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User`s Manual - Curlin, Inc.

1. INPUT SIGNALS OUTPUT SIGNALS YG 6 VV 0 5 0 Loading Lamp interlock 1 Spare 1 Pilot lam ower amp fault eon qu O 1 2 3 4 5 6 7 8 9 10111213 2 Raise 2 Inside 3 Lip Extend 3 VSL fault Jelemeganique 4 Lip Retract 4 5 1 5 Lower 5 SV2 6 STOP 6 SV4 7 Overload tripped 7 Motor contactor 8 Leveler stored 8 Audible alarm 9 Leveler in float 9 Door interlock lt 10 Restraint engaged 11 Door opened 12 Spare 13 Spare LEGEND PB1 RAISE PB2 EXTEND PB3 RETRACT EN 00 1 2 5 6 7 ow 8 9 PB4 LOWER 5 5 00 QOO QO0O0OQ0 00 Q0 Q0 00 Q0 Oo L 00000 CA DNS ass INTESLOCK gt m mou oi ALARMI AUX 7 8 1 8 4 17 B TN VSL 51 INTERLOCK GUTEUTS front A BJCIDJE F G H J K L M N O P Q R BACKPLATE TERMINALS 24V RED BLK 6768 5 ji STARTER RED WHT BLU PNK Es MUR WHT BLK BLU YEL POWER STOP OVERLOAD 111 ks WHT TEL PB5 OL1 ons BRN WHT 0 BLU GRN 112 gt JHHT GRN BLU RED HEN 36
2. a 5L3 6 TEE SEE ATOR SEE TABLE FOR FUSE SIZES F2 H3 60080240 F 1171 1172 208V PRI o 200VA 120 24 SECT x xi x2 H1oH2o 0H4Q H5 600 480 240 208 PR SM 18 gt SEC y Z00VA NOTE X1 TRANFORMER SHOWN IN 240V PRIMARY CONFIGURATION SEE TRANSFORMER DETAIL FOR ALTERNATE CONFIGURATIONS 1201 A 3231 X2 X Power to control box must from fused disconnect supplied 24VAC 24V NEU AMEN TE by others Fuse size can be no 5261 3251 greater than the size shown in 120VAC 120V NEU the above schematic or chart from 323 from 323 3231 3232 for dual element time delay DETD fuses All electrical work must be done by qualified technician and must meet all applicable codes All devices MOTOR DETAIL shown in deenergized state 208 230 SINGLE PHASE 50 60HZ WIRE LEGEND J li re PE PANEL WIRING 2 FIELD WIRING BY OTHERS NOTE PC BOARD TRACES 5 2 TERMINALS WILL ACCEPT STRANDED gt WH WIRE ONLY 8 WIRE COLOR GAUGE NFPA unless otherwise specified NOTE VISUALLY CONFIRM MOTOR TAG BLK 24 16 RED BLK NEUTRAL 16 WHT GROUND GRN SINGLE PHASE PANEL REFERENCE 24VDC 18 BLU VOLTAGE BCPD FUSE F2 MOTOR FLA PANEL FLA O L SETTING SERCO P N KELLEY P N Mee fe Le BLU WHT 208 15A 5A 8 8A 10 5A 8 6003327V2 6003328V2 12V COM 18 VIO WHT 240 12A 4 5 8 0A 8 83A 8 0A 6003327V3 6003328V3 DRY UNPOWERED 18 YLW
3. USE CLASS CC TIME DELAY FUSES 34 6001762N Vertical Hydraulic Dock Leveler 2013 4Front Entrematic April 2013 ELECTRICAL SCHEMATIC 208 575 60HZ Fig 26 208 575V 3PH 60HZ NOTE SUPPLY DISCONNECT MEANS CB FU TO BE SUPPLIED BY OTHERS SUPPLY BCPD CB FU SEE TABLE RE RANT PANEL FLA SEE TABLE CONTACTOR tre T ERR PES 14AWG BLK L2 MOT204 EE ES 2041 V FX O neat H ETE MOTOR AE BUC FLA SEE TABLE L3 2042 vet JT 3450 RPM PS RS de EI TEILTE IN 5L3 HO eve rs TRANSFORMER DETAIL ATOR SEE TABLE FOR FUSE SIZES F2 3 2061 2062 H3 H18H20 oH44H5 GROUP 4F LLU H19H2 iu UM 600 480 240 208 P vans PA SEC c 200VA N 2091 X3 x1 3231 2 2 0 24 120 2101 9 24V NEU TRANFORMER SHOWN IN 480V PRIMARY CONFIGURATION from 325 SEE TRANSFORMER DETAIL FOR ALTERNATE CONFIGURATIONS 24VAC 3251 from 326 3261 E NEY 120VAC 3232 from 323 3231 Power to control box must be from fused disconnect supplied by others Fuse size can be no MOTOR greater than the size shown in the above schematic or chart 600V THREE PHASE 60HZ 380 480V THREE PHASE 50 60HZ 200 24
4. 802999 5 3 em NEEDLE VALVE ASSEMBLY NV1 6012012 EA Eur 1 1 1 1 1 1 1 1 1 1 1 1 1 1 April 2013 6001762N Vertical Hydraulic Dock Leveler 49 2013 4Front Entrematic PARTS LIST DECK MOUNT POWER UNIT Fig 37 a CE 50 6001762N Vertical Hydraulic Dock Leveler April 2013 2013 4Front Entrematic PARTS LIST DECK MOUNT POWER UNIT 1 1 POWER UNIT VSL DM 120 220V 1 50 60 BHGR 6012949 POWER UNIT VSL DM 240 480V 3 50 60 BHGR 6012950 POWER UNIT VSL DM 575V 3 50 60 BHGR 6012951 FTG 45 PIPE ELBOW 3 4 CD45 6013449 FTG PIPE NIPPLE 3 4 NPT X 4 LG STEEL 6012997 FTG PIPE COUPLING 3 4 NPT STEEL 6012998 FTG STR THD CONN 8 37 FLARE M X 6 SAE OR M STL 6006640 FTG STR THD CONN 6 37 FLARE MALE X 6 SAE OR M STL 6000717 DIPSTICK ASSEMBLY 6012934 POWER CABLE SO 14 4 X 60 LG 172603 POWER CABLE SO 14 3X 60 LG 172607 1 STRAIN RELIEF CONNECTOR 90 DEG 1 2 IN 5 8 CBL 145084 1 VOLTAGE LABEL EXT ON PUMP 120 VOLT 921051 VOLTAGE LABEL EXT ON PUMP 240 VOLT 921052 VOLTAGE LABEL EXT ON PUMP 480 VOLT 921053 VOLTAGE LABEL EXT ON PUMP 575 VOLT 921054 PHASE LABEL EXT ON PUMP SINGLE PHASE 921026 PHASE LABEL EXT ON PUMP THREE PHASE 921027 SOLE
5. 012 34 56 7 8 910 1112 13 012 34 56 7 8 910 1112 13 ej jeje inputs jejejej inputs eje jeje jejejej jourruts ele fel 0 1234 56 7 8 9 0 1234 56 7 8 9 Paani Leveler between float and stored Raise button pressed Alarm condition LS1 and LS2 both on or overload tripped No buttons pressed 28 6001762N Vertical Hydraulic Dock Leveler April 2013 2013 4Front Entrematic DIAG N OSTICS continued Fig 19 VSL Input Board Leveler Float Restraint Stored Engaged 21 24 bi p a BOARD 6003321 LED TURNS OFF WHEN INPUT FUSE 15 BLOWN Input power Field terminal Input power supply energized LED 5 position supply fuse 1 4 amp Output Interlock suppl fuse Alarm Heater fuse 2A 8A socket socket Field terminal Fuse and light 7 position Mg sem LED s SV1 SVve SV4 LIGHTS F4 ar LABEL 6003324C BOARD 6003322 ON OFF WHEN INTERLOCK SOLENODS FUSES AREPOWERED ARE BLOWN T 4 17 4 sk al P VSL OUTPUTS VSL Output Board Diagnostic LED s SV1 On when power is being sent to output solenoid 1 SV2 On when power is being sent to solenoid 2 SV4 On when power is being sent to solenoid 4 Lights Off when power supplying the lights is not present F4 Off when power supplying all the solenoids and control circuit is off or
6. 32 Electrical Schematics 33 Main Cylinder Adjustment 39 Parts Elster etate eren i decisa ena 40 Warranty ose ce P eode e ut ace 57 Distributor Information 58 INTRODUCTION VSL remote mount assembly Welcome and thank you for choosing a VSL dock leveler VSL deck mount assembly This user s manual contains information that you need to safely install operate and maintain the VSL model dock leveler It also contains a complete product description and operating instructions for the VSL remote mounted and VSL deck mounted designs Product service guides parts list and information about ordering replacement parts is available in this manual Please read this user s manual before using your new dock leveler and keep a copy for future reference 2 6001762N Vertical Hydraulic Dock Leveler 2013 4Front Entrematic April 2013 SAFETY SIGNAL WORDS You may find safety signal words such as DANGER WARNING CAUTION or NOTICE throughout this user 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 possi
7. 9 Door interlock 12 Spare 13 Spare See interlocks on page 11 INPUTS OUTPUTS PWR RUN ERR STAT The charts below show all of the valid conditions for the PLC Unit 012 34 56 7 8 910 1112 13 012 34 56 7 8 910 1112 13 TT TT ej inputs jejej fol ejej jejo ele f le fo jejej o curruts 2 0 1234 56 7 8 9 2 60112 3141516 7 8 9 2 aan Leveler stored No pushbuttons pressed LEVELER STOP Leveler stored Lower button pressed pulled out April 2013 6001762N Vertical Hydraulic Dock Leveler 27 2013 4Front Entrematic D IAG NOSTICS continued Leveler in float range Lower button pressed Leveler stored Lip Retract button pressed 012 34 56 7 8 910 1112 13 012 34 56 7 8 910 1112 13 TI TT ef jejeje fel Jej jeje inputs ejej jejeje fel jourrurs ele Tele ejej ejourvrs 0 1234 56 7 8 9 0 1234 56 7 8 9 aan aa Leveler in float range No buttons pressed Leveler stored Lip Extend button pressed Leveler in float range Raise button pressed Leveler between float and stored No pushbuttons pressed
8. STOP button The Amber power light should be on Press and hold the RAISE pushbutton for only 5 seconds while looking into the hydraulic reservoir fill hole If the motor is turning in the correct direction you will immediately see the fluid level drop If after 5 seconds you see no drop in fluid level stop the pump and switch wires to reverse the rotation See troubleshooting guide and electrical schematics in this manual to correct Press and hold the RAISE pushbutton The main cylinder will begin to extend in an abrupt motion Hold the cylinder away from the leveler while extending so that it will extend freely The cylinder rod or adjusting end may be damaged by contact with the deck while extending If the sound of the pump changes before the cylinder reaches its full stroke 16 stop the pump and add 8 ounces of hydraulic fluid see page 13 under Components and Specifications for hydraulic fluid specifications Continue to run the pump until the main cylinder is fully extended Add more fluid if required Press the LOWER button and hold until the main cylinder is fully retracted This will eliminate excess air from the main cylinder Then press the LIP RETRACT button and hold until the lip is fully retracted Then press the LIP EXTEND button and hold until the lip is fully extended Then press the LIP RETRACT button again and hold until the lip is fully retracted This will eliminate air from the lip cylinder Run both cylinders in
9. between a loading dock and freight carrier to allow safe efficient freight transfers The 4Front Entrematic vertical dock leveler uses pushbutton controls to position the ramp Pressing and holding the LOWER button operates a hydraulic pump and retracts a hydraulic cylinder to lower the ramp When the ramp is lowered to the working range it floats down to rest on the bed of a trailer forming a bridge After loading pressing and holding the RAISE button extends the hydraulic cylinder to raise the ramp to the stored position When the dock leveler reaches its full raised position a second hydraulic cylinder extends the dock leveler lip Push the LEVELER STOP when the leveler is stored to prevent operation With the dock leveler in its fully stored position a maintenance strut may be secured with a lock out pin to prevent inadvertent operation April 2013 6001762N Vertical Hydraulic Dock Leveler 15 2013 4Front Entrematic OPERATING INSTRU CTIONS continued Safety First 1 Always secure the truck with a vehicle restraint or wheel chocks and set brakes before operating the dock leveler 2 Do not operate dock leveler with anyone standing on or in front of it 3 Always keep hands and feet clear of all moving parts 4 Always restore the leveler to its safe stored vertical position with the lip extended and the LEVELER STOP button pressed after servicing truck 5 Press LEVELER STOP button to stop leveler and lip
