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DA Owner`s/User Manual

1. 1 1 2374 Cotter Pin 5 3 79890180 Safety Chaint 1 f 426100 3 798 0019 Chan Safeyleg 2101 0216 Quick Link i 2101 0239 Chain Snap link 4111 0011 May 2015 38 Oct 2015 PARTS Weather Seal Kits Item Quantity Part Number Description A 1 0195 0021 Brush Kit Includes Seal and Track 1 1 2 in 82 Lg Both Sides B 1 0195 0033 Rubber Kit Includes Seal and Track 1 1 2 in 82 Lg Both Sides Individual Replacement Seals Item Quantity Part Number Description C 1 0192 0098 Brush Refill 1 1 2 in 82 Lg D 1 0192 0085 Rubber Refill 1 1 2 in 82 Lg E 1 0192 0146 Heplacement Channel AX rd 4 BSR Item Quantity Part Number Description G 1 0195 0044 Rear Powerseal Brush Seal 0195 0046 Foam Seal Fits 6 F 1 0195 0047 Foam Seal Fits 6 1 2 0195 0048 Foam Seal Fits 7 Provide dock leveler serial number and size of platform when calling or faxing orders Provide width of weatherstrip when replacing existing seals 4111 0011 May 2015 Oct 2015 39 PARTS Motor and Blower Assembly 9395 0359 PPAC Blower Assy B 1 9391 0021 Filter Element Included With 9395 0359 e LEES 9391 0022 Tube 2 50 8mm OD 36 914 4mm Length 6 and 8 Levelers Tube 2 50 8 OD 46 914 4mm Length 10 levelers D
2. NOTE If a transport vehicle is present the platform will lower until the lip rests on the transport vehicle bed See Operating Instructions in Operation section When drilling access hole in the control box DO NOT penetrate too deep components may be damaged DO NOT turn control upside down to drill any access holes To prevent damaged to electrical components from debris cover components prior to drilling Seal all conduit entrances to prevent moisture from entering the control box DO NOT use compressed air to clean control box Hecommended to vacuum debris from inside 4111 0011 May 2015 Oct 2015 INSTALLATION 7 When the platform lowers to the full below dock position the lip will fold Depress and hold the RAISE button until the platform rises just enough to clear the lip keepers then release the RAISE button to allow the platform to lower to the cross traffic stored position lip engages lip keepers 8 Perform steps 5 7 at least four times make sure the leveler functions properly and there is no binding Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop 9 Raise the platform fully Hold the platform at this position using the RAISE button and move the maintenance prop to the service upright position Helease the RAISE button to allow the
3. OL A JEN3SSV CLJ 151559 SANIT 40 135344 WYO4LVId Ne cd ty 4111 0011 May 2015 Oct 2015 27 TROUBLESHOOTING When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death Before performing the detailed troubleshooting procedures check the following items first Check all fuses and circuit breakers Replac
4. May 2015 32 Oct 2015 PARTS Lip Activation JAN 2012 and Newer Quantity PartNumber A 1 DLIP 0305 Lip AssistRod Complete 34 Lg DOTH 2550 Spring Lip Assist STD opring Lip Assist Heavy Duty po wu 5775 0004 Lip latch Assembly 16 Long 3 2014 and older Lip latch Assembly 21 Long 4 2014 and newer D 1 pomesti sorces O OS OSO 1 1 DPLAOS40 Lip Linkage O o S O DOTH 2214 M 1 DOTH2082 Bolt Shoulder gt SSS O O 1 2101 0217 Quicklink S O P 1 2101 0002 Chain Snubber O 1 DOTH 2555 Spring Snubber not shown R 1 0941 0013 Spring Lip Latch 4111 0011 May 2015 Oct 2015 33 PARTS This page intentionally left blank 4111 0011 May 2015 34 Oct 2015 PARTS Airbag and Support Pallet Mem Quantity Part Number Description 5812 0045 Hold Down Rod 45 long x 7 16 diameter 5811 0009 Air Bag Bladder 3 4 5 7 ap e 2101 0004 Rod Gamgs OOOO 4 2101 0078 Washer Ring Split 1 3 4 od 4111 0011 May 2015 Oct 2015 is PARTS Frame and Platform Lip latch Release Arm Up Grade Maybe required some levelers manufactured before 4 2014 if below dock is required 4111 0011 May 2015 36 Oct 2015 PARTS Frame and Platform item Quantity Part Number B 1 7
5. instructions warnings and maintenance schedules in NORMAL OPERATION a 1 Raise the platform by depressing and the manual and on placards Operation and servicing of holding the RAISE button dock leveler is restricted to KD o authorized personnel 2 Hold the RAISE button until the lip is fully Always chock transport vehicle wheels or engage vehicle restraint extended then release the RAISE button and set parking brakes before operating dock leveler or beginning The platform will lower until lip is resting on to load or unload the transport vehicle Before activating dock leveler ensure lip avoids contact with n STORING LEVELER transport vehicle sides and cargo If lip does not lower to transport Depress the RAISE button until the lip is vehicle bed reposition transport vehicle completely folded When the lip is folded Ensure the transport vehicle floor supports extended lip or the release the RAISE button The platform will leveler frame lip keepers or below dock endload supports supports lower returning to the cross traffic position the ramp before driving on ramp BELOW DOCK ENDLOADING Stay clear of hinges and front and sides of moving dock leveler HYDRAULIC ONLY Depress and hold Never use hands or equipment to move the ramp or lip the RAISE button until the leveler is fully Never use damaged or malfunctioning dock leveler Report problems raised As the lip starts to extend release immediately to supervisor the RAISE but
6. ENGLISH b CIRCUIT PROTECTION 1751 0478 DECAL FRENCH b SEE TABLES 1 2 AND 3 1751 0479 DECAL SPANISH b MOTOR LOCATED AT DOCK LEVELER LI L2 N GRD LEFT INSIDE OF ENCLOSURE VOLTAGE 115 V DWG 9 0 800 115 Volts 1 Phase 60 2 11 8 FLA E POWER EE b AFFIX TO RIGHT OUTSIDE OF ENCLOSURE COVER INSTALLED BY OTHERS O crounoine TERMINALS PLASTIC ENCLOSURE FOR METALLIC ENCLOSURE USE GROUNDING PROVISION IN ENCLOSURE BODY AND STUD ON ENCLOSURE COVER J BOX W DUPLEX AT REAR n T2 OF PIT WALL BY OTHERS 1 ALL WRES UNLESS INDICATED OTHERWISE BY OTHERS 2 ALL CONDUIT UNLESS INDICATED OTHERWISE BY OTHERS 57 3 ALL WIRE CONNECTIONS BY OTHERS XY POWERAMP mm MCGU gt quipment ELECTRICAL ENCLOSED STARTER BY POWERAMP AE CORD W PLUG DOCK LEVELER 115 VOLTS 1 PHASE 60 HERTZ INSTALLED BY OTHERS 1 DATE 9 16 03 DRAWING NO foram By J RO 800 Oct 2015 4111 0011 May 2015 30 Control Box 4 DANGER Anc Flash and shock Hazard PPE Peramal Protection Equipment Required LXI dr nS dn on c inicie Do nce Cu Cor wt E poe 11 8 FLA Amp Draw FPE Feeder ip POE dor 5 miy oon Te Lune La LI injun or Deoth OPERATING INSTRUCTIONS Read and follow POWERED DOCK LEVELERS
7. linkage assembly to push the lip out and up The lip assist spring not shown also helps keep the lip extended When the lip is fully extended the lip latch cable engages the lip latch assembly locking the lip in the extended position The dock leveler has reached its full height when the lip is fully extended E Lip Maintenance Prop Pivot Air Bag Support Pallet M Maintenance Prop J Lip Keepers 2 used N Blower Motor K Air Bag O Toe Guard 2 used L Main Frame P Raise Button Q Safety Legs To lower the platform release the Raise button P The platform will lower until the extended lip rests on the transport vehicle bed the lip did not fully extend or there is no transport vehicle at the dock the platform will lower until one of the following conditions occur Lip is resting on lip keepers cross traffic position Leveler went to the below dock position lip folds automatically leveler rests on the safety legs below dock position Leveler went to the below dock position with operator holding the safety leg retract cable not shown safety legs are retracted lip folds automatically causing dock to rest in the full below dock position 4111 0011 May 2015 Oct 2015 INSTALLATION Prepare Pit A Distance Pit Width B Distance Dock Floor to Pit C Distance Pit Length D Distance Pit Corner to Corner Front and Rear Floor All Four Corners Both S
