Owners manual Dock leveller
Contents
1. 1 3 Guarantee The guarantee conditions as inclu ded in the General Conditions of Sales and or Guarantee shall be deemed legally null and void should 1 Maintenance works and or repairs have been performed whilst not ob serving the instructions to the letter 2 Assembly repair works have not been performed by a qualified engineer 3 Other than original spare parts have been used 4 Non judicially unjust and or negligent handling of the materials delivered may be proven 5 The dock leveller has been used for other purposes than for which it has been designed and constructed 3 1 4 After Sales Should defaults or problems occur or should you have any questions please contact Lindab 1 5 Declaration of Conformity and CE marking Loading Systems International B V Loodsweg 1 8243 PH LELYSTAD the Netherlands Herewith declares at her own respon sibility that the products Dock leveller 232M 232J 232M100 Dock leveller 233M 233J 233M100 233NG e Comply with the Directives regar ding Machinery Directive 2006 42 EC as per the last modification e Comply to the conditions of the fol lowing additional EEC directives Electromagnetic Compatibility Direc tive 2004 108 EEC and subsequent amendments Low Voltage Directive 2006 95 EEC and subsequent amendments e Fully comply with the harmonized EC Directive EN 1398 2009 2 1 General Q Notwithstanding all safety measures as en2. o o gt o x o O a I 3 o o o c 3 e Lindab BES ee ek ye DUCT stat em indab on 1 General iio ii aer 131 Use of the manual ur aan a 1 2 Operator Technieian u 20 een AC ae emule 1 4 After Sales 2 2 2 0 1 5 Declaration of Conformity and CE marking 2 2 Regulative non regulative use uuensnnnessnnnensnnnernennnnn nennen nennen 2 3 Safety precautions with regard to the dock leveller 2 4 Obligatory annual inspection unesssnnnessnnnensnnnennnnnnnn nennen nennen 3 Description of the dock leveller 3 1 Description of the system run 3 2 Technical data ici cian 3 3 Assembly installation inspections ppp O taacndiedecgetseseasaseddavavecssauecetaadacseaacenas 3 5 Troubleshooting arena 3 6 Maintenance works eeeeesesesenenenunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnen 3 6 1 Preventive maintenance 232M 232M100 nnnnssssnsneneeeneennnnnn 3 6 2 Preventive maintenance 233M 233M100 233NG 3 6 3 Annual MANTENAN Cessioni cies evinces SAJAMEN sario Sade dete a 3 8 Qut of Operation a GNN 3 9 Disassembly removal and processing ppp 2 1 1 Use of the manual This manual describes how Lindab dock levellers are to be operated Which safety measures are to be observed including a description of the dock leveller as well as how de fects may be solved This description has been made for the use by
3. closed during operation regarding electrical operated dock levellers only e Only a technician who has com pleted an electro technical course may open the control unit N Safety comes before Opera tion 4 2 3 Safety precautions with regard to the dock leveller Q Safety precautions e The dock leveller has been desig ned and produced in accordance with the applicable EC directives The manufacturer has given the utmost attention to the safety of the dock leveller with regard to safety precautions emergency stop door dock leveller security device e Periodically 1x per month an inspection is to be carried out regarding whether or not the safety precautions are compromised and that they still perform e Always disconnect the power regarding electrical operated dock levellers only prior to working on the system Always ensure that no unaut horised activation of the power can be performed Moreover the working area is to be fenced off to clearly indicate the working area 2 4 Obligatory annual inspection A In order to comply with the statutory regulations the user operator is to have the dock leveller inspected once per year as a minimum if re quired the dock leveller is to be alig ned by a fully authorised technician 3 1 Description of the system N The dock leveller and its movable upper deck and lip has been de signed and produced to bridge the difference in height be
4. of movement of the dock leveller Remove the object if so required e Check if one or various safety precautions have been activated e Check the presence of a load on the upper deck Remove if so required Should the defects not be solved please contact Lindab Technical Service and inform them accor dingly The user may never perform overriding the set safety precau tions Other works may not be performed by the user for this could mean termination of the guarantee 3 6 Maintenance works Complicated maintenance works require qualified knowledge For your own safety we strongly advise you to contact your supplier if complicated maintenance works are required Skilled personnel within the own or ganisation can perform the following maintenance N During maintenance on a dock leveller always use the maintenance chock Picture 1 Picture 2 3 6 1 Preventive maintenance 232M 232M100 Weekly Once a week all functions of the dock leveller must be tested even if it has not been used This check can easily be performed by putting the dock leveller through its cycle several times Monthly Every month a number of grease points must be checked see picture on the next page cleaned and greased and the fixation of the axles should be controlled see for instance photographs picture 1 and picture 2 1 Back hinges upper deck 2 Pivot points on main cylinder in front beam and upper deck 3 Sprin
5. 418 230 V 400 V 50 Hz Outside diameter main cylinder From L2 4 500 mm 233NG 65 mm 110 mm 2 x 50 mm Outside diameter lip cylinder 45 mm for 232 50 mm for 233 3 4 Operation Electrical operation The control panel is positioned as such that the area where any risk could occur can be observed during operation of the dock leveller Hinged lip e The control panel is provided with 2 control functions for Up and To rest position R e As long as the control function is activated the upper deck shall be lifted e As soon as the upper deck has reached the top level the flap shall rotate horizontally e As soon as the control function has been released the upper deck shall be lowered immediately and as such be positioned into the vehicle The flap support is to be 100 mm as a minimum e The control function Up is used as a dead man function which means that the lifting of the upper deck or the rotation of the flap stops imme diately after releasing the button e In order to convey the dock leveller to the rest position once again the control function To rest position R is to be activated as a result of which the upper deck shall be lifted and the flap shall be in vertical po sition Subsequently the upper deck shall lower to the rest position of the upper deck e Check the interlocking of the flap in the flap catchers Should after a certain p