10. breakdown premature wear death or serious injury Fig 32 REMOTE MOUNTED UNITS 5 Foot and 6 Foot Leveler Torque nut Item 24 to 200 250 8 Foot Leveler 40 6001762N Vertical Hydraulic Dock Leveler April 2013 2013 4Front Entrematic PARTS LIST DOCK LEVELER continued Fig 33 DECK MOUNTED UNITS iii FAM 2013 4Front Entrematic April 2013 6001762N Vertical Hydraulic Dock Leveler 41 PARTS LIST DOCK LEVELER continued seede 5 PNREAHNGERYDOYL 8958 2 2 2 USER HAZARD LABEL 6000847 LOCK OUT TAG 6000873 1 10 1 Eom ENT 2 30 PLATED WASHER 2493 _ 1 DANGER WARNING LABEL 1 samo 1 J PinetevisuPperevsL pe _ 1
11. 17 2 BA ALARMI ES did K vet OUTPUTS DOOR INTERLOCK a Restraint Engaged L E amp Leveler Stored X e LEGEND E EA BLUE SV1 POWER DOWN SOLENOID BROWN 1 2 WHITE SV2 MAIN SOLENOID EET du ees E SV4 LIP SOLENOID SV4 ind 5 GREY 1 BROWN SV2 BLUE 4 BLACK SV4 5 GREY 38 6001762N Vertical Hydraulic Dock Leveler April 2013 2013 4Front Entrematic MAIN CYLINDER ADJUSTMENT Before servicing the dock leveler read and follow the Safety Practices on page 3 and the Operation section in this manual Be certain before doing any maintenance or repair on the dock leveler that 1 THE LEVELER IS STORED IN A VERTICAL POSITION WITH THE LIP EXTENDED AND THE LOCK OUT PIN INSERTED THROUGH THE MAINTENANCE STRUT AND BRACKET ON DECK and 2 The power is disconnected and properly tagged or locked out Failure to do so could result in death or serious injury 1 This requires a 1 1 2 and 2 open end wrenches Loosen the jam nut on the threaded rod end of the main cylinder 2 Using the 2 wrench to hold the chrome cylinder rod tighten the jam nut using the 1 1 2 wrench Turn the chrome cylinder rod counter clockwise to push the leveler back or clockwise to pull the leveler forward until the lockout pin in the maintenance strut move freely See Fig 31 NOTE See Page 18 for maintenance strut operation A WARNING There must not be more
12. 6001762N Vertical Hydraulic Dock Leveler April 2013 2013 4Front Entrematic ELECTRICAL SCHEMATIC REMOTE MOUNT FIELD WIRING Fig 28 RESTRAINT ENGAGED DOOR_ OPENED PHOTOEYE OT CONNECTED 0 BRN WHT 4 24VDC WIRE BOND 625 208 POSITION DIP 4 OFF IF USED 1 AUXILIARY CONTACT Q FROM RESTRAINT PANEL LEVELER STOREDSWITCHLS1 me T ront cic ww 94 VSL 25 INPUTS 9 www 4FrontES com ml AL INPUT MODULE PLUGS 38 LED Turns POWER NOT SHOWN INPUT OFF WHEN FUSE INPUT FUSE o a n n n a n MDL 0 25 IS BLOWN INPUT SIGNALS OUTPUT SIGNALS 0 Spare Loading Lamp interlock 1 5 1 Pilot lam ower amp fault om qu O 1 2 3 4 5 6 7 8 910111213 2 Roise 2 Inside 5 Lip Extend 5 VSL fault Telemecanique 4 Lip Retract 4 SV1 5 Lower 5 SV2 6 STOP 6 SV4 7 Overload tripped 7 Motor contactor 1 8 Leveler stored 8 Audible a
13. 8FT levelers ra RER April 2013 6001762N Vertical Hydraulic Dock Leveler 47 2013 4Front Entrematic PARTS LIST REMOTE MOUNT POWER UNIT Fig 36 48 6001762N Vertical Hydraulic Dock Leveler 2013 4Front Entrematic April 2013 PARTS LIST REMOTE MOUNT POWER UNIT continued Primes HYDRAULIC POWER ASSY VSL 120 220V 1 50 60 6012602 HYDRAULIC POWER ASSY VSL 208 480V 3 50 60 6012603 HYDRAULIC POWER ASSY VSL 575V 3 60 6012604 2 2 eJCSWNEL END 1 ASSY encens 8 JIC SWNEL END FTE _ 4 BSRACKETWONTPUMPWALLMOUNT BHOR _ 1 FesmrmpconnsJcmXesarorsmsn 1 FIG BOW3OSWVELNUTSJCMXSIGFST som 1 FIG STR THD CONN BJIGMXG SAE OREM ST 1 FTG ING STRTHO CONN _ ail 2 5 16 18UNC 1 LG ROUND HEAD CARRIAGE BOLT ZP 120 VOLT LABEL EXT ON PUMP 921 051 208 VOLT LABEL EXT ON PUMP 921 050 240 VOLT LABEL EXT ON PUMP 921 052 480 VOLT LABEL EXT ON PUMP 921 053 575 VOLT LABEL EXT ON PUMP 921 054 14 p SINGLE PHASE LABEL EXT ON PUMP THREE PHASE LABEL EXT ON PUMP 921 027 3 VAMENOZWYPOPPETSOLYNVE SE 1 WAIVE PRESS SEQ DRECTACTCARTRDGE comes _ WAIVE NEEDLE CARTRIDGE ADJ SAETHRD FNV eones 3
14. F4 fuse is blown Input Power LED off when PLC input power supply fuse 0 25A is blown NOTE There is no LED indicator for the 2A interlock fuse April 2013 6001762N Vertical Hydraulic Dock Leveler 29 2013 4Front Entrematic HYDRAULIC POWER UNIT ADJUSTMENT Fig 20 SV4 lip solenoid valve REMOTE MOUNTED UNITS RV1 primary relief valve adjust maximum system pressure FNV float needle SQ sequence valve adjust lip activation timing C2 Lip cylinder extend hose C1 Main cylinder extend hose C3 Cylinder retract common hose de man NV1 Power down needle solenoid vave valve adjust lowering speed A SV1 power down solenoid valve Fig 21 am SV1 power down DECK MOUNTED UNITS solenoid valve SQ sequence valve adjust lip activation timing SV2 main solenoid valve A SV4 lip solenoid valve RV1 primary relief valve FNV NV1 Power down adjust maximum float needle needle valve adjust system pressure valve lowering speed 30 6001762N Vertical Hydraulic Dock Leveler April 2013 2013 4Front Entrematic HYDRAULIC POWER UNIT ADJUSTMENT continue ADANGER Fig 22 Do not perform any maintenance or repair in the area in front of or under the leveler unless the leveler is fully raised and lip extended lock out pin is inserted through the maintenance strut and
15. HOSE ASSY 1 2 X 72 8FT LEVELER 6000724 STREET ELBOW 1 2 NPT X 8J1C VELOCITY FUSE 10 GPM HOSE ASSY 1 2 ID X 24 100R2 DUAL HOSE CLAMP 1 2 HOSE 6000837 HHMS 1 4 20UNC X 1 ZINC 212 005 April 2013 6001762N Vertical Hydraulic Dock Leveler 45 2013 4Front Entrematic PARTS LIST DECK MOUNT HYDRAULIC Fig 35 46 6001762N Vertical Hydraulic Dock Leveler 2013 4Front Entrematic April 2013 PARTS LIST DECK MOUNT HYDRAULIC 1 MANCYLSSXTESTKDBLACTON 9 LIP CYL 2 5 X 6 ST DBL ACTION CE HOSE ASSY 1 4 ID X 19 LOA 6 EL90 JIC FS X 6 STR FS 6003818 2 HOSE ASSY 1 4 ID X 45 LOA 6 STR FS X 6 STR FS 5FT LEVELER HOSE ASSY 1 4 ID X 57 5 6 STR FS X 6 STR FS 6FT LEVELER HOSE ASSY 1 4 ID X 75 5 6 STR FS X 6 STR FS LEVELER 1 1 1 VELOCITY FUSE 10GPM 313239 HOME RUN CABLE QD 5 LEADS 6010347 CORD SET QD SLP SV1 SV4 6010346 8 32 X 7 8 LG PAN HEAD MACHINE SCREW 6011671 1 ES 1 EC _ 718 ID CLAMP TUBE INSULATED 1 2 ID 6006656 2 2 LN 10 24 2 6001878 2 2 SPIRAL WRAP 3 8 ID 2 HEX NUT 1 8 UNC FINISHED AND 6FT LEVELER ONLY CYLINDER END VSLW 5FT AND 6FT LEVELER ONLY PIN 1 X 3 1 2 LG TAPER DRILLED AND 6FT LEVELER ONLY 5 16 18 X 3 4 LG ROUND HEAD CARRIAGE BOLT PW 1 BOLT SIZE 1 1 16 HOLE 33 VSL PIN ANTI ROTATE WDMT 5 AND 6 UNITS ONLY Quantity 3 on
16. S gal 8 9 lit level measured by visual inspection Hydraulic Fluid Acceptable Hydraulic fluids U L approved Pilot Light LED Solenoid Valves 24VAC Shell Tellus T 15 Motor NEMA Standard T E N V 48YZ frame Mobil Aero HFA 49011 Exxon Univis Grade J13 Texaco Aircraft Oil 1554 1HP 15 duty cycle single or three phase U S Oil Co Inc ZFI 5606 Low Temp Pump Fixed displacement gear pump 1 primary relief valve factory set at 2000 PSI 13 2013 4Front Entrematic April 2013 6001762N Vertical Hydraulic Dock Leveler HYDRAULIC SYSTEM OPERATION The following describes the operation of the hydraulic and electrical system when the controls are activated AUDIBLE ALARM Sounds when leveler stops between float and fully stored position Will silence when RAISE LOWER or LEVELER STOP is pressed LEVELER STOP Push in Control circuit disabled Amber pilot light turns off Solenoid valves SV2 deenergizes preventing leveler movement Pull out Control circuit enabled Amber pilot light turns on Main solenoid valve SV2 remains deenergized except when RAISE is pressed when pump is running or leveler is lowered to working range LOWER PUSHBUTTON Pump starts Power down solenoid valve SV1 opens to retract main cylinder When leveler lowers to working range the pump stops the power down solenoid valve SV1 closes and Main solenoid valve SV2 is open
17. bracket on deck the Leveler Stop button is pressed and barriers are in place NOTICE Before making any adjustments to the power unit always install a hydraulic pressure gauge 3000 psi liquid filled in line on the C1 port TOOLS REQUIRED e Pressure gauge 3000 psi liquid filled e 3 16 hex wrench e 7 16 open end wrench e 9 16 open end wrench Description Purpose Primary relief Controls maximum valve RV1 pressure in the hydraulic system and protects the other components from excessive force Float needle Controls the lowering valve FNV speed of the leveler in the float range when the green light is on Sequence valve Controls lip plate retraction and extension Power down Controls the lowering needle valve speed of the leveler while NV1 under power Test gauge 3 000 psi C1 port Adjustment Loosen the lock nut Turn screw clockwise to increase relief pressure Relief pressure is factory set at 2 000 PSI and should not require adjustment Do not adjust without a pressure gauge or pump may be damaged Reference TSB2009 0722G equipment requirements Loosen jamb nut with 7 16 wrench Turn the knob clockwise to decrease lowering speed The speed of the deck while lowering in the float range should be equal to or slower than the speed in the powered range Loosen locknut turn set screw CW inward to increase pressure CCW outward to reduce pressure If the lip extends before the deck is