8. platform to lower until it is resting on the maintenance prop 10 With the maintenance prop supporting the platform remove the lifting brackets 11 Support the toe guards remove the cotter pin used in shipping and carefully release the toe guards 12 Depress and hold the RAISE button until the maintenance prop drops to its stored position Helease the RAISE button and allow the platform to lower fully Check operation of toe guards 13 When the platform lowers to the full below dock position the lip will fold Depress and hold the RAISE button until the platform rises just enough to clear the lip keepers then release the RAISE button to allow the platform to lower to the cross traffic stored position lip engages lip keepers Always stand clear of platform lip when working in front of the dock leveler Serious personal injury or death may result OPERATION Operating Instructions DANGER Stay clear of dock leveler when transport vehicle carrier is entering or leaving dock area DO NOT move or use the dock leveler if anyone is under or in front of leveler Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts Failure to follow these instructions may result in severe personal injury or death Only trained personnel should operate the dock leveler DO NOT use a broken or damaged dock leveler Make sure proper service and maintenance procedures have been perfo
9. power cable to the outlet Shock Hazard in the pit junction box Refer to the electrical PPE Personal Protection drawings supplied with the dock leveler Equipment Required 6 After all electrical connections in the pit have De enerngize equipment before been made raise the leveler disengage the working on or inside Do not maintenance prop and allow the platform to lower open cover without appropriate PPE Refer to NFPA 70E for 7 PPE requirements This panel may contain more than one power source Install the Placard s D in close proximity to the control box and in plain sight Hazardous Voltage Will Cause Sever Injury or Death 4111 0011 May 2015 16 Oct 2015 Put New Dock Leveler Into Service 1 Disconnect the external lifting device and chains from the lifting brackets 2 Check that the leveler is flush with the dock floor and that the platform lip contacts both lip keepers evenly If an excessive transition exists between the dock floor and leveler and or lip does not contact both lip keepers evenly contact Technical Services for further instructions 3 Install the dock bumpers as required 4 Turn the main electrical power ON 5 Raise the leveler platform fully by depressing and holding the RAISE button 6 Release the RAISE button to lower the platform As long as there is no transport vehicle present at the dock the platform will lower to the full below dock position as the lip folds
10. the unit the other person to engage the maintenance prop Failure to follow these instructions may result in serious personal injury or death 4111 0011 May 2015 Oct 2015 C Lock Out Device D Lip Prop Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Whenever performing maintenance under the dock leveler platform support the platform with the maintenance prop A Position the maintenance prop behind front header plate E while staying clear of the lip The Lip Prop may be used to keep the lip extended D Additional supports should be used to prevent the lip from collapsing if working under the leveler Lock the maintenance prop in the service upright position using an OSHA approved lockout device C and tagout device B Whenever servicing the dock leveler lock the electrical power disconnect in the OFF position Use only an OSHA approved lockout tagout device C and tagout device B Only the person servicing the equipment should have the capability to remove the lockout tagout devices The Tag out devices must inform that repairs are in process and clearly state who is responsible for the lockout condition Refer to OSHA regulation 1910 146 Refer to OSHA regulation 1910 147 21 MAINTENANCE Periodic M
11. 1 0207 Push Button Controller 9 RO 800 A A i A 1751 0477 Decal English 1751 0736 Decal Arc Flash 4111 0011 2015 Oct 2015 31 PARTS Lip Activation Before 2012 ber 4 w nel 1 9514 0107 Lip Latch Assy bolts on to DPLA 2130 1 DPLA 2130 Lip Assist Rod Complete 34 Lg Includes Items A D B 2 DOTH249 Bearing 005 D 1 DOTH2060 NuNyon O 1 DOTH 2546 Spring Lip assist 4 F 2 DOTH225 Washer 0050054 G 1 DPLA2016 LipBaner 002 pH 2 2061 Bolt Shoulder 1 2 x 1 H2Lg 3 DOTH2131 Nut Nylon lock 3 8 o LJ 1 576000 Lip latch Assembly S K 1 0941 0013 Lip Latch Rod Spring 00 pt 1 DOTH 2555 Spring Snubber 005 pM 1 DPLA212 Chain Snubber Spring gt S O O 3 2101 0217 Quicklink 0 0 0 0 1 2101 0216 Quick bine 025 1 DOTH 2421 Cold Shut 5 0 PR 3 DOTH 2214 Washer 002 _5 1 DOTH 2547 Spring Lip Maintenance S 1 DOTP200 Prop Lip Maintenance U 2 DOTH20 Bolt Shoulder V 1 DOTH 2351 Bolt Clevis 00 W 1 DOTH2163 Nut Locking 1 2 S 1 DOTH2210 Washer 00 LY 1 2374 CotterPin S 4111 0011
12. 3 8 in 6 in 9 5 mm A Front of Dock Pit B Dock Leveler Frame C Side Pit Curb Angle D Gap 3 4 in 19 mm Minimum 8 With rear hinge frame angle F tight against rear pit curb angle G perform check the following e Pry between the platform and rear hinge frame angle at locations E to make sure rear edge of platform is parallel to the rear hinge frame angle F Gap D must exist equally along both sides of leveler so weather seal if equipped will not bind during dock leveler operation 9 If gap D cannot be obtained equally at both sides of leveler grind or add material at the rear edge of rear hinge frame angle F as needed 4111 0011 May 2015 Oct 2015 1 52 mm E Pry Locations F Rear Hinge Frame Angle G Rear Pit Curb Angle H Flare Bevel Weld Typical To Fit Spacing 10 Allow the dock leveler to rest fully on the shim stacks Check that a smooth and level transition exists between the dock floor and the dock leveler platform Add or remove shims as necessary until a smooth transition is obtained 11 If leveler cannot be squared and or made level as instructed in steps 8 10 contact Technical Services 12 With the leveler square in the pit and flush with the surrounding dock remove the banding on the lip of the leveler 13 INSTALLATION 13 14 15 16 17 18 Connect the blower motor to the temporary power supply Slowly raise
13. 7083 OL 2 ANI AINO HOVLIV SANN LL INNOD 1 ONINdS Y3GSNNS 3Hl 30 M3lN3O JHL H NOYHL NIVHO ONINIVW3Y JHL 31004 19S 51 39NYS IJAYIS 3ONO G 13033 SV SANIT 40 M38NON 145384 IHL IYON OL ba ANM YANO IN3AUSRIPOV 3Hi ONINOIISOd38 8 HIONT TWYSAO 3HL 3SV3HONI Zt NVHL SSJI SI 39NYM 39 A3S 900 3A08V 31 531 N3HM 03033N SY SWNT NIVHO JO N38WAN 13S34d JHL SSII OL 1 MANO INIWISNCAY IHL JNINOLISOd3S AB HLONST TWYSAO JHL 390038 701 NYHL M31V349 SI 39NYM 30148435 900 JAQAY 31 ONUSIL N3HM 1 YANO ONY v2 Q IN3ACT34 INVA 5 438 v 8270 90 410 ATEN3SSY 15155 lt 1 1910 166 4381 170 10210210 NIGENNS 5 9000 1 60 1 NOlldlH2S30 ON 1 4 JAD JViJilvW 30 GSSZ HLOG WI 2 Snubber Spring assembly WLI A18W3SSV 1SISSY dN JHL WOM4 318VL Ni SANIT 40 Y3SWNN JHL OL 135384 SI HION31 TIVYJAO JHL Z ATGWISSY ONIYdS ONY NIVHO SIHL 30 HIONJI 3HL GANINSSLIG SE SHL 40 JONVY FOIANSS 3200 JAQAY FHL I SALON sen eov O NotdloS3Q JION Ca ANN OL 1 AINO NOHA SANIT NIVHO 01 ale ANIT AINO 0 145484 804 Ya 1 355 SANIT NIVHO SANIT VE HLONST WIOL ee ale NI
14. 823__ Platform Welded Assembly o Pin Lip Hinge 6 W C 1 Pin Lip Hinge 6 5W Pin Lip Hinge 7W Toe Guard Assembly 6 Foot Both Sides and Hardware 1 Toe Guard Assembly 8 Foot Both Sides and Hardware Toe Guard Assembly 10 Foot Both Sides and Hardware 1 3 9202 0002 RearHingePin gt 0000 J 6 2101047 Cotter Pin 4x2in Maintenance Prop 39 50 K 1 Maintenance Prop 43 50 Maintenance Prop 39 50 1 Provide dock leveler serial number platform size and lip size when calling or faxing orders 2 Provide length and width of inspection plate opening when calling or faxing orders For left right orientation of dock leveler see inside back cover of this manual 1 20 0506 1502 0505 1605 0561508 0696 511 08951814 0595 1517 _ 0595 1536 0595 1539 0595 1542 0595 1545 0595 1548 0595 1551 0595 1537 0595 1540 0595 1543 0595 1546 0595 1549 0595 1552 0595 1538 0595 1541 0595 1544 0595 1547 0595 1550 0595 1553 4111 0011 2015 Oct 2015 37 PARTS Below Dock Control 9514 0108 Leg Right Safety Assembly with Spring B 1 9514 0109 Leg Left Safety Assembly with Spring DOTH 6231 Spring Leg Included with the Safety Leg 1 DPLA 2122 Pull Bar Assembly Safety Leg DOTH 2075 Cap Screw Lip Stop 5 8 11 UNC DOTH 2356 Nut Hex 5 8 11 UNC DOTP 6647 Rod Push poTH 2356 Pm Ces _
