Home

DLM DH Manual May2014

1. oN 7 7 APTT eee 38 4111 0003 May 2014 PARTS Frame and Platform Part Number Descriptor B 1 7828 gt Platform Welded Assembly o Z C 1 95155 PinlipHnge OO DKIT 9179 Toe Guards Sliding 6 Includes Both Sides 9180 9180 Toe Sliding 8 Includes Both Sides DKIT 9181 Ww occ Toe Sliding 10 Includes Both Sides 1 9202 FrameDH 4 F 6 2110047 CotterPin 1 4x2in S Q AR 210 001 Cap Screw 5 16 18 UNCx1in R 1 J 17510010 Decal Model Serial D __ o HEEL E EN TERES Lip Keeper 16 Inch Lip 20 Inch Pit 0984 Lip Keeper 18 Inch Lip 20 Inch Pit 0985 Lip Keeper 20 Inch Lip 20 Inch Pit Se 0986 Lip Keeper 16 Inch Lip 24 Inch Pit 0987 Lip Keeper 16 Inch Lip 24 Inch Pit 8432 0988 0988 Lip Keeper 16 Inch Lip 24 Inch Pit AR As Required 1 Provide dock leveler serial number platform size and lip size when calling or faxing orders 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 4111 0003 May 2014 39 PARTS Hydraulic Components Dow 12 00 6 4111 0003 May 2014 PARTS Hydraulic Components 9391 0045 0045 PPAC Monarch 1 25HP
2. 11 install Dock Leveler sci c 12 Install Control Panel and Wiring 18 Put New Leveler Into Service ecce 19 Operation Operating Instructions 2 2 20 Ramp Loading Unloading Instructions 21 Loading Unloading Instructions 22 Maintenance Service Dock Leveler Safely 23 Periodic Maintenance deua Gui pruo 24 Adjustments Valve Adjustment 27 Adjust Auto Return To Dock ARTD 30 Troubleshooting MORO UNS SOO CN T 33 Parts CONOIS c 37 Frame and 38 Hydraulic 2 40 Power Pack 556 01 UE aeu Fuuuiu ax UR 42 Operation Instruction cc 46 Weather SOA 2 aaa a 47 Miscellaneous sized 48 Customer Information 49 E Back Cover Recogniz
3. acc lle 2 ee Lis in 305 mm The DH hydraulic dock leveler is designed to compensate for a maximum 12 in 305 mm of height difference between the loading dock and the transport vehicles bed DO NOT use the dock leveler if the transport vehicles bed is more than 12 in 305 mm higher or lower than the dock floor 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 Service height may vary with design specifications DO NOT overload the dock leveler DO NOT use a broken or damaged dock leveler Make sure proper service and maintenance procedures have been performed on leveler before using DO NOT operate any equipment while under the influence of alcohol or drugs DO NOT leave equipment or material unattended Transport vehicles wheels must be chocked unless on the dock leveler the vehicle restraint is used Never remove the wheel chocks until loading unloading is finished and transport driver has been given permission to leave Failure to follow these instructions may result in personal injury and or damage to equipment The dock leveler operating instructions are Make sure platform lip rests on the transport divided into the two methods o
4. e Return the dock leveler to its stored position at dock level Failure to follow posted instructions will result in death or serious injury labels or owner users 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 ADANGER CRUSH HAZARD 1 75 1 0 1 3 8 DO NOT REMOVE hydraulic cylinder until leveler is safely supported by maintenance prop Refer to owner s user s manual for proper maintenance procedure Failure to comply will result in death or serious injury 1751 0729 ADANGER CRUSH HAZARD Do not work under dock leveler unless this maintenance prop has been secured in the upright position See owner s user s manual for proper procedures Failure to comply will result in death or serious injury 1751 0729 DANGER CRUSH HAZARD Rotate prop to maintenance position Open the pin latch 1 7 1 7 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 4 DANGER CRUSH HAZARD DO NOT ENTER PIT unless dock leveler is 1 75 1 072 6 safely supported by maintenance prop Place barriers on driveway and dock floor to indicate service work being performed Refer to owner s user s manual for proper maintenance procedures Failure to comply will resul