18. caused by improper installation abuse 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 4FRONT 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 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 AWARRANTY OF MERCHANTABILITY OR OF FITNESS FORA PARTICULAR PURPOSE ALL OF WHICH 4FRONT HEREBY DISCLAIMS April 2013 6001762N Vertical Hydraulic Dock Leveler 57 2013 4Front Entrematic Please direct questions about your dock leveler to your local distr
19. from moving A DANGER DO NOT walk in front of dock leveler until you Restore the leveler to its safe stored vertical position with lip extended Press LEVELER STOP button to stop the leveler from moving Failure to do so could result in death or serious injury NORMAL OPERATION 1 To lower the dock leveler pull the LEVELER STOP button on control panel to switch on power Amber light indicates power on Press and hold LOWER button The pump will start and the leveler will start to lower Release the LOWER button when the Green light on the control panel turns on Green light on leveler control panel indicates leveler has reached operating range The leveler will float down to the truck bed See Fig 10 2 To stop the leveler release the LOWER button Audible Alarm will sound if the button is released before the leveler is in its operating range Push the LEVELER STOP button at any time to stop all operation and silence the Audible Alarm If this condition persists a short duration tone will sound periodically to remind the operator of the illegal leveler condition Amber and Green lights will turn off To resume operation of the leveler pull the LEVELER STOP button Amber light on and press and hold the LOWER button and leveler will float down to the truck bed Release the LOWER button when Green light on leveler control panel indicates leveler has reached the operating range See Fig 11 16 6001762N Vertical Hydr
20. gage is adequate for length of wire a Set overload to full load current specified for voltage on motor nameplate b Check for voltage at all three motor connections T1 T2 T3 at output of overload in control panel a See solution 2 b b Check for voltage at all three motor connections T1 T2 T3 at output of overload in control panel April 2013 TROUBLESHOOTING GUIDE continued PROBLEM 5 Leveler does not raise or lower Motor runs POSSIBLE CAUSE a Low fluid in reservoir b Main solenoid valve SV2 does not open c Pump running in reverse d Pump damaged or broken internally Insufficient pressure Primary relief valve RV1 setting too low 6 Leveler will not lower Motor runs and leveler raises a Lower solenoid valve SV1 does not open b Automatic safety stop velocity fuse is locked c NV1 needle valve set too tight 7 Leveler floats down too fast or too slowly in float range a Float needle FNV valve requires adjustment 8 Leveler will not raise Motor runs a Solenoid valve SV1 not closed April 2013 SOLUTION a Check fluid level See Planned Maintenance section in this manual for instructions for your specific leveler type b Check for magnetism at solenoid coil If magnetism present remove and inspect valve for contamination and then replace solenoid valve c Check motor rotation and reverse electrical connection
21. out a minimum of 4 times until any abrupt motion is eliminated Oil Inspection Remote mount assembly With both the main cylinder and the lip cylinder retracted check the oil level in the reservoir Oil should be clear and within 1 2 3 4 of the top with the lip plate fully retracted Add oil if necessary See page 13 under Components Specifications for hydraulic fluid specifications Deck mount assembly Inspect the oil level with the deck in the vertical stored position and the lip extended remove and clean the dipstick reinsert the cap to the top of the opening and remove to read the oil level on the dipstick Proper oil level should be between the holes on the dipstick See Fig 17 for more information If the oil is foamy leave for approximately 15 minutes to let the oil settle before checking oil level INSTALLATION continued April 2013 6001762N Vertical Hydraulic Dock Leveler 9 2013 4Front Entrematic STALLATION continued 20 5FT AND 6FT LEVELERS This step requires 1 1 2 and 2 open end wrenches Loosen the jam nut on the threaded rod end of the main cylinder Press the RAISE button and hold until the main cylinder is fully extended With the main cylinder rod fully extended rotate the rod end so that the pivot pin can be inserted freely through the cylinder pivot on the embedded channel frame Orient the tab on the cylinder pivot pin such that it goes over the top of the cylinder
22. the leveler securely using other means and determine the cause of the interference Failure to follow these instructions will result in death or serious injury Refer to user s manual for proper procedure 6007867A 2013 4Front Entrematic 6000873 DANGER Do not remove the lock out pin from the maintenance post unless authorized personnel have confirmed that the hydraulic cylinders valve and hoses have been properly installed and filled with fluid Failure to do so could result in death or serious injury Refer to user s manual for proper procedure 600 08730 6001 761 A DANGER OPERATING INSTRUCTIONS 4 Warning and operation placard mounted near controls 6001762N Vertical Hydraulic Dock Leveler April 2013 Use the Troubleshooting Guide if ever the leveler fails to perform properly Find the condition that most closely matches your situation and make the recommended adjustments Observe all safety warnings before attempting any maintenance procedure Before servicing the dock leveler read and follow the Safety Practices on page 3 and the Operation section in this manual Be certain before doing any maintenance or repair on the dock leveler that 1 THE LEVELER IS STORED IN A VERTICAL POSITION WITH THE LIP EXTENDED AND THE LOC
23. to allow leveler to float down to RAISE PUSHBUTTON continued Green pilot light turns off when leveler raises above working range Fully Raised Leveler stored sensor closes Pressure increases Sequence valve shifts Lip cylinder extends LIP RETRACT PUSHBUTTON Pump starts Main solenoid valve SV2 opens allowing leveler to raise and lip to retract Green pilot light turns off when leveler raises above the working range LIP EXTEND PUSHBUTTON Pump starts Main cylinder solenoid valve SV2 is closed Sequence valve shifts allowing lip to extend Fig 9 the truck bed ue S Green light Lip solenoid valve SV4 closes to prevent lip from retracting Green pilot light turns when leveler reaches working range Raise RAISE PUSHBUTTON Lip retract Pump starts Main solenoid valve SV2 opens to extend main cylinder Lower Lip solenoid valve SV4 closes to prevent lip from retracting Power Amber light 14 6001762N Vertical Hydraulic Dock Leveler April 2013 2013 4Front Entrematic Before operating the dock leveler read and follow the Safety practices on page 3 Restrict use of dock leveler to trained operators Follow safe operating procedures described in this manual and in the operation placard which was shipped with the leveler The placard should be posted near the leveler If either labels or placard is lost contact your local distribut
24. to position dock leveler ramp or lip orto store dock leveler Do not use the dock leveler if it appears damaged or does not operate properly Inform your supervisor immediately Do not attempt to manually lift the dock leveler ramp or lip If the SAFETY PRACTICES dock leveler does not operate correctly using the operational procedures contained in this user s manual do not use the leveler Refer to the troubleshooting guide in this user s manual If the dock leveler still does not operate properly call an authorized service representative Do not stand in the driveway between the dock leveler and the backing truck Chock truck wheels or lock truck into place with truck restraining device and set brakes before loading or unloading Never drive on dock leveler unless Green Light is lit on the dock leveler control panel and the truck bed supports extended lip or ramp is supported by the concrete below Always restore leveler to its safe stored vertical position with lip extended and Leveler Stop button pressed after servicing truck DO NOT walk in front of dock leveler until you Restore the leveler to its safe stored vertical position with lip extended Press LEVELER STOP button to stop the leveler and lip from moving Move all equipment material or people off the dock leveler and store the dock leveler after use Do not use a fork truck or other material handling equipment to lower the leveler Before chocking whe
25. 0V THREE PHASE 50 60HZ for dual element time delay fuses All electrical RD oe ie work must be done by qualified 2 technician and must meet BK 7 applicable codes All devices i shown deenergized state NOTE VISUALLY CONFIRM MOTOR TAG WIRE LEGEND NOTE TERMINALS WILL ACCEPT STRANDED WIRE ONLY WIRE COLOR GAUGE NFPA unless otherwise specified 208 600 14 BLK 120 16 RED THREE PHASE PANEL REFERENCE 24VAC 16 RED BLK VOLTAGE BCPD FUSE F2 MOTOR FLA PANEL FLA SERCO P N KELLEY P N NERA WHT 208 2 4 5 76A 6003327V4 6003328V4 24VDC 18 BLU 240 7A 2 4 2 5 03A 6003327V5 6003328V5 24V COM OVDC 18 BLU WHT 480 4A 1A 2 1A 2 52A 6003327V7 6003328 7 T2VAC NDC 18 575 3A 0 8A 1 9A 2 25 6003327V8 6003328V8 irae UE YLW USE CLASS CC TIME DELAY FUSES April 2013 6001762N Vertical Hydraulic Dock Leveler 35 2013 4Front Entrematic ELECTRICAL SCHEMATIC PANEL WIRING Fig 27 BLU WHT ORG OVERLOAD OL1 YEL BLU PB2 pi EE RED BLU o o xo BLK RED PB3 BLK WHT 5 0 WHT GRY 4 3 F BLU WHT PlolNIMILIKIJ A JBACKPLATE TERMINALS