15. A Division of Systems Inc DLM DA Series DOCK LEVELER Dock Leveler MANUFACTURING DLM Division of Systems Inc W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 255 5917 www docksystemsinc com techservices 9 docksystemsinc com Printed in U S A Manual No 4111 0011 Copyright O 2015 May 2015 Oct 2015 Table of Contents Page Safety Recognize Safety Information eese nenne 1 General Operational Safety Precautions 1 Operational Safety 2 Maintenance Safety Precautions 4 DECA Saracens e 5 Owner s User s 6 Introduction General MOnato is eros te Aou pueda ate 7 Dock Leveler Stock 7 COMPONENT IGSNUNGAU ON itunes esu tene A 8 TICON C O 8 Installation Prepare Pe RE 9 Prepare DOCK EeVeleTr eio ese eterne E ee 10 Stal DOCK EBVOlOE iue e REL 11 Install Control Panel and 16 Put New Leveler Into Service 17 Operation Operating IBSIFctlOllS 18 Ramp Loading Unloading Instructio
16. age 20 4111 0011 May 2015 18 Oct 2015 Operating Instructions Continued Ramp Loading Unloading Instructions NOTE If end unloading is required see End Loading Unloading Instructions on page 20 For ramp loading or unloading the DA dock leveler can be operated by using the RAISE button on the control panel 1 Check to make sure transport vehicle is positioned squarely against dock bumpers 2 Instruct driver to remain at the dock until the loading or unloading process has been completed 3 Chock the transport vehicle wheels or use vehicle restraint if available A RAISE Button 4 Extend the platform lip onto transport vehicle as follows a Raise the platform by depressing and holding RAISE button b Hold the RAISE button until the lip is fully extended then release the RAISE button The platform will lower until the lip is resting on the transport vehicle bed c Make sure that the lip is fully extended and supported on the transport vehicle along the entire width of the platform with at least 4 in 102 mm of lip contacting the transport bed Tere 5 Proceed with loading or unloading the transport vehicle 6 If below dock loading is necessary see steps 7 11 If not proceed to step 12 Unloading Instructions on page 20 4111 0011 May 2015 Oct 2015 OPERATION Below Dock Loading Unloading Instructions NOTE If end unloading is required see End Loading Unload
17. aintenance A Lip Hinge Area C Lip Link Pivots E Lip Assist Pin G Safety leg linkage B Lip Maintenance Prop D Platform Hinge Area F Lip Linkage Pivot pivots Pivot Under platform service Air Filter service under rear of platform 4111 0011 May 2015 22 Oct 2015 Regular maintenance must be performed on a weekly and quarterly schedule FOLLOW ALL SAFETY PRECAUTIONS Weekly Maintenance Operate the dock leveler through the complete operating cycle to maintain lubrication NOTE To thoroughly inspect the platform hinge area put the platform in the full below dock position Inspect the platform hinge and the lip hinge areas The hinge areas must be kept free of dirt and debris Build up of foreign material in the hinge areas will cause abnormal operation Inspect the area under the platform around and under the air bag Build up of foreign material in this area may damage air bag components causing abnormal operation Inspect air bag and seams for signs of wear or damage Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler DANGER A maintenance prop permanently attached and hinged to the unit with means for lock out tag out requirements per OSHA 1910 147 is included with each pit style dock leveler In addition it is recommended and good safety practice to use an additional means to support the dock platform and lip anytime when physically working
18. ct the blower motor from weld sparks and splatter With the rear hinge frame angle F tight against the rear pit curb angle and flush with the curb angle G weld the rear hinge frame angle F to the rear pit curb angle G using a 3 8 in 9 5 mm flare bevel skip weld each weld being 6 in 152 mm long Start at each end with a 6 in 152 mm long weld Space all the other welds out evenly leaving approximately 6 in 152 mm space between each weld All model levelers Install shims at locations B p 11 using the pyramid or stepped shimming method Make sure the platform is level from side to side as well as from front to back and flush with dock floor NOTICE DO NOT weld before disconnecting all electrical components DO NOT weld before removing air bag air bag support pallet and hoses from leveler Protect or remove the blower motor before welding Failure to follow these instructions may result damage to these components from stray sparks and weld splatter 4111 0011 May 2015 Oct 2015 DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded DO NOT grind or weld if uncontained hydraulic fluid INSTALLATION NOTICE DO NOT weld continuously along the full length of the rear hinge frame angle This can put unnecessary stress on the leveler components causing the leveler to malfunction and shorten the life span of the affected compone
19. e any blown fuse s with a fuse of equal specification and reset cir e Make sure the correct voltages are present at the proper locations inside the control panel s Symptom Possible Cause Platform does not rise Motor fuse blown Reset circuit panel or disconnect fuse Determine Motor does not energize cause of overload Motor failure Check voltage to motor e If voltage is present and motor does not energize replace motor e If voltage is not present check all components in series with the motor Platform does not rise Incorrect voltage is present Check line for proper voltage Motor hums but does notion line run If proper voltage is not present check all components in series with the motor If proper voltage is present and motor does not run check for obstructions If no obstructions are found replace motor Platform does not rise Motor energizes but does not run Line voltage too low Check wiring to motor for high resistance Check for loose or corroded connections Check if gauge of wires to motor are of correct size and specification for load requirement Replace if necessary 4111 0011 May 2015 28 Oct 2015 TROUBLESHOOTING Platform rises slowly Air bladder or connecting Check air bladder and ducting replace as needed ducts punctured Damaged or restricted Replace damaged ducting or remove restriction ducting Air intake clogged Remove intake filter clean or replace as needed Dock leve
20. e 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 4111 0011 May 2015 Oct 2015 General Information Congratulations on your choice of a DLM dock leveler This manual covers the Air Bag DA model air powered dock leveler Designed by DLM to be a marvel of simplicity and efficiency your dock leveler when properly installed will provide many years of trouble free performance with an absolute minimum of maintenance Its revolutionary air bag system efficiently controls and operates every function To obtain maximum performance and longest possible use a simple program of preventive maintenance is recommended The DA dock leveler comes equipped with an electrical control panel which allows push button operation of the dock leveler functions Each DA dock leveler unit and control panel has been factory prewired and tested to ensure satisfactory operation To illustrate which connections are to be made in the field at installation electrical drawings are incl