5. If lip malfunctions cleaning or replacement may be required RV1 Main Relief Valve Sets system pressure 2W 2 Way Normally Open Spool Valve Optional If present can extend lip with Lip Out option or it can be used as an emergency stop if power is not running 27 ADJUSTMENTS Valve Adjustment Procedure Monarch Bucher Valve location varies by production date A S2 Valve C S1 Valve E NV1 Valve G To Hoist Cylinder B RV1 Valve D Not Used F Breather Tube Fitting H To Lip Cylinder 51 Sequence Valve 1 NV1 Need Valve 1 Controls the Platform Cylinder When the leveler has Controls the Down speed of the ramp cylinder reached the top of its travel allow the leveler to float Increase Down speed by turning NV1 counter down Fluid should flow through the NV1 valve If you clockwise Decrease Down speed by turning hear the motor spinning backwards or Leveler and or NV1 clockwise Lip may dropping prematurely adjust 1 clockwise in small increments testing each time until the motor is PO CHK Pilot Operated Check Valve not spinning backwards or Leveler and or Lip may drop Keeps Lip from collapsing until it is below dock This correctly valve is not adjustable If lip malfunctions cleaning or replacement may be required S2 Sequence Valve 2 Controls the Lip Cylinder This valve should be set RV1 Main Relief Valve to allow a smooth quiet shift Turning S2 counter Sets system pressure clockwise causes the lip to exte
6. 42 4111 0003 2014 PARTS Hoke KTI Power Pack Components Quantity Part Number Besciplon 1 8581 0133 2 Way Normally 1 8581 0128 Valve Sequence 51 Silver Tip 1 1 9391 001 Breather Hoke PowerPack o i O 1 Provide dock leveler serial number and type of installation when calling or faxing orders Provide dock leveler serial number voltage and phase when calling or faxing orders 4111 0003 May 2014 43 PARTS Monarch Bucher Power Pack Assembly Valve Block Valve location varies by production date Monarch Single Phase First Gen 115 Volt 1 PH 230 Volt 1 PH Monarch 3 Phase 208 230 Volt 3 PH 460 Volt 3 PH 6 5 4 6 5 4 9 87 9 8 7 I l 321 3 24 T1 T2 T3 T1 T2 T3 Notes Low Voltage connect as shown High Voltage Move lead J to Term 3 move Lead 2 to Term 4 44 4111 0003 May 2014 PARTS Monarch Bucher Power Pack Components Quantity Part number _ Valve Sequence S1 Red Tip Valve Sequence 2 Silver Tip B D EN Monarch Single Phase Second gen 115volt 1 PH 230 Volt 1 PH Color Chart 34 3 2 1 Blue 2 White 1 2 14 3 Orange 4 Yellow T1 T2 T1 T2 4111 0003 May 2014 45 PARTS Operating Instruction A DANGER e Read and follow all instructions warnings and main
7. ON position if equipped After approximately six seconds the platform will automatically rise to the cross traffic position OR e Push the Raise button B until the lip clears the lip keepers Release Raise button leveler will return to the stored or cross traffic position 11 Remove chocks from transport vehicles wheels or release the restraint if used 12 Indicate to the driver that the transport vehicle may leave the dock 4111 0003 May 2014 Service Dock Leveler Safely MAINTENANCE Side View A Maintenance Prop B Tag Out Tag C 2 Styles of 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 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 pro
8. corner to corner diagonal distance D at both sides Take measurements at dock floor level and at pit floor level If any measurement is off by more than 1 8 in 3 18 mm contact DLM Technical Services before proceeding Make sure the field junction box for the dock leveler E is at the correct location per pit diagrams 4111 0003 May 2014 Prepare Dock Leveler A Lifting Bracket 2 used B Shipping Bands DLM dock leveler s 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 4111 0003 May 2014 INSTALLATION IMPORTANT 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 IMPORTANT DO NOT over tighten the lifting bracket hardware Over tightening ca