26. 2013 2013 4Front Entrematic PLANNED MAINTENANCE continued Fig 17 DECK MOUNTED UNITS Legend ss Symbol I ess Lubricate Oil as ore Light Oil SAE 30 il level oil leve Lubricate Grease Oil level Molybdenum Disulfide with deck in Minimum oil level NA NLGI 2 stored position and lip extended Cleaning Location Frequency Visually Inspect Replace Damaged Or Worn far q CM LL I 1 4 eta say EE Lip Hinge Weekly In Da Pins 4 1 1 T Av oe E 10 Hoses i Quarterly 15 5 Places L d Maintenance Strut 1 Place Pit Area Weekly Except for 8 April 2013 6001762N Vertical Hydraulic Dock Leveler 21 2013 4Front Entrematic PLANNED MAINTENANCE continued Every 90 days quarterly inspect all safety labels and tags to ensure they are o
27. 23 3231 3232 for dual element time delay DETD fuses All electrical work must be done by qualified technician and must meet all applicable codes All devices OTOR WIRING DETAILS SINGLE PHASE shown deenergized state 110 115 SINGLE PHASE WIRE LEGEND PANEL WIRING y FIELD WIRING BY OTHERS NOTE PC BOARD TRACES Edw TERMINALS WILL ACCEPT STRANDED WIRE ONLY il 2 WIRE COLOR GAUGE unless otherwise specified NOTE VISUALLY CONFIRM MOTOR TAG 208 600 14 BLK 120VAC 16 RED 24VAC 16 RED BLK NEUTRAL 16 WHT SINGLE PHASE PANEL REFERENCE eee a VOLTAGE BCPD FUSE F2 MOTOR FLA PANEL FLA SERCO P N KELLEY P N 24V COM OVDC 18 BLU WHT 12VAC VDC 18 VIO 120 25A 4A 16 0A 17 67A 6003327V1 6003328V1 12 COM 18 VIO WHT DRY UNPOWERED 18 YLW USE CLASS CC TIME DELAY FUSES April 2013 6001762N Vertical Hydraulic Dock Leveler 33 2013 4Front Entrematic ELECTRICAL SCHEMATIC 208 240V 1PH 60HZ Fig 25 208 240V 1PH 60HZ NOTE SUPPLY DISCONNECT MEANS CB FU TO BE SUPPLIED BY OTHERS SUPPLY BCPD CB FU SEE TABLE RESTRAINT PANEL FLA SEE TABLE CONTACTOR SCCIR 5KA 14AWG BLK MOT114 ON L1 1141 JER LEVELER MOTOR as T pani d E SEE ABLE s i p i
28. Dock Leveler April 2013 NOTES April 2013 6001762N Vertical Hydraulic Dock Leveler 55 2013 4Front Entrematic 5 56 2013 4Front Entrematic 6001762N Vertical Hydraulic Dock Leveler April 2013 LIMITED WARRANTY THIS LIMITED WARRANTY IS 4FRONT S SOLE AND EXCLUSIVE WARRANTY WITH RESPECT TO THE DOCK LEVELERAND 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 4FRONT 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
29. K OUT PIN INSERTED THROUGH THE MAINTENANCE STRUT AND BRACKET ON DECK and 2 The power is disconnected and properly tagged or locked out ADANGER Do not perform any maintenance or repair in the area in front of or under the leveler unless the leveler is fully raised and lip extended lock out pin is inserted through the maintenance strut and bracket on deck the Leveler Stop button is pressed and barriers are in place If the dock leveler will not raise with the RAISE pushbutton and it must be raised by external mechanical means to close the dock door use extreme caution and do not allow anyone to stand in front of the leveler Ensure that the lock out pin is inserted through the maintenance strut and bracket on deck before the mechanical lifting means is removed During lifting of the leveler by mechanical means it is likely that hydraulic fluid will vent itself through the breather of the hydraulic reservoir Lift the leveler slowly and without getting in front of the leveler place a container under the reservoir if possible to catch the fluid The lock out pin must not be removed until the hydraulic system has been bled of air and all hydraulic functions have been tested by a qualified service technician If the dock leveler has been raised to the stored position April 2013 TROUBLESHOOTING GUIDE by external means the main cylinder will be full of airand there may be a vacuum exerting a strong retracting force on the cyli
30. LEVELER IS STORED IN A VERTICAL POSITION WITH THE LIP EXTENDED AND THE LOCK OUT PIN INSERTED THROUGH THE MAINTENANCE STRUT AND BRACKET ON DECK 2 The LEVELER STOP button is pressed 3 Barriers are in place Failure to do so could result in death or serious injury WEEKLY 1 Check that the lock out pin can be freely inserted through the maintenance strut and the bracket on the deck when the leveler is fully raised 2 Check the 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 3 Inspect that both control panel lights are working and replace bulbs if necessary 4 Clean away any debris from the pit area If washing out take care not to direct spray at any electrical parts 5 Clean away any dirt and debris from the lip hinge April 2013 PLANNED MAINTENANCE QUARTERLY 1 Inspect and lubricate all mechanical pivot points on the leveler with S A E 30 oil Cycle the leveler when lubricating 2 Inspect the hydraulic cylinders valves and hoses for any fluid loss and check the reservoir level Add fluid as required See pages 20 and 21 for oil check procedure for your model leveler NOTE To inspect reservoir level unscrew dip stick cap clean stick then insert stick into reservoir Do not screw in Read fluid level and replenish as required Screw in cap when finished 3 Inspect all welds under leveler for fatigue or f
31. LLATION ADANGER Important Installer Responsibility Vertical levelers ship partially disassembled and require field assembly Prior to complete electrical and hydraulic installation levelers must be stored safely If leveler is mounted on hinges and stored vertically maintenance strut must be secured with lock out pin and padlock until the leveler is completely wired tested and fully operational Padlock must not be removed until leveler is completely wired tested and fully operational Failure to follow safety practices could result in death or serious injury GENERAL INFORMATION The successful installation of a vertical leveler requires good coordination with other trades involved on the site You must have a clear access to the dock area inside and out Ideally the leveler should not be installed until the control panel is installed has live power connected to the control panel and field wiring to the power unit is complete This will allow the complete installation at one time as opposed to making several trips The bumper assemblies must not be installed until the leveler is functional as pit construction errors may not be evident until that time Make sure the customer gets the user s manual and is properly trained The installed location of the control panel and hydraulic power unit must be specified on a job specific approval drawing PIT CHECK Check the entire dock leveler pit layout and dimensions to verify conforma
32. MANTENANGESTRUT 600208 1 MHexHEADJAMNUTTSUNG pe _ 2 BRAND LABEL SERCO 6001712 EE BRAND LABEL KELLEY o MEE ME NE pow HEINE p 2 EE Lae pgs 1 1 1 1 1 1 1 WALL MOUNTED PLACARD SAFETY AND OPERATIONS 6001761 1 1 1 1 1 1 ROD END ADJ ASSY 5 AND 6 UNITS ONLY ROD END ASSY 1 8 8 UNIT ONLY NYLOCK NUT 1 8UNC 8 UNIT ONLY VSL PIN ANTI ROTATE WDMT 5 16 NYLON LOCKNUT DECK MOUNT UNITS ONLY CARRIAGE BOLT 5 16 X 1 DECK MOUNT UNITS ONLY MOUNT DAMPER DECK MOUNT UNITS ONLY VSL DM BRACKET WDMT DECK MOUNT UNITS ONLY 42 6001762N Vertical Hydraulic Dock Leveler April 2013 2013 4Front Entrematic 1 2 2 2 2 2 2 E PARTS LIST DOCK LEVELER continued Capacity and Part Number April 2013 6001762N Vertical Hydraulic Dock Leveler 43 2013 4Front Entrematic PARTS LIST REMOTE MOUNT HYDRAULIC Fig 34 Detail A Detail B 3 Detail C 44 2013 4 Entrematic 1 14415 Lip cylinder extend Main cylinder extend Cylinder retract common 6001762N Vertical Hydraulic Dock Leveler April 2013 PARTS LIST REMOTE MOUNT HYDRAULIC continued HOSE ASSY 1 2 X 37 LEVELER 6000722 HOSE ASSY 1 2 X 48 6FT LEVELER 3 1959
33. MPS 6012557 1 1 4 FUSE BLOCK 1 POLE FINGERSAFE 6006849 1 FUSE BLOCK 2 POLE FINGERSAFE 6006850 1 1 1 1 FUSE 4A FNQR CLASS CC 600V 6014368 1 FUSE 3A FNQR CLASS 600V 6009361 FUSE TIME DELAY 2A FNQ R 2 6009546 FUSE 1 600V CLASS CC FNQ R 1 6011963 Fe more mos 3 NENNEN 7 EE EEE fr vsrouteutsoaroassemmiv 1 miorusmrieosr enannae emer 1 1 1 mioruesrieomeeenzenono omme 1 Pa EEE 3 3 1 Tr ren Ce PUSHBUTTON Buck 7 1 rususurowvenow sorso 3 1 Cie wounrine conar coms s 5 moocoommornominivoren eese 4 eroek conme norway roseo 2 2 2conbucTOR soos s 3 s 3 3 Em 1 1 o o Em womExAw EE 3 a 22 PANEL FACE LABEL SERCO 6006289 1 PANEL FACE LABEL KELLEY 6006288 1 g ss sl ss ok Aa ay ay Se aj ajaj IN AJIA _ ES _ April 2013 6001762N Vertical Hydraulic Dock Leveler 53 2013 4Front Entrematic 5 54 2013 4Front Entrematic 6001762N Vertical Hydraulic
34. N Vertical Hydraulic Dock Leveler April 2013 2013 4Front Entrematic Fig 24 120V 1PH 60HZ ELECTRICAL SCHEMATIC 120V 1PH 60HZ NOTE SUPPLY DISCONNECT MEANS CB FU TO BE SUPPLIED BY OTHERS SUPPLY BCPD CB FU SEE TABLE RER PANEL FLA SEE TABLE CONTACTOR SCCIR 5KA MOT103 D EE L1 1031 iid M10100L101 1032 _ e LEVELER MOTOR 7 TT MP SEE 3232 0 me ME G aru ue SEE T 53 i ee 16 SEE TABLE ATQR FOR FUSE SIZES F2 4 14AWG WHT ADANGER 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 3 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 Hy HSA gH2 SHE NOTE 240 120V PRI XF107 Er AN SEC AAR 2004 Power to control box must be 355 x2 Xt 3251 from fused disconnect supplied DAC IP NEU by others Fuse size can be no AT aoe greater than the size shown in 120VAC 120V NEU the above schematic or chart from 323 from 3
35. NOID VALVE 2W2P 8 NC SPOOL SV1 amp SV2 6011935 SOLENOID VALVE 2W2P 8 NO POPPET SV4 6011480 8 COIL 1 2 SOLENOID 125VAC DELTROL SERIES 8 6011938 2 RETAINING NUT 1 2 SOLENOID RETAINING NUT 1 2 SOLENOID LONG EC ERE KEN s 2013 6001762N Vertical Hydraulic Dock Leveler 51 2013 4Front Entrematic PARTS LIST CONTROL PANEL 480V shown typical Fig 38 52 DO NO 2013 4Front Entrematic IT DRIVE ON DOCK LEVELER UNLESS GRI EEN LIGHT IS ON o 6001762N Vertical Hydraulic Dock Leveler April 2013 PARTS LIST CONTROL PANEL continued Where Used Quantity Complete Control Panel Kelley 6003328V1 6003328V2 V3 6003328V4 V5 600332817 6003328 8 Assy Number Serco 600332701 6003327V2 V3 60033271415 600332717 6003327V8 Item Part Description Part Number 1200160 208 240V 60 208 240v 3 60 480 3 60 575V 3 60 1 XFMR 200VA 120 240V 24V 6014593 1 XFMR 208 600V 120 24V 6012568 1 1 1 1 2 CONTACTOR 18AMP 24V COIL 50 60 HZ 6000467 1 CONTACTOR 9AMP 24V COIL 50 60 HZ 6012924 1 1 1 1 3 OVERLOAD 12 18 AMPS 6013781 1 OVERLOAD 9 13 AMPS 6012560 1 V2 OVERLOAD 5 5 8 AMPS 6012559 1 V3 OVERLOAD 4 6 AMPS 6013883 1 OVERLOAD 1 6 2 5 A