21. e sure transport vehicle is positioned squarely against dock bumpers 2 Instruct driver to remain at the dock until the loading or unloading process has been completed 3 Chock the transport vehicle wheels or use vehicle restraint if available eX End Loading Unloading Platform at Cross Traffic Position 4 f transport vehicle bed is at or above dock floor level leave leveler at the cross traffic position and proceed with loading or unloading 3 End Loading Unloading Platform Too High Use Below Dock Position 5 If transport vehicle bed is below the dock floor level perform steps 6 12 End Loading Unloading Platform at Below Dock Position 20 6 Depress the Raise button to the platform high enough to clear the lip keepers but not high enough to extend the lip 7 Walk out on the leveler pull and hold the safety leg retract pull ring B located in the recess at the front of the platform This will cause the lip to extend away from the lip keepers and the cross traffic safety legs to fold to allow the leveler to lower to the below dock position 8 When the platform lip clears the lip keepers continue to hold the pull chain as the leveler lowers to the below dock service position The platform will drift down to the full below dock position 9 Proceed with loading or unloading NOTE When end unloading is finished and access to the rest of the transport vehicle is still requi
22. ems immediately to supervisor Kelle MMs Always chock trailer wheels or engage truck restraint before MAINTENANCEISERVICE gt 5 operating dock leveler beginningto 1 Read and follow all instructions ee EE orunioad warnings maintenance the dock always Never use hands or equipment to schedules in the owner sluser s move ramp or li manual 5 Before activating dock leveler 2 Maintenance Service of dock leveler Ensure no equipment Ensure trailer is backed in against restricted to trained personnel bumpers 3 Place barriers on the driveway and material or people are on Remove any end loads ifrequired dock floor to indicate service work is dock leveler Check trailer alignment to avoid lip being performed interference If lip does not lower to 4 DO NOT ENTER PIT unless dock a traller bed reposition vehicle leveler is securely supported by etum docklevelertois tae red ric stored position at dock level the ramp OSHAlockouttagout procedures Failure to follow posted instructions will result in death or serious injury Call 262 255 1510 for replacement placards wamning labels or owner s user s manual decal placed in same position on both sides 1751 0329 x2 decal placed in same position on both sides 1751 0330 x2 decal placed in same position on both sides 1751 0729 ADANGER CRUSH HAZARD Do not wor
23. er on left hand corner next to blower motor MISCELLANEOUS Dock Leveler Information Serial No Systems Inc Job No Original Owner Information 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 manufacturers recommendations and or specified design parameters and not otherwise have been subject to abuse misuse misapplication acts of nature overloading unauthorized repair or modification 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 neg
24. he manufacturer s instructions If you have any questions ask your supervisor DANGER Te Stay clear of dock leveling device when transport Chock restrain all transport vehicles Never remove vehicle is entering or leaving area the wheel chocks until loading or unloading is finished and transport driver has been given permission to drive away INT Tee Do not use a broken or damage dock leveling Do not move or use the dock leveling device if device Make sure proper service and maintenance anyone is under or in front of it procedures have been performed before using _ or Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts Make sure lip overlaps onto transport vehicle bed at least 4 in 102 mm Keep a safe distance from both side edges 4111 0011 May 2015 2 Oct 2015 SAFETY eer Do not use dock leveling device if transport vehicle is too high or too low Do not operate any equipment while under the influence of alcohol or drugs Do not leave equipment or material unattended on dock leveling device 4111 0011 May 2015 Oct 2015 3 SAFETY DANGER Hydraulic and electrical power must be OFF when servicing the equipment For maximum protection use an OSHA approved locking device to lock out all power sources Only the person servicing the equipment should have the key to unlock the device Always post safety warnings and ba
25. hims Failure to do this may result in serious 69 personal injury or death For left right orientation of dock leveler see inside back cover of this manual 4111 0011 May 2015 Oct 2015 15 INSTALLATION Install Control Panel and Wiring The electrical power must be OFF prior to electrical installation For maximum protection use an OSHA approved locking device to lock out all power sources Only the person installing the equipment should have the key to unlock the power source Failure to follow these instructions may result in serious personal injury or death DO NOT make any final electrical connections until all welding has been completed Failure to do this may result in serious personal injury or death All electrical work including the installation of the disconnect panel control panel and final A Disconnect Panel provided by others connections to the pit junction box must be B Control Panel C Distance 48 in 14 630 mm performed by a certified electrician and conform to O PIRANG all local and applicable national codes 1 Mount the push button control panel B so bottom of control panel to dock floor distance C is 48 in 1219 2 mm h D AN G 2 Install electrical disconnect panel if not already installed 3 Install and connect the control wiring 4 Re install the air bag air bag support pallet and blower motor Arc Flash and 5 Connect the dock leveler
26. ides of Pit Top Bottom and Both Sides 1 Before lowering the dock leveler into the pit the following must be performed Post safety warnings and barricade the work area at 2 Remove all debris from the pit and sweep the pit dock level and ground level to prevent unauthorized clean use of the dock leveler before installation has been completed 3 Check the entire dock leveler pit for proper construction according to approved certified pit Failure to follow the installation instructions can drawings Make sure pit is square by making the result in damage to dock leveler the facilities and following measurements or serious personal injury or death e Measure pit width distance A at both front and rear of pit e Measure dock floor to pit floor distance B at all four corners e Measure pit length distance C at sides e Measure corner to corner criss cross dis tance D at both sides Take measurements at dock floor level and at pit floor level NO TICE If any measurement is off by more than 1 8 DO NOT remove the shipping bands around the in 3 18 mm contact Technical Services dock leveler lip until instructed to do so before proceeding Only trained installation professionals with the proper equipment should install this product 4 Make sure the field junction box for the dock leveler E is at the correct location per pit diagrams 4111 0011 May 2015 Oct 2015 9 INSTALLATION Prepare Doc
27. in front of or under the dock leveler This additional means may include but not limited to a boom truck fork truck stabilizing bar or equivalent 4111 0011 May 2015 Oct 2015 MAINTENANCE Quarterly Maintenance Perform Weekly Service Items Lubricate the following areas with light weight machine oil A Lip hinge area unless equipped with grease fittings apply oil to the top of the entire length of lip hinge when platform is at the full below dock position and lip is folded D Platform hinge area apply oil to top of all platform hinges when platform is at the full below dock position E Lip assist rod NOTE Apply grease to lip hinge grease fittings if equipped Lubricate the following areas with light weight machine oil B Lip maintenance prop pivot C Lip link pivots F Lip Linkage assembly pivot G Safety leg linkage pivots Lubricate the following areas with white lithium grease if equipped with grease fittings A Lip hinge area inject grease into all the lip hinge grease fittings D Platform hinge area inject grease into all the platform hinge grease fittings E Lip assist pin 23 ADJUSTMENTS Adjusting the Latch and Lip Actuator Spring Tension WARNING When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do