9. frame shim stacks to the front pit curb steel Shim Stacking Methods N P Q 2 For left right orientation of dock leveler see inside back cover of this manual 4111 0003 May 2014 INSTALLATION 20 When all welding has been completed paint all the welds and shims NOTE DH models are shipped with a front frame section C installed This temporary frame holds the leveler frame at the correct dimensions until the leveler is permanently anchored into place Only then should it be removed 21 For all DH models remove the Clean Sweep frame section C by grinding the tack welds that hold it in place during transport Paint after INSTALLATION Install Control Panel and Wiring cs SSS PBR 4 DANGER AW Arc Flash and Shock Hazard PPE Personal Protection Equipment Required De energize equipment before working on or inside Do not open cover without appropriate PPE Refer to 70E for PPE requirements This panel may contain more than one power source Hazardous Voltage Will Cause Severe Injury or Death DO NOT make any final electrical connections until A Disconnect Panel provided by others all welding has been completed Failure to do this B Distance 48 in 14 630 mm may result in serious personal injury or death 1 Mount the push button control panel B so bottom of control panel to dock floor distance C is 48 in The electrical power must b
10. reaches the full raised position 4111 0003 May 2014 Clean and inspect valves Flush contaminated oil from hydraulic system Fill system with new oil See Periodic Maintenance in the Maintenance section Replace damaged hose s Remove restriction Increase pressure relief See Valve Adjustment section NOTE The pressure relief valve RV1 must not be set at a level that causes the motor operating current to exceed the full load amp value at any time including when operating in pressure relief The full load amp value can be found on the inside cover of the control panel Decrease pressure relief See Adjust Main Pressure Relief in the Adjustment section NOTE The pressure relief valve RV1 must not be set at a level that causes the motor operating current to exceed the full load amp value at any time including when operating in pressure relief The full load amp value can be found on the inside cover of the control panel 35 TROUBLESHOOTING Platform does not rise to Low hydraulic fluid Add fluid as needed See Periodic Maintenance in full height the Maintenance section Lip does not stay 1 Sequence Valve requires See Valve Adjustment Procedure Section extended when leveler adjustment 1 8 increments lowers clockwise at a time Platform DOES rise to Low hydraulic fluid Add fluid as needed See Periodic Maintenance in full height but lip DOES the Maintenance section NOT extend or extend f
11. 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 c Raise maintenance prop D to the service upright position and lock prop in this position using an OSHA approved locking device d Proceed to step 18 4111 0003 May 2014 Make sure the platform is properly supported in the raised position before entering the pit to finish weld the shims Failure to do this may result in serious personal injury or death 18 All model leveler s Install shims at locations B using the pyramid or stepped shimming method Both platform cylinder trunnions must be solidly shimmed the entire length of the trunnion Make sure the trunnions are level from side to side as well as from front to back 19 Finish weld all frame and cylinder trunnion shims using a fillet weld Adjust shim height as needed Remember each upright rear frame member must be solidly shimmed between the floor of the leveler pit and the bottom of the frame section Weld all shims within each shim stack to each other then weld the shim stack to the leveler frame Weld the front leveler
12. switches have an indicator light at the back of the housing and some have the light at the side of the housing 30 Adjust the ARTD as Follows 1 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 Raise platform fully and engage the maintenance prop in the service position Allow platform to rest on the prop so the lip will fully fold until it contacts