36. NPUTS BE MODULE PLUGS 3 LED POWER NOT SHOWN INPUT OFF WHEN qe FUSE INPUT FUSE a a a n n n a a a n MDL 0 25 18 BLOWN INPUT SIGNALS OUTPUT SIGNALS VO G YOY 0 Spare 0 Loading interlock 12 25 1 Pilot lam ower amp fault eon 1 2 3 4 5 6 7 8 9 10111213 Rise UN 5 Lip Extend 5 VSL fault Telemecanique 4 Lip Retract 4 SV1 5 Lower 5 SV2 6 SIOP 6 SV4 7 Overload tripped 7 Motor contactor m1 8 Leveler stored 8 Audible alarm 0123456789101112151 9 Leveler in float 9 Door interlock lt T 10 Restraint engaged 89 11 Door opened 12 Spare DEFAULT DIP SWITCH SETTINGS 13 Spare LOCATED ON INPUT BOARD CRG SIDE OFF ole ON JUMPERED 5143211 i STORED Ke LE FE FLOAT ee ENGAGED ooo0 lo00000000000000 DOOR OPENED LA a TONLARA ga MODULE PLUGS MODULE PLUGS 88 NOT SHOWN NOT SHOWN BE 42 7 8 8 2 4
37. Vertical Hydraulic Leveler 40 50K Capacity D 0 ES ml 0 This manual applies to Vertical dock levelers manufactured beginning February 2013 with the serial numbers 61070073 and higher SET User s M Do not install operate or service this product unless you 5 5 n have read and understand the Safety Practices Warnings x Installation and Operating Instructions contained in this n sta atio n I O pe ratio NS user s manual Failure to do so could result in death or M ai ntenance and rts serious injury Part No 6001762N TABLE OF CONTENTS IntrOdUCHON cec e dc e ne ET D e 2 Safety Signal 3 Safety Practices uic er ppt gs tee estere 3 Owner s Responsibilities 24 4 Deck and Lip Grades 5 Installation tertie m e edens 6 Components and 12 Hydraulic System 14 Operating Instructions 15 Service Tools unrated Lev sere to 18 Planned Maintenance 19 Troubleshooting Guide 23 PLC Diagnostics 27 Hydraulic Power Unit 30 Hydraulic
38. ailure particularly the lip plate hinge and under the top plate 4 Inspect all warning labels and placard Replace as required See page 22 for part numbers and label location 5 Inspect and lubricate the hinge tube and cylinder rod end clevis 5 and 6 only with molybdenum disulfide NLGI 2 grease Do not over grease Stop when grease begins to ooze out of the tube ends Wipe off excess grease 6 Inspect dock bumpers Four inches 4 of projection is required Worn torn loose or missing bumpers must be repaired or replaced 6001762N Vertical Hydraulic Dock Leveler 19 2013 4Front Entrematic PLANNED MAINTENANCE continued Fig 16 REMOTE MOUNTED UNITS Legend Symbol Lubricate Oil Light Oil SAE 30 Lubricate Grease Molybdenum Disulfide NLGI 2 Oil level with leveler fully lowered and lip pendant Cleaning Location Frequency Visually Inspect 9 Replace Damaged Or Worn Weekly Pins Hoses Quarterly 4 Hinge Pins 5 Places Maintenance Strut 1 Place Pit Area Except for 8 Weekly 20 6001762N Vertical Hydraulic Dock Leveler April
39. ans is removed OPERATING INSTRUCTIONS ADANGER During lifting of the leveler by mechanical means it is likely that hydraulic fluid will vent itself through the breather of the hydraulic reservoir Lift the leveler slowly and without getting in front of the leveler place a container under the reservoir if possible to catch the fluid The lock out pin must not be removed until the hydraulic system has been bled of air and all hydraulic functions have been tested by a qualified service technician If the dock leveler has been raised to the stored position by external means the main cylinder will be full of airand there may be a vacuum exerting a strong retracting force on the cylinder rod A technician will need to perform a bleed procedure to remove the air from the hydraulic cylinder With the lock out pin in place the technician should loosen the hydraulic hose fitting on the top port of the main cylinder and allow air to fill the vacuum before attempting to remove the pin from the cylinder rod lower end With the lock out pin in place the technician must remove the pin from the main cylinder rod lower end and perform steps 18 through 25 of the installation instructions on pages 9 11 Failure to follow this instruction can allow the leveler to free fall rapidly and may result in severe injury or death INTRODUCTION The 4Front Entrematic vertical dock leveler is designed to span and compensate for space and height differences
40. aulic Dock Leveler 2013 4Front Entrematic Fig 10 Green light on Press lower button Pull for power on Powered float down Amber light on Fig 11 Green light Press to lower Push to stop Pull for power on NOTE Audible alarm pulses and green lamp goes off if the LEVELER STOP button is pressed while leveler is in float range Amber lamp flashes if both LS1 and LS2 are on or an overload condition exists April 2013 OPERATING INSTRUCTIONS continued STORING LEVELER 3 To return the leveler to its vertical stored position press and hold the RAISE button Green light will turn off Audible Alarm will sound if the button is released before the leveler is fully raised When the leveler is fully raised and the lip is extended release the RAISE button Push the LEVELER STOP button to turn off power amber light off See Fig 12 END LOADING OPERATION 1 Pull the LEVELER STOP button to switch on power Amber 2 indicates power on Press and hold LOWER button until the leveler is partially lowered Press and hold LIP RETRACT button until the lip is fully retracted Press and hold LOWER button until Green light on leveler control panel indicates the leveler has reached the operating range Leveler will float down to the pit floor See Fig 13 To reposition the leveler for normal loading unloading press the RAISE button until li
41. ble death or injury A DANGER 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 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 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 distributor OPERATION Restrict use of dock leveler to trained operators Follow safe operating procedures described in this user s manual and in the operation placard which was shipped with the leveler The placard should be posted near the leveler If either labels or placard is lost contact your local distributor for replacement Do not use the dock leveler to service trailers outside of its intended working range which is 6 above dock and 6 below the building floor Do not operate the dock leveler when anyone is in front of it Do not operate the dock leveler with equipment material or people on the ramp or lip Stay clear of the dock leveler when it is moving KEEP HANDS CLEAR OF HINGES AT ALLTIMES Do not use hands
42. e flat uniform and smooth Bumper must have good contact 10 6001762N Vertical Hydraulic Dock Leveler 2013 4Front Entrematic April 2013 24 Press hold the RAISE button until the leveler is raised above the working range and the Green light goes off RELEASE the pushbutton The leveler should remain in position and the alarm should sound 25 Press and hold the RAISE button until the leveler reaches the stored position and the lip is fully extended The Green light on the control panel should remain off and the alarm should not sound Insert the lock out pin through the maintenance strut and bracket on the deck The pin must insert freely If there is any resistance adjust the hydraulic cylinder as described in steps 1 and 2 on page 39 26 Remove the lock out pin and lower the leveler as instructed in step 22 Observe the lowering speed before and after the green light turns on The lowering speeds should be approximately the same If not the lowering speed after the green light turns on can be adjusted using the needle valve Adjust needle valve as necessary see page 30 and 31 27 With the leveler in the fully lowered position place each bumper assembly on the floor between the leveler and the door jamb A 1 space must be present between the side of the leveler and the nearest face of the bumper assembly This space is important for the bottom pad to work properly The bumper assemblies must be welded
43. e to increase pressure so the lip plate does not extend until the leveler is fully raised See page 30 and 31 a Inspect and clean pilot check valve b Inspect SV4 coil for magnetism Test valve with good coil Replace if necessary c Inspect SV4 valve for contamination Clean or replace a Adjust as required See page 39 a Adjust main cylinder see page 39 b Replace proximity sensor or repair wiring between sensor and control panel a Adjust sensor bracket angle b Replace proximity sensor or repair wiring between sensor and control panel April 2013 PLC DIAGNOSTICS A WARNING Do not service this product unless you have read and followed the Safety Practices Warnings and Operating Instructions in this manual Failure to follow these safety practices could result in death or serious injury The vertical leveler is controlled by a programmable logic controller PLC which reads input signals from pushbuttons and proximity sensors and closes the appropriate output relays to the motor solenoid valves audible alarm and warning lights INPUTS 0 Spare 1 Spare OUTPUTS 2 Raise PB 0 Loading lamp interlock 3 Lip Extend PB 1 Pilot lamp Amber 4 Lip Retract PB 2 Pilot lamp Green 5 Lower PB 3 VSL fault 6 Stop MB 4 SV1 7 Overload tripped 5 SV2 8 Leveler stored 6 SV4 9 Float 7 Motor 10 Restraint engaged dip switch 3 off if used 8 Audible alarm 11 Door opened dip switch 4 off if used