28. ing Instructions on page 20 7 Check to make sure transport vehicle is positioned squarely against dock bumpers 8 Instruct driver to remain at the dock until the loading or unloading process has been completed 9 Chock the transport vehicle wheels or use vehicle restraint if present 10 Raise the platform by depressing the raise button A to fully raise the leveler and extend the lip 11 Walk out on the leveler Pull and Hold the release ring see picture below until the platform lowers onto the transport vehicle Make sure there is a minimum of 4 of lip overlapping the transport vehicle bed A RAISE Button 12 When loading or unloading is finished raise the platform by depressing and holding RAISE button A 13 Hold the RAISE button until the lip folds enough to clear the transport vehicle bed then release the RAISE button The lip will fold and the platform will return to the cross traffic position 14 Remove chocks from transport vehicle wheels or release the vehicle restraint if used 15 Indicate to driver that transport vehicle may leave the dock OPERATION Operating Instructions Continued End Loading Unloading Instructions NOTE If ramp loading is required see Ramp Loading Unloading Instructions on page 19 End loading or unloading can be done with the dock at the cross traffic position or below dock position depending on the height of the transport vehicle bed 1 Check to mak
29. ion of the equipment regardless of previous experience should be done on a regular basis and should include an understanding and familiarity with all functions of the equipment Owner s user s shall actively maintain update and retrain all operators on safe working habits and operations of the equipment The manufacturer shall provide to the initial purchaser all necessary information regarding Safety Information Operation Installation and Safety Precautions Recommended Initial and Periodic Inspections Procedures Planned Maintenance Schedule Product Specifications Troubleshooting Guide Parts Break Down Warranty Information and Manufacturers Contact Information as well as tables to identify the grade slope for all variations of length or configuration of the dock leveling device and information identifying the maximum uncontrolled drop encountered when sudden removal of support while in the working range of the equipment It is recommended that when the transportation vehicle is positioned correctly in the dock opening and in contact with both bumpers there shall be a minimum of 4 00 inches 100mm overlap of the leveling device and the transportation vehicle at all times during the loading and unloading process The Owner User must review all name plates placards decals instructions and posted warnings and place the same in view of the operator or maintenance personnel for whom such warnings are intended for Contact manufacturer for an
30. ious personal injury or death ALWAYS stand clear of dock leveler lip when working in front of the dock leveler Failure to do this may result in serious personal injury or death DANGER AW Arc Flash and Shock Hazard PPE Personal Protection Equipment Required equipment boone Working on or insice Do not Open cova withiaul appmeonaee PRE Redes to TOE WE PPE mcuiermenis This pared megy coni amp dgin Thon one Hazardous Voltage Will Cause Sewer 4111 0011 May 2015 Oct 2015 SAFETY Safety Decal s Every 90 days quarterly inspect all safety labels and tags to ensure they are on the dock leveler and are easily legible If any are missing or require replacement please call 1 800 643 5424 for replacements CRUSH HAZARD Maintenance prop must support leveler behind bar 1 751 0727 Do not force maintenance prop forward of bar to support lip Failure to comply will result in death or decal placed on serious injury Refer to owner s user s manual for front header proper uae ybi 1751 0730 x2 SAFETY INFORMATION OPERATION 7 Stay clear of hinges and front and Read and follow all instructions and sides of moving dock leveler warningsin owner sluser smanual 8 Never use damaged or Unsupported dock leveler Use of dock leveler restricted to malfunctioning dock leveler Report trained operators probl
31. k Leveler 122 ix E TR A Lifting Bracket 2 used B Shipping Bands DLM dock levelers are designed with installation in mind Each unit is shipped with lifting brackets A fastened to the platform side joists The dock leveler is heavy Use a lifting device and chains with the appropriate lifting capacity and reach Always use the lifting brackets provided with the unit whenever lowering or lifting a dock leveler into or out of a pit Failure to follow these instructions may result in damage to dock leveler and or serious personal injury or death 10 NOTICE DO NOT remove the shipping bands B around the platform lip and leveler frame at this time The shipping bands are needed to hold the leveler together during the installation process 1 Remove any control panel and bumpers that may be banded to the frame of the dock leveler DO NOT remove the shipping bands B around the platform lip and leveler frame at this time NOTICE DO NOT over tighten the lifting bracket hardware Over tightening can damage the weather seal if equipped NOTE Overall width of platform and lifting brackets A must be kept to a minimum to prevent interference between the lifting brackets and the pit walls as the dock leveler is lowered into the pit 2 Make sure the mounting hardware of lifting brackets A is snug The brackets should pivot relatively freely on the mounting cap screw DO NOT o
32. k under dock leveler unless this maintenance prop has been secured in the upright position Failure to comply will result in death or serious injury See owner s user s manual for proper procedures 1751 0729 Rev A 4 DANGER CRUSH HAZARD Rotate prop to maintenance position Open the pin latch 1 75 1 07 3 1 and insert through the maintenance prop housing Close the pin latch to secure prop Use every time dock leveler is serviced Failure to comply will result in death or serious injury 4751 0731 4 DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is 1 751 0726 safely supported by maintenance prop Place barriers on driveway and dock floor to indicate service work being performed Failure to comply will result in death or serious injury Refer to owner s user s manual for proper maintenance procedures 1761 0726 Rev A 4111 0011 May 2015 Oct 2015 5 OWNER S USER S RESPONSIBILITIES 10 The owner user should recognize the inherent dangers of the interface between the loading dock and the transportation vehicle The owner user should therefore train and instruct all operators in the safe operation and use of the loading dock equipment in accordance with manufacturer s recommendations and industry standards Effective operator training should also focus on the owner s user s company policies and operating conditions Maintaining updating and re training all operators on safe working habits and operat
33. ler binding Check for visible obstructions that could cause binding Remove obstructions If no obstructions found call Technical Services See inside back cover for phone number and address Platform does not rise to See Platform Rises Slowly See Platform Rises Slowly full height See Periodic Maintenance in the Maintenance section Platform DOES rise to Lip actuator spring needs Inspect lip actuator chain repair or replace as full height but lip DOES additional tension needed NOT extend or extend fully Lip extends but does Lip latch spring needs See Adjustment Section Lip Latch Spring not remain extended as additional tension Increase tension as needed to keep latch leveler drops engaged Clean any debris from lip latch area Lubricate as instructed in maintenance section Air bladder damaged Replace air bladder 4111 0011 May 2015 Oct 2015 29 Electrical Controls BILL OF MATERIAL 118 VT PHASE GU HZ QTY PART NUMBER DESCRIPTION FROM BRANCH CIRCUIT DISCONNECT SWITCH 7141 0207 ENCLOSED STARTER PLSTC amp OVERCURRENT DEMCE BY OTHERS 7141 0285 ENCLOSED STARTER P B METAL SELECT DISCONNECT SWITCH amp 1 1751 0504 LABEL a OVERCURRENT DEVICE PER THE NEC 1751 0474 DECAL ENGLISH LOCATE A DISCONNECT SWITCH Z DECAL FRENCH NEXT TO THE ENCLOSED STARTER 175150475 DECAL FRENCH DUAL ELEMENT TIME DELAY FUSES mri DECAL SPANISH MUST BE USED FOR BRANCH 1751 0477 _ DECAL