6. dock leveller has been as such that the disassem bly shall need to be performed by qualified personnel Lindab cannot be held liable and or responsible for 9 any unjust or incorrect disassembly as performed by third parties With regard to the materials as used for the production of the system no specific circumstances or procedures need to be taken into consideration with regard to removal and proces sing All parts are to be removed in accordance with the at that time valid environmental regulations Notes 10 Notes 11 Lindab Owners manual Dock leveller Lindab Coverline for roof and facades is the best solution for agricultural and industrial buildings The sheets are available in many types of profiles and colours which can easily be combined and offer a great number of possibilities A strong and durable solution A complete range of strong reliable sectional over head doors which are ideal in meeting the tough demands to industrial and farm buildings There is a wide selection of colours and attracti
7. eveller system be out of order for a longer period Annual maintenance Mechanical parts replace the part screws if needed Check all welds on cracks If a weld is cracked block the leveller The level ler can not be used Consult your supplier about safety risks and or how to repair the weld The leveller can be used again after the weld is repaired Check clean and grease hinges pivot points and guide ways Check the leveller for corrosion Clean corroded parts and use primer and paint or zinc spray to protect the part When parts are seriously corroded Check screw connections on front beam tie rod and upper deck Tie the Annual maintenance Hydraulic parts parts Use only Univis J13 or equivalent Check all cylinders connections and hoses on leaking Replace defective Check oil level Only one type of oil must be used in the hydraulic system Annual maintenance Electrical parts Check all cables The isolation of the cables must be undamaged Replace damaged cables because they are causing a high safety risk Check all connections on the solenoids at the power pack and in the control box Loose contacts or bad connections can cause malfunction of time the power is to be discon nected regarding electrical operated dock levellers only and it should subsequently be safeguarded against unintended and unauthorised use 3 9 Disassembly removal and processing The manufacture of the
8. g unit on side lips option Every two months Check the oil in the tank Move the dock leveller in its lowest position and switch off the power If there is an open pit you can easily crawl under the leveller The powerpack is mounted on the upper deck Use a screw driver as a dip stick to determine the oil level The oil level must be not lower than 20mm below the filling opening Note Only one type of oil must be used in the hydraulic system Use only Univis J13 or equivalent 3 6 2 Preventive maintenance 233M 233M 100 233NG Weekly Once a week all functions of the dock leveller must be tested even if it has not been used This check can easily be performed by putting the dock leveller through its cycle several times Monthly Every month a number of grease points must be checked see picture on the next page cleaned and greased and the fixation of the axles should be controlled see for instance photographs picture 1 and picture 2 shown at the 232 above 1 Back hinges upper deck 2 Pivot points on main cylinder in front beam and upper deck 3 Pivot points on lip cylinder 4 Guide blocks lip round nylon 5 Spring unit and guide system side lips option Every two months Check the oil in the tank Move the dock leveller in its lowest position and switch off the power If there is an open pit you can easily crawl under the leveller The powerpack is mounted on the uppe
9. r deck Use a screw driver as a dip stick to determine the oil level The oil level must be not lower than 20mm below the filling opening Note Only one type of oil must be used in the hydraulic system Use only Univis J13 or equivalent 8 3 6 3 Annual maintenance Annual maintenance works to loading platform systems may be imple mented by authorised and skilled persons only During a service visit the dock leveller must be carefully inspected on malfunctions or defec tive parts Inspect all mechanical hydraulic and electric parts After inspecting the leveller operate the leveller several times to deter mine if all functions work properly If not use this manual to determine the malfunction and to solve or repair the leveller 3 7 Alignment Upon assembly the dock leveller system shall be aligned as such that the settings comply with the agreed upon requirements The user is not to initiate any modifications to the settings Should any modifications be applicable at a later stage the supplier is to be contacted after which these shall be modified by the supplier Should any modifications be per formed with regard to the settings as set by the manufacturer either by the user or by any third party termination of the guarantee could be a result of unauthorised modifi cations 3 8 Out of operation CZ In order to be able to perform maintenance works by a technician or should the dock l
10. sing one of these buttons the deck will always be lifted first for 1 5 se conds After this movement the in or outward movement will start 6 e In order to convey the dock leveller to the rest position once again the control function To rest position R is to be activated resulting in the lifting of the upper deck As soon as the upper level has been reached the lip is retracted After this the upper deck will return to the rest position Should after a certain pulse the dock leveller not activate a certain function it could be that one of the described safety precautions has been activated In this case please check Should the latter not be ap plicable please refer to Chapter 3 5 Troubleshooting Emergency stop Activating set main switch to zero Unlocking set main switch to 1 and operate the control function Up during a short period of time only A All types of control include the major and dominant function of the emer gency stop system as a result of which the dock leveller with an inter rupted contact may be de activated regarding electrical operated dock levellers only 3 5 Troubleshooting Should the dock leveller not react im mediately upon the activation of the control element or should the dock leveller for some reason halt the fol lowing procedure is to be observed e Check if an obstacle is present within the direction of moment which prevents the freedom