44. els or engaging vehicle restraint dump air from air ride suspensions and set parking brakes April 2013 6001762N Vertical Hydraulic Dock Leveler 3 2013 4Front Entrematic SAFETY PRACTICES continued INSTALLATION MAINTENANCE AND SERVICE ADANGER Place barricades the dock floor around the dock leveler and in the driveway in front of the dock leveler while installing maintaining or repairing the dock If the leveler is left in a disabled condition the lock out pin must be padlocked in position Do not operate the dock leveler when anyone is standing in front of the dock leveler Before doing any maintenance or repair under the leveler be certain that the leveler is stored with the lock out pin inserted through the maintenance strut and bracket on the deck the LEVELER STOP button is pressed the power is disconnected and properly tagged or locked out and barriers are in place Disconnect the power and properly tag or lock out before entering the pit or doing any maintenance or repair under the leveler All electrical troubleshooting or repair must be done by qualified technician and must meet applicable codes If it is necessary to make troubleshooting checks inside the control box with power on USE EXTREME CAUTION Do not place fingers oruninsulated tools inside the control box Touching wires or other parts inside the control box could result in electrical shock serious injury or death Vertical
45. es 24VAC Motor NEMA Standard T E N V 48YZ frame 1HP 15 mi duty cycle single or three phase Pump Fixed displacement gear pump 1 primary relief valve factory set at 2000 PSI 12 6001762N Vertical Hydraulic Dock Leveler 2013 4Front Entrematic Lock out pin with warning tag Maintenance strut Sequence Pressure 1750 factory set Reservoir Capacity 1 2 U S gal 4 5 lit level measured by visual inspection Hydraulic Fluid Acceptable Hydraulic fluids Shell Tellus T 15 Mobil Aero HFA 49011 Exxon Univis Grade J13 Texaco Aircraft Oil 1554 U S Oil Co Inc ZFI 5606 Low Temp April 2013 COMPONENTS AND SPECIFICATIONS DECK MOUNT The main components of the leveler are shown below See the Parts List for specific part numbers Lip cylinder Fig 8 0 Lip hinge Lip plate Lie re Eu ES A Er IE User warning label on both sides Velocity fuse Deck assembly M EI m Warning label Lock out pin with warning tag Adjustable rod end Maintenance strut Main lift cylinder Control Panel Standard NEMA 12 automatic motor Sequence Pressure 1750 factory set starter thermal overload resettable control circuit breaker Reservoir Capacity 2 84 U
46. 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 trucks 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 engaged The dock leveler should never be used outside its vertical working range or outside the manufacturer s labeled rated capacity It must also be compatible with the loading equipment and other conditions relating to the dock 4 6001762N Vertical Hydraulic Dock Leveler 2013 4Front Entrematic April 2013 RAMP AND LIP GRADES Fig 1 Ramp grade I Lip grade TRUCK BED DECK and LIP grades for Dock leveler length 1 e Leveler from DOCK 5 Leveler 6 Leveler 8 Leveler tn m lt ow gt AOOU B E L W D K Deck and lip grade 16 lip April 2013 6001762N Vertical Hydraulic Dock Leveler 5 2013 4Front Entrematic INSTA
47. fully raised the valve should be turned clockwise Tightening the valve too far will cause very slow lip extension or no extension at all Trial run the leveler lowering it from stored to below dock position Record time observed NV1 Adjustment With the leveler at rest in below dock position loosen the Recommended settings NV1 needle valve lock nut and turn the Descent knob clockwise to slow lowering speed Leveler Time or counter clockwise to increase speed Size ft Sec Hold the adjustment knob in place 5 while tightening the lock nut Raise the leveler and test lowering speed Make 6 adjustments in 1 4 to 1 2 turn increments 8 with each test April 2013 6001762N Vertical Hydraulic Dock Leveler 31 2013 4Front Entrematic HYDRAULIC SCHEMATIC Fig 23 TON MAIN CYLINDER PE ur 111 VELOCITY CYLINDER to FUSE Ll C2 C3 C1 N i 6 SAE 6 SAE 6 SAE T1 La SV4 Or cv2 i 5 2 LA H FNV LIP ADJUST SEQUENCE NEEDLE VALVE VALVE Q CV3 1750 PSI PC1 2 G SV1 e e NV1 POWER DOWN e NEEDLE gt VALVE RV1 MA 2000 PSI 1 0 GPM 7 Q CV1 L1 Li Li 32 6001762
48. ibutor or to 4Front Entrematic Corporate Head Office Your local distributor is 1612 Hutton Dr Suite 140 Carrollton TX 75006 Tel 972 466 0707 Fax 972 323 2661 2013 4Front Entrematic Part No 6001762N
49. in from the main cylinder rod end and perform steps 18 through 25 of the Installation Instructions on pages 9 11 before removing the lockout pin from the maintenance strut and bracket on deck Failure to do so could result in death or serious injury PROBLEM 1 Leveler does not raise or lower Motor not running 2 Leveler does not raise or lower motor starts then stops motor starter relay chatters 3 Overload relay tripping check full load amperage and relay setting 4 Leveler does not raise or lower Motor hums 24 2013 4Front Entrematic POSSIBLE CAUSE a No electrical power to control panel b Electrical connections incorrect or broken c No electrical power to PLC d PLC not running a Loose wiring connection b Voltage drop due to long wiring distance from power source a Overload relay set too low b Loss of 1 phase Three phase only a Voltage drop b Loss of 1 phase Three phase only 6001762N Vertical Hydraulic Dock Leveler SOLUTION a Check that voltage is present at terminal connections to the control panel b Check that wiring matches the wiring diagram c No electrical wiring to the PLC d If the fault light is flashing replace PLC a Check all wiring connections from line to motor starter relay overload and to motor b Check voltage when motor is started Voltage drop is more often a problem on single phase motors Verify wire
50. k when the leveler is fully raised 13 Audible alarm sounds when leveler is in the stored position 14 Leveler will not enter Float range when lowered no green light on control panel alarm continues to sound and leveler stops when in working range 26 2013 4Front Entrematic POSSIBLE CAUSE a Low fluid level in reservoir b Sequence valve pressure set too high c Lip hinge binding d Primary relief valve pressure set too low a Sequence valve pressure set too low a Pilot check valve is leaking b Lip solenoid SV4 not energizing or not closing c Lip Solenoid SV4 may be clogged or damaged a Main cylinder adjustable rod end needs adjustment a Main cylinder rod end adjuster not adjusted correctly b Leveler stored proximity sensor damaged or connection to sensor lost a Sensor mounting bracket out of position b Leveler float proximity sensor damaged or connection to sensor lost 6001762N Vertical Hydraulic Dock Leveler SOLUTION a Check fluid level See Planned Maintenance section in this manual for instructions for your specific leveler type b Decrease sequence valve setting See page 30 and 31 c Inspect hinge area for damage or trapped debris d Set primary relief valve to 2000 PSI See page 30 and 31 Do not adjust relief valve without a pressure gauge Reference TSB 2008 0722G for equipment requirements a Turn sequence valve clockwis
51. larm 0123456789101112131 9 Leveler in float 9 Door interlock lt B 10 Restraint engaged 0125456789 1 11 Door opened 12 Spare DEFAULT DIP SWITCH SETTINGS 13 Spare LOCATED ON INPUT BOARD RIGHT SIDE OFF olo ON JUMPERED 514131211 LEVELER STORED BEER UP FLOAT ENGAGED DDD DODDDDDDDDDDDD Logor OPENED 7 100000 eq T MODULE PLUGS Denis MEI C MODULE PLUG 88 NEUTRAL NOT SHOWN SHOWN T WIRE ene DU BOND 7 9N 12 8 4 17 18 E SEE AL ln VSL 4 nt Y OXUAnTeums T l amp x DOOR INTERLOCK Restraint Engaged EI WHT E i amp Leveler Stored SV1 ALARM L WHT 6003335 L MT LEGEND SV1 POWER DOWN SOLENOID SV2 MAIN SOLENOID A i XA 5 4 LIP SOLENOID WHT April 2013 6001762N Vertical Hydraulic Dock Leveler 37 2013 4Front Entrematic ELECTRICAL SCHEMATIC DECK MOUNT FIELD WIRING Fig 29 RESTRAINT ENGAGED DOOR_ OPE HOTOEYE P BLU BRN JONO 24VDC WIRE BOND 625 208 POSITION DIP 4 OFF IF USED ED WHT 4 OT CONNECTED AUXILIARY CONTACT Q FROM RESTRAINT PANEL POSITION DIP 3 OFF IF USED gt LEVELER FLOAT SWITCH LEVELER STOREDSWITCH 1 m C C cV V C 21 22 23 24 VSL F I
52. leveler hinge pins and the lower pin of the maintenance strut with the flat washers and cotter pins provided Remove the lifting device from the leveler lip Leave the lip fully extended The hydraulic power unit is pre assembled The deck mounted assembly will have the power unit attached to the deck with the hoses pre assembled The remote mounted power unit will be separate on a mounting bracket with all valves attached This mounting bracket is designed to suit many different applications The mounting position is specified on the job specific approval drawing for the project Fasten the power unit mounting bracket as required Lay cardboard or other absorbent material under the hydraulic power unit This prevents staining the floor in the event of an overflow Place a pan directly under the reservoir to catch any spilled fluid The three hydraulic hoses and the leveler stored and maintained float sensor cables located on the deck are marked with numbers for identification Do not remove the plugs from the hydraulic hoses at this time Feed the hose assemblies and the sensor cables through the conduit Remove the plugs and make the connections to the correct hose fittings Refer to Fig 4 for the hydraulic hoses connections These fittings are all JIC type and require no thread sealant NOTE If the hoses are too long coil the hoses neatly at the bottom of the power unit and secure with plastic ties Do not leave excess hose