34. ligence 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 PRODUCT SPECIFIC WARRANTY DA SERIES LEVELER In addition to the Standard Product Warranty provided with all DLM Products guarantees materials components and workmanship to be free of defects for the following extended periods e Structural Warranty For a period of ten 10 years from the date of shipment product will carry a prorated structural warranty This warranty specifically applies to the deck section lip section frame rear hinge assembly and front hinge assembly only This warranty covers structural repairs to or replacement of dock leveler in DLM sole discretion and expense including reasonable labor materials freight and travel If DLM determines replacement is necessary it will provide the original purchaser with a credit toward the purchase of the new replacement DLM product in the amount equal to the original purchase price of the warranted product F O B point of manufacture discou
35. lip maintenance prop adjustment 6 Depress RAISE button dis engage maintenance 1 Fully raise platform and engage the maintenance prop allow platform to lower to cross traffic stored prop Manually raise the lip and engage lip position maintenance prop 7 Checklip position in both keepers Repeat procedure 2 Loosen jam nut B if necessary 3 Adjust stop bolt C as necessary Turn stop bolt in clockwise to allow lip to fold closer to platform frame A e Turn stop bolt counterclockwise to hold lip further away from platform frame A 4111 0011 May 2015 26 Oct 2015 ADJUSTMENTS OOLO ELGE 230 E Vr WNOLLOYMA 539Nv43101 ONIMOTIOS ON ONIMYS JHL HUM 3 NI JUV SNOISN3MI TIV 3385 Q4H29 lt 0 92 50 31 0 HR 9 NWYWYO WoO S 33S AIBA3SSV NV ONISdS S3880NS LSISSV IM NMOINVINH39 SW3ISAS 40 NOISIAIQ CL IX V HM Od dV NO ONIINNON NNHO 5 16 50 810 G0 V F y 5310 0300 60 07 901 W18 8 SANN OL 3lL 3901 IMG 300v 90 62 90 900 901 2 HOANI ONIMdS JHL JU 1 32 2NIRON AEN 7 NIIS 91 01 79 20 61 0 FI SENOS ST NIVAS JAN 380925 Ol QVIYHL 01 QO3l lddV 3114001 3718 3AVH 01 SANO AANO TW 4 440 LNO YO NMOHS SV NO 1437 38 NVO S 4NIl 9NINIVN3J 9 MONO JHL NIVHD ONIYdS JHL 108 350
36. ns 19 End Loading Unloading 2 20 Maintenance Service Dock Leveler 21 E 22 Adjustments Adjust Lip Latch and Lip Actuator 24 Adj st LIp StOoD used eso cti ea a Cites obese 26 onubber Spring Assembly s ways v 27 Troubleshooting Eisen 28 Parts 30 Control BOX MTS 31 AG UVLO d 32 Airbag and Support Pallet i ir a mie eee Feo e iet ns 35 Fraime PIA Or D anco tod DD 36 Below DOCK idis vnd fed 38 Weallier M 39 Motor and Blower Assembly 40 BElOW DOCK CONWOl RR 33 Miscellaneous Customer TInforrmalloli seh o eoe eee oe eae 41 VAS Ia ESI RIS T Back Cover SAFETY Recognize Safety Information General Operational Safety Precautions Safety Alert Symbol The Safety Alert Symbol identifies import safety messages on equipment safety signs in manuals or elsewhere When you see this symbol be alert to the possibility of personal injury of death Read and understand the Owner s User s manual and Follow the instructions in the safety mes
37. nted on a ten year straight line basis by the number of years of use prior to replacement Pneumatic Warranty For a period of four 4 years from the expiration of the Standard Product Warranty Systems will provide replacement component parts from defective lifting system This warranty specifically covers material and freight only and applies to the air bladder seals hoses and motor assembly
38. nts or other flammable liquid is present Stray sparks can ignite spills or leaks near the work area Always clean up the oil leaks and spills before proceeding NOTE The illustration on page 13 shows a typical with grinding or welding weld pattern The weld pattern will vary slightly depending on size of dock leveler Always keep a fire extinguisher of the proper type nearby when grinding or welding 22 Weld front of dock leveler frame B to shims Failure to follow these instructions may result in located under the keepers then weld the shims to serious personal injury or death the front pit curb steel 23 Finish weld all shims using a fillet weld NOTICE s e Weld all shims within each shim stack to each DO NOT connect the dock leveler electrical wiring other then weld the shim stack to the leveler and ground connections until all welding has been completed e Weld the front leveler frame shim stacks to the DO NOT ground welding equipment to any hydraulic i Sheen or electrical components of the dock leveler Always ground welding equipment to the dock leveler frame NEVER to the platform welds and shims 24 When all welding has been completed paint all the Failure to follow these instructions may damage the motor wiring and or control panel Shim Stacking Methods Make sure the platform is properly supported in the P raised position before entering the pit to finish weld the s
39. p DE Pipe PVC 1 1 2 SCH40 X 24 38 1 X 609 6mm 9392 0068 Pipe PVC 1 1 2 SCH40 X 24 38 1 X 609 6mm With 90Deg Elbow E 4 93910023 Clamp Tube LE a see Nut Hex Nylon Locking 1 4 2 2101 0007 Screw Cap Hex 1 4 2 X 1 LG a 2101 0005 Washer Flat 1 4 4111 0011 May 2015 40 Oct 2015 Customer Information NOTE Refer to illustration for left right orientation of dock leveler The model serial number decal A is located on the right platform joist near the front lip of dock leveler When you receive your DA Series dock leveler write down the dock leveler model and serial number in the form provided This will help ensure safe keeping of the numbers in the event the model serial number decal A becomes lost or damaged Also write down Systems Inc s job number the company that installed the dock leveler and the original owner s name This will all help to identify the specific dock leveler if more information is required When ordering use part numbers and description to help identify the item ordered Do not use item numbers These are only for locating the position of the parts Always give dock leveler MODEL NUMBER and or SERIAL NUMBER For service call or contact Systems Inc P O Box 309 Germantown WI 53022 Phone 800 643 5424 Fax 262 255 5917 E mail techservices docksystemsinc com 4111 0011 May 2015 Oct 2015 Air Bag serial numb
40. red the platform lip will need to be extended See Ramp Loading Unloading Instructions on page 19 for further instructions 10 When the loading or unloading is finished return the dock leveler platform to the cross traffic stored position 11 Depress the Raise button B until the lip clears the lip keepers Release Raise button leveler will return to the stored or cross traffic position 12 Remove chocks from transport vehicle wheels or release the vehicle restraint if used 13 Indicate to the driver that the transport vehicle may leave the dock 4111 0011 May 2015 Oct 2015 Service Dock Leveler Safely MAINTENANCE A Maintenance Prop B Tag Out Device When service under the dock leveler is required always lock all electrical disconnects in the OFF position after raising the platform and engaging the maintenance prop Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered remote two people are required to engage the maintenance prop one person to operate
41. rmed on leveler before using transport vehicle wheels must be chocked unless the vehicle restraint is used Never remove the wheel chocks until loading unloading is finished and transport vehicle driver has been given permission to leave Make sure platform lip rests on the transport 12in 805mm MEE MI 12in 805mm The DA pneumatic dock leveler is designed to compensate for a maximum 12 in 305 mm of height difference between the loading dock and the transport vehicle bed DO NOT use the dock leveler if the transport vehicle bed is more than 12 in 305 mm higher or lower than the dock floor service height may vary with design specifications DO NOT overload the dock leveler DO NOT operate any equipment while under the influence of alcohol or drugs DO NOT leave equipment or material unattended on the dock leveler Failure to follow these instructions may result in personal injury and or damage to equipment The dock leveler operating instructions are divided vehicle bed with at least 4 in 102 mm of overlap i into the two methods of loading and unloading Maintain a safe distance from side edges of leveler during the loading unloading process For ramp loading and unloading see Ramp Loading Unloading Instructions on page 19 Failure to follow these instructions may result in serious personal injury or death For end loading and unloading see End Loading Unloading Instructions on p