11. sured by Lindab the following aspects are to be taken into consi deration e During the operation of the dock leveller the surroundings are to be observed if possible e One is not to insert any objects between underneath or into the dock leveller or any moving parts of the dock leveller e Each person is to ensure a certain distance during the movement of the surface of the dock leveller e The direction of the movement of the surface of the dock leveller should not be blocked in order to ensure free movement The manufacturer cannot be held liable for any handling or works which have been performed by a non authorised non qualified or not sufficiently qualified user operator or technician 2 2 Regulative non regulative use Q Safety precautions e Prior to operating the dock leveller for the first time the operator is to read the full contents of the pertai ning manual e The dock leveller is to be used in accordance with the instructions Any other use could result in unpredic table circumstances or occurrences and is therefore strictly forbidden e The instructions as stipulated in the manual are to be observed to the letter e Always disconnect the power regarding electrical operated dock levellers only prior to working on the system Always ensure that no unaut horised activation of the power can be performed e Special attention is to be given to ensure that the control unit is always
12. the operator of the dock leveller and in dicates that after reading the manual you shall be capable of operating the dock leveller however not autho rised to solve dock leveller related defaults With regard to technical defaults you are to contact a quali fied engineer Text layout Text in Italic information to which extra attention is to be given Text in bold important information Symbols used N Warning Should instructions be pre ceded by this symbol this indicates a warning regarding the possible risk of damaging the dock leveller or risk regarding occurring defaults should the instructions not be observed to the letter Should text be preceded by this sym bol this indicates a warning against the risk of physical injury should the instructions not be observed to the letter 1 2 Operator Technician User The user is each person handling the dock leveller in any way Operator The operator is each person who is under normal circumstances involved with handling the dock level ler The operator is to be familiar with all stipulations regarding safety as detailed in this manual The operator is not to perform any repair activities on or to the dock leveller Technician The technician is a technician qua lified to perform technical repairs on or to the dock leveller He she is qualified to perform mechanical and or electro technical repairs to the system s and or maintenance activities
13. tween the loading bay and vehicle floor This enables the loading and unloading of vehicles Depending on the model the movements lifting in and out are activated manually or by means of a push button e Never exceed the lifting capacity for which the dock leveller has been designed and produced e Only use the dock leveller for the purpose to which is has been desig ned and produced e Never leave a lifting device fork lift truck or pallet truck etc unattended on the dock leveller 3 2 Technical data 3 3 Assembly installation inspections N The dock leveller is to be assembled by a technician approved by Lindab Prior to the initial use of the dock leveller the appointed technician has inspected the safety and the operati on of the dock leveller and has relea sed it for use to the appropriate user or operator The safety of the dock leveller system is to be inspected once per year as a minimum This inspection is to be performed by a authorized technician and all inspec tions shall be in accordance with the safety precautions Top deck Steel durbar execution Sub frame Profiled steel self supporting Lip angle 4 degrees for 232M 100 5 degrees for 233M 100 233NG Protective devices Hydraulic safety stop with integrated hose burst valve in cylinder Motor 230 V eller 400 V Frequency 50 Hz Hand return Standard Control panel Emergency stop in accordance with EN
14. ulse the dock leveller not activate a certain function it could be that one of the described safety precautions has been activated In this case please check Should the latter not be ap plicable please refer to Chapter 3 5 Troubleshooting Sliding lip e The control panel is provided with 4 control functions being Up Extend Retract and To rest position R e As long as the control function Up is activated the upper deck shall move to a higher level 1 5 seconds after the function is released the deck will start lowering e As soon as the upper deck has reached the upper level the control function Extend is to be operated The deck will raise little before the lip is extended and will not lower as long as the control function is used A The control function Extend can only be used after the control func tion Up has been used for at least 2 seconds e The movement of the flap shall stop as soon as the control function has been released The upper deck shall start lowering after 1 5 seconds resulting in the position of the flap on the vehicle floor The flap support is to be 100 mm as a minimum It should be safeguarded that there are no obstacles under the flap while resting on the vehicle floor Only the flap may rest on the vehicle floor e Adjusting the flap support can be done easily afterwards by using the button Extend or Retract When u
15. ve combina tion options so you have great freedom of design Bu using Lindab loading docks shelters and industrial overhead doors you achieve the ultimate system to ensure a good working environment and efficient logistics Efficient unloading and loading of goods onto vehicles is an important parameter in modern logistics systems For more information www lindab dk Lindab Lindab Profil A S Tlf 45 73 99 73 73 www lindab dk
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