53. levelers ship partially disassembled and require field assembly Prior to complete electrical and hydraulic installation levelers should be stored safely If leveler is mounted on hinges and stored vertically the lock out pin must be inserted through the maintenance strut and the bracket on deck and secured with a padlock until the leveler is completely wired tested and fully operational 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 instruct operators in the safe use of dock leveling devices When a transport vehicle is positioned at the dock there shall be at least 4 of overlap between the front edge of the lip of the dock leveler and the edge of the floor or sill 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 in effect at time of shipment shall be followed and written records of the performance of these procedures should be kept Adock leveler that is structurally damaged or has experienced a sudden loss of support while under load such as might occur when a transport vehicle is pulled out from under the dock leveler shall be removed
54. n the dock leveler and are easily legible If any are missing or require replacement please call your local distributor for replacements Fig 18 22 6000847 ADANGER CRUSH HAZARD WALI FRONT OF D LEVE Failure to follow posted instructions could result in death or serious injury 6007867 ADANGER X Before doing any maintenance repair or adjustments on the dock leveler store the leveler in a vertical position with lip extended and engage the lock out pin in the maintenance strut Do not remove the lock out pin from the maintenance strut until you are sure the hydraulic system is in proper working condition Do not stand in front of the dock leveler while removing the lock out pin Reach from the side of the leveler Do not force the lock out pin out of the maintenance strut If the pin does not slide freely support
55. nce with the job specific approval drawings Check electrical service running to the control panel to ensure it agrees with the phase and voltage of the motor and control box supplied with the dock leveler See the wiring diagram located inside the control panel Schematics for standard control panels are provided in this manual NOTE Conduits which stub out through the rear pit wall must not project greater than 1 Saw off to 1 if necessary Make sure lifting devices are in good condition and have rated capacity of at least 3000 Ib at the lifting angle they are being used Stand clear of the dock leveler when it is being placed into the pit Never allow anyone to stand or near the dock leveler when it is being lifted or placed into the pit The dock leveler can tip or swing into bystanders which could result in death or serious injury Fig 2 3 4 UNC load centering eyebolt 3 000 Ib capacity minimum 7 NOTICE Take care when moving the dock leveler to ensure that the electrical and hydraulic components are not damaged 6 6001762N Vertical Hydraulic Dock Leveler 2013 4Front Entrematic April 2013 HANDLING AND UNLOADING The rear fixed hinge channels will be installed first by the concrete contractor In most cases these components will have arrived at the site much earlier than the levelers The levelers will arrive on a truck laid flat with the hydraulic cylinde
56. nder rod A technician will need to perform a bleed procedure to remove the air from the hydraulic cylinder With the lock out pin in place the technician should loosen the hydraulic hose fitting on the top port of the main cylinder and allow air to fill the vacuum before attempting to remove the pin from the cylinder rod lower end With the lock out pin in place the technician must remove the pin from the main cylinder rod lower end and perform steps 18 through 25 of the installation instructions on pages 9 11 Failure to follow this instruction can allow the leveler to free fall rapidly and may result in severe injury or death ADANGER Do not disconnect hoses unless the leveler is fully raised with lip extended the lockout pin is inserted through the maintenance strut Leveler Stop button is pressed and barriers are in place After replacing hoses and or motor pump cycle the leveler at least four times to remove air from the cylinder Check and add if required Failure to do so could result in death or serious injury 6001762N Vertical Hydraulic Dock Leveler 23 2013 4Front Entrematic TROUBLESHOOTING GUIDE continued ADANGER Do not disconnect hoses or any hydraulic components unless the leveler is fully raised with lip extended the lockout pin is inserted through the maintenance strut LEVELER STOP button is pressed and barriers are in place If you do disconnect any hydraulic components remove the p
57. on the sensor so it sees the edge of the door panel and the sensor face is around 2 from the panel See Fig 6 Be careful not to let any door parts such as cables rollers etc to touch the sensor or it will be damaged In some applications it is necessary to fabricate a simple sheet metal bracket to mount the sensor Restraint Interlock Consult factory NOTE Position sensor below the top of the door opening for door opened application and above the top of the door opening for door closed applications 12 24 typical Position the sensor so that it faces the edge of the door panel with the sensor face approximately 2 from the door April 2013 6001762N Vertical Hydraulic Dock Leveler 11 2013 4Front Entrematic COMPONENTS AND SPECIFICATIONS REMOTE MOUNT The main components of the leveler are shown below See the Parts List for specific part numbers Fig 7 Lip plate Deck assembly Velocity fuse Lip cylinder Lip hinge User warning label on both sides Warning label Adjustable rod end Main lift cylinder Control Panel Standard NEMA 12 automatic motor starter thermal overload resettable control circuit breaker U L approved Pilot Light LED Solenoid Valv
58. or replacement DO NOT USE DOCK LEVELER IF IT LOOKS DAMAGED OR DOES NOT SEEM TO WORK PROPERLY Inform your supervisor immediately Always be certain that the truck wheels are chocked or that the truck is locked in place by a truck restraining device and the brakes are set before loading or unloading Trucks pulling away unexpectedly can cause uncontrolled drop of the dock leveler which can result in death or serious injury Never drive on dock leveler unless Green Light is lit on the dock leveler control panel and truck bed supports the extended lip or the ramp is supported by the concrete below Always return the dock leveler to its safe stored vertical position with lip extended with the LEVELER STOP button pressed after servicing truck If the truck pulls away before the dock leveler is stored the lip will fall to its pendant position and will not be supported In addition failure to properly store the dock leveler may leave the leveler in a position below dock level These conditions may result in unexpected drop of personnel or material handling equipment and result in death or serious injury If the dock leveler will not raise with the RAISE pushbutton and it must be raised by external mechanical means to close the dock door use extreme caution and do not allow anyone to stand in front of the leveler Ensure that the lock out pin is inserted through the maintenance strut and bracket on deck before the mechanical lifting me
59. p is clear of the truck The Green light will go off and the Audible Alarm will sound if the leveler is stopped above the operating range Press the LIP EXTEND button until lip is fully extended If above the operating range press and hold the LOWER button until the Green light on the control panel indicates leveler has reached the operating range Leveler will float down to the truck bed See Fig 14 Fig 12 April 2013 Green light off Press Raise button Push for power off Amber light off Fig 13 Green light on Lip in Press to retract lip Press Lower button Pull for power on RE ES Float down Push to stop Pull for power on Amber light Green light Press to raise Press to extend lip Press to lower Float down 6001762N Vertical Hydraulic Dock Leveler 17 2013 4Front Entrematic SERVICE TOOLS A WARNING Before servicing the dock leveler read and follow the Safety Practices on page 3 and the Operation section in this manual ADANGER Before doing any maintenance or repair on the dock leveler be certain that 1 THE LEVELER IS STORED VERTICAL POSITION WITH THE LIP EXTENDED AND THE LOCK OUT PIN INSERTED THROUGH THE MAINTENANCE STRUT AND BRACKET ON DECK 2 The LEVELER STOP button i
60. rs facing upward Spacers will be inserted between the levelers to prevent damage to the leveler components The levelers can be lifted off the truck in stacks of three but using the forks to separate the levelers is not recommended as damage to the hydraulic components may occur The levelers should be lifted individually by installing a 3 4 UNC load centering eyebolt through the hole supplied in the lip plate See Fig 2 TO INSTALL NOTE Do not install the dock bumpers before the leveler is operational 1 Mount and wire the control panel in the location as shown on the job specific approval drawing Ensure that the voltage and phase of the incoming power agrees with the control panel and the decals on the pump and motor Power to the control must come from a user supplied fused disconnect with correct fuse sizes for the voltage and phase of the motor See electrical diagram for correct fuse size 2 Pick up the leveler using the load centering eyebolt and suspend the leveler vertically as shown in Fig 2 3 Align the leveler rear hinges with the fixed hinge section and insert the two outer hinge pins from the side without standing in front of or underneath the suspended leveler Do not install the center pins until the maintenance strut has been installed and secured See Fig 3 and 15 on page 18 4 Insert the maintenance strut bar through the guide bracket on the leveler and secure the lower end to the frame with the pin In