42. rricade the work area at dock level and ground level to prevent unauthorized use of the unit before maintenance is complete Lf jJ e 4 maintenance prop permanently attached and hinged to the unit with means for lock out tag out requirements per OSHA 1910 147 is included with each pit style dock leveler In addition it is recommended and good safety practice to use an additional means to support the dock platform and lip anytime when physically working in front of or under the dock leveler This additional means may include but not limited to a boom truck fork truck stabilizing bar or equivalent ALWAYS disconnect electrical power source and ground wire before welding on dock leveler DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler Always ground to the dock leveler frame Failure to follow these instructions may result in damage to dock leveler and or serious personal injury or death DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present Stray sparks can ignite spills or leaks near the work area Always clean up the oil leaks and spills before proceeding with grinding or welding Always keep a fire extinguisher of the proper type nearby when grinding or welding Failure to follow these instructions may result in ser
43. s obtained Adjust spring tension as follows 1 Loosen jam nut B To increase spring tension turn nut B clockwise 3 To decrease spring tension turn nut B counterclockwise 4 Tighten jam nut Recheck operation of platform and lip Readjust lift spring tension and lip assist spring tension until proper operation is obtained 25 ADJUSTMENTS Adjust Lip Stop Bolt Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death A Always stand clear of the dock leveler lip when working in front of the dock leveler Failure to do this may result in serious personal injury or death The platform maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop A Platform Frame D Lip Keeper Failure to follow these instructions may result in B Jam Nut E Lip serious personal injury or death C Stop Bolt Check that lip E is fully resting on the lip keepers 4 Tighten jam nut D and at the lowest part of the keeper cradle If lip is not resting properly in keepers perform the following 5 Disengage
44. s designed to hold the lip in the extended position until the platform drifts down to the below dock position If the lip does not remain extended check proper engagement of the lip latch NOTE Use two turn increments when adjusting lip assist spring Check lip operation after each adjustment Repeat until proper operation is obtained Adjust spring tension as follows 1 Loosen jam nut A 2 To increase spring tension turn nut A clockwise 3 To decrease spring tension turn nut A counterclockwise 4 Tighten jam nut Hecheck operation of platform and lip Readjust lip latch spring tension and lip assist spring tension until proper operation is obtained 4111 0011 May 2015 Oct 2015 ADJUSTMENTS Adjusting Lip Actuator Spring Tension This adjustment is set at the factory and should not require additional adjustment Unlike mechanical levelers the lip will not immediately begin to fold as the platform returns to the stored position The DA leveler lip remains extended as the platform drifts down to the below dock position The lip will automatically fold when the platform when the dock is resting on the safety legs in the below dock position 1 Check air bag and hoses for possible leaks 2 If the lip does not fully extend additional spring tension may be needed NOTE Use two turn increments when adjusting lip assist spring Check lip operation after each adjustment Repeat until proper operation i
45. sage become thoroughly familiar with the equipment and its controls before operating the dock leveler Never operate a dock leveler while a safety device or DAN G R guard is removed or disconnected 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 Never remove DANGER WARNING or CAUTION signs or Decal s on the equipment unless replacing The use of the word WARNING signifies the presence of a serious hazard or unsafe practice which may result in serious injury or death The use of the word CAUTION signifies possible hazard or unsafe practice which could result in personal injury N O oF Do not start the equipment until all unauthorized personnel in the area have been warned and have The use of the word NOTICE is to draw attention moved outside the operating zone to a procedure that needs to be followed to prevent machine damage Remove tools 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 INSTRUCTIONS Indicates a type of safety sign or separate panel on a safety sign where safety related instructions or procedures as described 4111 0011 May 2015 Oct 2015 1 SAFETY Operational Safety Precautions Learn the safe way to operate this equipment Read and understand t
46. t across the pit opening directly over the shim locations 3 Verify that each shim stack is at the correct height by measuring distance K top of shim stack L to dock floor Distance K must equal the dock leveler height A 12 4 For all DA models put a 1 4 in 6 6 mm thick shim at locations D NOTE A 1 4 in 6 6 mm thick shim at locations D is used only as a starting point The final shim stack height will be determined after dock leveler is lowered into the pit The dock leveler is heavy Use chains and a lifting device with the appropriate lifting capacity and reach Failure to do so may result in damage to dock leveler and or serious personal injury or death 5 Using an appropriate lifting device connected to the lifting brackets lower dock leveler into the pit so rear hinge frame angle H is tight against rear pit curb angle F across full width of the leveler frame 6 Allow rear of dock leveler to rest on the rear shims while keeping the front of the dock leveler level with the dock floor 7 Forall DA models add shims at front shim locations D so front of dock leveler will stay level with dock floor when leveler is resting fully on shims 4111 0011 May 2015 Oct 2015 JAMES P INSTALLATION SSSSS 7 YK 2 gt AZ 74 7 RAS RAN TRAN RA RANA 72 STR NA RIAN GAR RES RY ARES AGREED PRA WA 2 eis A G
47. the platform Check for binding as platform is being raised If binding occurs lower the platform Reposition leveler and or add or remove shims as necessary Slowly raise platform again If platform still binds contact Technical Services for further instructions All DA models Once leveler is flush square and does not bind a Install shims under maintenance prop C where prop attaches to leveler frame Make sure prop is solidly shimmed b Using the levelers blower motor raise the dock to the fully open position c Raise maintenance prop to the service upright position and lock prop in this position using an OSHA approved locking device Disconnect power supply from motor Remove air bag and pallet support from the leveler by disconnecting air bag positioning rods from 1 figure 1 figure 2 14 Two people are required to engage the maintenance prop one person to operate the lifting device the other person to engage the maintenance prop DO NOT use the maintenance prop to support the raised platform until the maintenance prop has been properly shimmed and welded The shims must be welded to each other the leveler frame and to the front pit curb steel Failure to do this may result in serious personal injury or death 19 20 21 hooks on the underside of platform figure 1 and removing the band clamp from the motor coupler figure 2 Remove or prote
