service The owner shall see that all nameplates caution and instruction markings or labels are in place and legible and that the appropriate operating and maintenance manuals are provided to users Modifications or alterations of dock leveling devices shall be made only with written permission of the original manufacturer When industrial vehicles are driven on and off transport vehicles during the loading and unloading operation the brakes on the transport vehicle shall be applied and wheel chocks or positive restraints that provide the equivalent of wheel chocks
57. y resets the leveler whenever a vehicle just pulls away from the loading dock with the lip resting on the vehicle 1 If the vehicle pulls away the leveler will float down to the lowest position and the lip will fall The leveler will automatically raise retract the lip then float down to the stored position See Fig 25 February 2013 3 Button Controls Fig 22 Release to lower gt s Ottimo e s Float down Fig 23 Press to raise m Release to lower Fig 24 Press to raise Press to extend lip E Float down 6001947C Heavy Capacity Hydraulic Dock Levelers 60 80K 17 2013 4Front Engineered Solutions Inc OPERATING INSTRUCTIONS 1 Button Control Before operating the dock leveler read and follow the Safety Practices on page 3 Use by untrained people can result in death or serious injury Read and follow complete operating instructions DO NOT USE DOCK LEVELER IF IT APPEARS DAMAGED OR DOES NOT SEEM TO WORK PROPERLY Inform your supervisor immediately Always be certain that the vehicle wheels are chocked or that the vehicle is locked in place by a vehicle restraining device and the brakes set before loading or unloading Visually inspect vehicle restraint to make sure it is properly engaged Vehicles pulling away unexpectedly can cause uncontrolled drop of the dock level
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