61. s T1 and T2 if necessary d With the leveler safely secured by the lock out pin inserted in the maintenance strut and bracket on deck remove the hose from the upper port of the main lift cylinder and point free end into the reservoir opening If no fluid is pumped replace hydraulic power unit Set primary relief valve to 2000 PSI See instructions on page 30 and 31 a Check for magnetism at solenoid coil If magnetism present remove and inspect valve for contamination and then replace solenoid valve b If load was on the leveler remove the load and jog the RAISE or LOWER buttons to unlock the leveler c Adjust NV1 needle valve CCW See hydraulic power unit adjustment on pages 30 and 31 a Adjust float needle valve Turn counter clockwise to increase lowering speed or clockwise to decrease speed The speed of the deck while lowering in the float range should be equal to the speed in the powered range See page 30 and 31 a Confirm SV1 solenoid coil is de engergized Inspect SV1 for contamination and then replace solenoid valve 6001762N Vertical Hydraulic Dock Leveler 25 2013 4Front Entrematic TROUBLESHOOTING GUIDE continued PROBLEM 9 Lip plate will not extend or extends too slowly 10 Lip plate extends too soon 11 Lip plate will not stay out falls as leveler is lowering 12 Lock out pin can not be freely inserted through the maintenance strut and the bracket on the dec
62. s pressed 3 Barriers are in place Failure to do so could result in death or serious injury MAINTENANCE STRUT The vertical dock leveler is equipped with a maintenance strut to hold the leveler in the stored position during maintenance Always follow the procedure below when performing maintenance or adjustments of any kind to the dock leveler 1 Raise the leveler to its fully stored position with the lip extended 2 Press the LEVELER STOP button on the control panel 3 Insert the Lock out pin through the maintenance strut and the bracket on the deck Reach from the side of the leveler while inserting Lock out pin The Lock out pin should insert freely 4 Place a padlock through the hole in the Lock out pin to prevent accidental activation of the dock leveler 5 Place barricades around the dock leveler to show leveler is out of service Fig 15 Padlock 1 RER 18 6001762N Vertical Hydraulic Dock Leveler 2013 4Front Entrematic Guide bracket Lock out pin Warni ng tag April 2013 To ensure the continued proper operation of your dock leveler perform the following planned maintenance procedures Before servicing the dock leveler read and follow the Safety Practices on page 3 and the Operation section in this manual A DANGER Before doing any maintenance or repair on the dock leveler be certain that 1 THE
63. sert the pin from the side without standing in front of or underneath the suspended leveler See Fig 3 5 Allow the leveler to lean away from the dock door until the lock out pin can be inserted through the upper end of the maintenance strut and the bracket on the deck See Fig 15 page 18 Place a padlock through the hole provided in the lock out pin This will prevent any unauthorized activation of the leveler and is essential to the personal safety of anyone near this leveler INSTALLATION continued Fig 3 Torque nut to 200 250 ft lbs 8 ft leveler only NOTE All pins require flat washers under the cotter pin except for the lockout pin ADANGER Ensure that the leveler is leaning away from the dock door If the leveler is standing vertical or leaning towards the dock door do not proceed with installation The lock out pin must be inserted through the maintenance strut and the bracket on the deck The pin must be secured with a padlock before the lifting device is removed Failure to do so could result in death or serious injury See Fig 15 on page 18 for lock out pin location April 2013 6001762N Vertical Hydraulic Dock Leveler 7 2013 4Front Entrematic STALLATION continued 10 11 Install the remaining hinge pins Secure all five
64. sound if the leveler is stopped between the lowered working range and the stored position Continue to press the LOWER button until the pump stops The leveler will hesitate momentarily and the Green light will turn on when the maintain float sensor trips When the green light is on the leveler is in float Allow the leveler to fully lower As soon as the lip begins to fall press the LEVELER STOP button Visually check that the ramp stops are resting on the front curb steel If ramp stops are not in full contact with curb steel consult factory Fig 5 B N VB420 11F dock bumpers dia x 5 wedge anchor supplied others Stored position 2 5 beyond vertical Te 2 2 support bar AS Cylinder pivot pin Shim under main cylinder using 4 x 4 shims as needed mi 5 with concrete dock face Bumper mounting area to b
65. support bar See Fig 5 Secure the pivot pin with the pin provided See Fig 3 Ensure the grease fitting faces the dock door 8FT LEVELERS This step requires 1 1 2 and 2 open end wrenches Loosen the jam nut on the threaded rod end of the main cylinder Press the RAISE button and hold until the main cylinder is fully extended With the main cylinder rod fully extended rotate the rod end so that pivot screw and spacers can be inserted freely through the cylinder pivot on the embedded channel frame Add washer and nylock nut to screw Torque nut to 200 250 ft lbs See Fig 3 ADANGER Incorrect hydraulic power unit adjustment that allows the leveler to descend rapidly could result in death or serious injury 21 Using the 2 wrench to hold the chrome cylinder rod securely tighten the jam nut using the 1 1 2 wrench Using the 2 wrench Turn the chrome cylinder rod clockwise to pull the leveler forward until the pins in the maintenance strut move freely There must not be more than 1 1 2 on 5 and 6 dock levelers and 9 16 on 8 dock levelers of thread showing on If more than the allowed amount do not proceed 22 23 Ensure that the pit area is clear Remove the padlock from the lock out pin Stand at the side of the leveler reach in and remove the lock out pin from the maintenance strut Press and hold the LOWER button The pump will run and the leveler will move forward and start to lower The alarm will
66. than 1 1 2 of thread showing on the adjustable rod end on 5 and 6 models 9 16 on 8 models If more than specified thread shows do not proceed Ensure that the leveler is leaning away from the dock door If the leveler is standing vertical or leaning towards the dock door than the leveler is not in a safe stored position Correct immediately using the steps above Failure to do so could result in death or serious injury April 2013 Fig 30 Vertical leveler in stored position Vertical line gt Stored position 2 5 beyond vertical Leveler stored sensor LS1 Maintain float sensor LS2 Fig 31 Rotate cylinder rod clockwise to tilt Rotate cylinder rod counter clockwise leveler forward lt gt to tilt leveler back Lock nut Adjustable r EB rod end ui 1 1 2 5 and 6 9 16 8 models 6001762N Vertical Hydraulic Dock Leveler 39 2013 4Front Entrematic PARTS LIST DOCK LEVELER To ensure proper function durability and safety of the 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 ina way alter the product from its normal working condition at the time of purchase from 4Front Entrematic could result in product malfunction
67. to the front curb steel using proper weld techniques Vertical down weld passes are not acceptable All applicable anchors must be 3 4 x 5 min depth wedge anchors See Fig 5 NOTE Reference TSB 2008 1020G for acceptable anchor bolt installation practices 28 Shim and weld as required under main cylinder bracket See Fig 5 29 Permanently mount the laminated WARNING and OPERATION instruction placard near the dock leveler control panel Make sure the customer gets the user s manual and is properly trained to operate the dock leveler 30 Install the bottom pad Refer to included installation instructions INTERLOCK OPTIONS Door Opened A door opened interlock can be added by adding a door opened photoeye switch that senses when the door is fully opened The leveler lower will not be enabled until the door is fully opened The door opened sensor emits an infrared light beam with a sharp cutoff around 3 beyond the face of the sensor The sensor should be positioned below the top INSTALLATION continued Fig 6 Top view NE Recommended NS photoeye door 20 SU Door jamb Door panel position Door track Detail A Door tracka Door switch Door mounting opened location Position Opened NC m b Finished closed opening Detail B door opening typically 12 below and on the same side of the door as the control panel Positi
68. under the leveler but leave a loop so hoses are not pulled tight 12 13 Install the solenoid home run cable deck mount only and route it with the stored and float sensors wires through the conduit to the control panel Install protective cable wrap over the wires between the deck and conduit port in the embed to the control panel in conduit according to the installation specifications Allow additional wire in a manner that leaves a service loop The electrician can now connect the wiring from the control panel to the motor and solenoid valves Fig 4 171 through conduit Route hoses port in embed pu cylinder extend Ne cylinder extend Cylinder retract common 6001762N Vertical Hydraulic Dock Leveler April 2013 2013 4Front Entrematic ADANGER Do not remove the lock out pin from the maintenance strut until the following steps have been completed to ensure that the leveler is functioning property Failure to do so could result in death or serious injury 14 15 16 17 18 19 Remove shipping plug from the hydraulic reservoir replace with the breather breather cap dipstick Turn on power to control panel Pull out the LEVELER

User`s Manual - Curlin, Inc.

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