48. this may result in serious personal injury or death WARNING Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death WARNING Always stand clear of the dock leveler lip when working in front of the dock leveler The maintenance prop and lip maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Unless the dock leveler is equipped with a tethered A Lip Latch Spring B Lip Actuator Spring remote two people are required to engage the Adjustment Adjustment maintenance prop one person to operate the unit the other person to engage the maintenance prop C Lip Linkage Assembly Failure to follow these instructions may result in serious personal injury or death 4111 0011 May 2015 24 Oct 2015 Adjusting Lip Latch Spring Tension This adjustment is set at the factory and should not require additional adjustment Unlike mechanical levelers the lip will not immediately begin to fold as the platform returns to the stored position After the platform is fully raised and the lip extends the lip latch i
49. ton The leveler will lower Always store dock leveler and remove people material and to the below dock position provided the equipment from ramp before vehicle leaves the dock lip extension allows the lip to clear the lip DO NOT ENTER PIT unless dock leveler is securely supported by keepers the maintenance prop AIR POWERED ONLY Depress and hold the RAISE button until the leveler is 12 Disconnect power and follow proper lockout tagout procedures for above dock level Pull the below dock level the dock leveler before entering the dock leveler pit or doing any chain until the leveler passes the below repair or inspection under the dock leveler dock position FAILURE TO FOLLOW THESE INSTRUCTIONS COULD HYDRAULIC WITH INFINITE LIP RESULT IN DEATH OR OTHER SERIOUS INJURY CONTROL If equipped raise the platform by depressing and holding the RAISE rs Scan to view our owner s user s 7v button When the lip is just above the lip AT manuals online DLM keepers simultaneously depress and www DockSystemsinc com hold the RAISE button and the LIP OUT A 1 800 643 5424 Loading Dock Equipment button until lip has extended beyond the lip Call for additional placards or manuals or with questions keepers Release both buttons regarding proper use maintenance and repair of dock leveler 4754 0874 Rev a NOTE If equipped depressing E STOP button will stop platform from lowering ile Quantity Part Number Description 714
50. uded with each order or by contacting Technical Services Once again thank you and congratulations on your purchase of a DLM DA dock leveler 4111 0011 May 2015 Oct 2015 INTRODUCTION Dock Leveler Stock Specifications DA Series dock levelers are available in the following sizes weight capacities and options Width DA 6 ft 1828 8 mm 6 1 2 ft 1981 2 mm 7 ft 2133 6 mm Length 6 ft 1828 8 mm 8 ft 2438 mm 10 ft 8048 mm Capacity CIR 25 000 Ib 11 340 kg 30 000 Ib 13 608 kg 35 000 Ib 15 876 kg 40 000 Ib 18 144 kg 45 000 Ib 20 412 kg 50 000 Ib 22 680 kg 7 r ee eee CIR Comparative Industry Rating All docks are available in 115V motors only INTRODUCTION Component Identification A Lip B Below Dock Control F Lip Snubber Spring C Lip Linkage Assembly G Lip Actuator Chain D Lip Latch Assembly H Lip Actuator Chain Adjustment Link THEORY The DA dock leveler uses a blower motor and one button operation for ease of use The dock leveler can be operated remotely using the RAISE button P on the control panel This activates an electric blower motor N The blower forces air into the air bag K causing the platform to rise Releasing the RAISE button allows the platform to lower When the platform rises to the point where there is 2 3 in 51 76 mm from its full raised height the lip spring F and lip actuator chain G causes the lip
51. ver tighten 3 Attach lifting chains to lifting brackets A and toa lifting device i e hoist or fork transport having the appropriate lifting capacity and reach 4 Remove wood blocks that are attached to the leveler frame before putting the dock leveler into the pit 5 Attach a temporary switched power supply to the blower before lowing leveler into pit Keep power cables clear of frame members shim locations and pinch points DO NOT CONNECT POWER AT THIS TIME 6 Remove 3 plastic ties that hold the bag and bag support skid to the underside of the leveler during shipping before lowering leveler into pit 4111 0011 May 2015 Oct 2015 INSTALLATION Shim Install Dock Leveler Stacking Methods 0 E LA qx A 4 Ww CDS EI EB D A Distance Leveler Frame K Distance Top of Shim Height Stack to Dock Floor B Shim Locations Under L Shim Stack Rear Vertical Supports M Dock Leveler Frame C Shim Location Under N Pyramid Preferred Lip Keepers P Stepped Acceptable D Shim Location Q Offset Not Acceptable Maintenance Prop R Straight Not Acceptable E Dock Floor S Removable Frame Section F Rear Pit Curb Angle T Shim Location Under G String Snubber Spring H Rear Hinge Frame Angle U Lip Keeper Shim between J Distance Dock Floor to lip keeper and curb angle Pit Floor as required 4111 0011 Ma
52. y 2015 Oct 2015 11 INSTALLATION NOTE DLM dock levelers are designed with a nominal 1 2 in 12 7 mm shimming distance to allow for pit inconsistencies 1 Determine height of shim stack L for each shim location B by performing the following a Measure leveler frame height distance A b Measure dock floor to pit floor distance J at each shim location B Write down the dimensions obtained at each location c Subtract distance A from distance J to obtain the shim height Repeat for each shim location NOTICE The minimum size of the shim that contacts the leveler frame i e the top shim of each shim stack must be at least 4 1 2 x 4 1 2 in 114 3 x 114 3 mm to support the full width of the hoist cylinder storage prop weldment Use the thickest shim stock possible for stability and weld penetration purposes DO NOT use multiple layers of 1 8 in 3 18 mm or thinner shim stock 2 Using the results obtained in step 1 create the individual shim stacks on the pit floor at locations B Build each shim stack L using the pyramid method N preferred or stepped method P with the top shim having a minimum size of 4 1 2 x 4 1 2 in 114 3 x 114 3 mm and each successive lower shim being larger so the shims can be welded together using a fillet weld DO NOT use offset method or straight method NOTE Toassistin obtaining an accurate measurement of distance K use a string G pulled tigh
53. y replacements Manufacturer s recommended periodic maintenance and inspection procedures in effect at the date of shipment shall be followed at all times Written documentation of maintenance replacement parts or damage should be retained In the event of damage notification to the manufacturer is required Loading dock equipment that has been structurally damaged or has experienced a sudden loss of main support while under load such as what might occur when a transport vehicle pulls out from under the leveling device shall be removed from service inspected by a manufacturer s authorized representative and repaired or replaced as needed before being placed back in service Any modifications or alterations of loading dock equipment shall only be done with prior written approval from the manufacturer and the same shall be at least as safe as the original equipment was prior to the modification and shall also satisfy all safety requirements of the manufacturer for the particular application of the leveling device When industrial moving devices are being used in the loading or unloading of product from the transportation vehicle this vehicle shall have the brakes and wheel chocks applied appropriately or all other positive restraining device shall be fully utilized It is recommended that transport vehicles with air ride suspension systems shall have its air exhausted prior to performing loading and unloading operation to minimize transport vehicl

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