13. 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 26 NOTE All DLM DH leveler s are factory tested and should not require additional adjustments in the field Consult the factory if minor adjustments do not result in proper operation Whenever valve adjustments are made note the number of turns made to allow an undesirable adjustment result to be reversed CAUTION Do not adjust relief valve RV1 this valve is preset has a security lock to prevent adjustment 4111 0003 May 2014 ADJUSTMENTS Valve Adjustment Procedure Hoke A S2 Valve B RV1 Valve C S1 Valve E NV1 Valve D 2W NO Spool Valve Coil F Breather Tube Fitting G To Hoist Cylinder H To Lip Cylinder Note Not pictured on the bottom of the valve body are the RV2 and PO Check Valves S1 Sequence Valve 1 NV1 Need Valve 1 Controls the Platform Cylinder When the leveler has reached the top of its travel allow the leveler to float down Fluid should flow through the NV1 valve If you hear the motor spinning backwards or Leveler and or Lip may dropping p
14. 014 Weather Seal Brush Style Weather Seal Kits PARTS Item Quantity Part Number Description A 1 DOTH 9393 Brush Kit Inclueds Seal and Track 1 1 2 in 82 Lg Both Sides B 1 DOTH 9292 Rubber Kit Inclueds Seal and Track 1 1 2 in 82 Lg Both Sides Individual Replacemet Seals Item Quantity Part Number Description C 1 DOTH 2822 Brush Refill 1 1 2 in 82 Lg D 1 DOTH 2820 Extrusion 1 1 2 in 82 Lg Must be purchased with DOTH 2822 E 1 DOTH 2824 Rubber Refill 1 1 2 in 82 Lg 1 2820 Heplacemt Channel Item Quantity Part Number Description G 3 0195 0044 Hear Powerseal Brush Seal H 1 DOTH 2808 Foam Seal Fits 6 6 1 2 and 7 Provide dock leveler serial number and size of platform when calling or faxing orders Provide width of weatherstrip when replacing existing seals 4111 0003 May 2014 47 Electrical CUSTOMER SUPPLIED 208 V 1 PHASE 60 HZ FROM DISCONNECT SWITCH amp OVERCURRENT DEMCE BY OTHERS SELECT DISCONNECT SWITCH amp OVERCURRENT DEVICE PER THE NEC LOCATE A FUSED DISCONNECT SWITCH NEXT TO THE ENCLOSED STARTER DUAL ELEMENT TIME DELAY FUSES MUST BE USED FOR BRANCH CIRCUIT PROTECTION SEE TABLES 1 2 AND 3 L1 L2 GRD Jumper wire to be installed by others Jumper wire to be ENCLOSED STARTER installed by others BY POWERAMP INSTALLED BY OTHERS GROUNDIN
15. 1PH 115 230V pal 1 PPAC Monarch 1 25 3PH 208 230 460 575V B 1 0521 0159 Cylinder Platform in mm Barrel Length D 1 05220156 Yoke Roll Pin 1 4 x 1 5 Long Clevis Pin 3 4 x 2 Plated Cotter Pin 1 8 Diameter x 1 Long Clip Hairpin 5 8 Diameter Pin Lip Cylinder Mounting 3 4 x 4 38 Long Cotter Pin 1 4 x 2 Long Pin Hoist Cylinder Mounting 1 25 x 7 5 Long Tube Vent 3 8 OD x 1 16 Wall O 1 9301 0111 Fitting 6 ORB Male x 8 JIC Male 9904 0128 Hose Lip Cylinder 6 Leveler 9904 0129 0129 Hose Lip Cylinder 8 Leveler 5020130 0130 Hose Lip Cylinder 10 Leveler OBE OFT Velocy Fuse Ago 88 Male ORE To FIC Ml R f 1 990 0128 Hose Platform Cotter Pin 1 4 x 2 Long Pin Hoist Cylinder Mounting 1 25 x 5 5 Long 1 Provide length and diameter of hose when calling or faxing orders Provide length of lip cylinder when calling or faxing orders 3 Provide dock leveler serial number voltage and phase when calling or faxing orders 4111 0003 May 2014 41 PARTS Hoke KTI Power Pack Assembly Hoke PPAC Motor 115 Volt 1 PH 220 Volt 1 PH 1 2 2 3 208 230 Volt 3 460 Volt 3 PH Ti T2 Ti T2 654 4 5 6 9 8 7 9 8 7 I l 2nd Design 1Phase 2 1 321 Hoke PPAC Motor T1 T2 T3 T1 T2 T3 115 Volt 1 PH 220 Volt 1 PH 1 L1 P1 L1 T2 T4 T5 L2 T4 T5 L2 P2 T9 T8 P2 2 3 8
16. A Division of A Division of Systems inc Inc DLM DH SERIES DOCK LEVELER Dock Leveler MANUFACTURING Owner s User s Manual 1 E DS i DLM Division of Systems Inc W194 N11481 McCormick Drive Germantown WI 53022 800 643 5424 fax 262 255 5917 www docksystemsinc com techservices docksystemsinc com Printed in U S A Manual No 4111 0003 Copyright 2014 May 2014 Table of Contents Page Safety Recognize Safety Information ecceeeeeee ees 1 General Operational Safety Precautions 1 Operational Safety 2 Maintenance Safety 4 ALCL Decal 5 Owner s User s Responsibilities 6 Introduction General Informatio 7 Dock Leveler Stock Specifications 7 Component Nen E Run 8 liii fee e 8 Installation Placard 0 C eR 9 Prepare 10 Prepare Dock Leveler c
17. G TERMINALS OVERHEAD DOOR DOOR CONTACT DOOR CONTACT IF USED DOOR CONTACT BY OTHERS CONTACT TO BE OPEN WHEN DOOR IS NOT FULLY RAISED CONTACT TO BE CLOSED WHEN DOOR IS FULLY RAISED IF DOOR CONTACT NOT USED WIRE FROM TERMINAL L1 TO TERMINAL 95 ON THE STARTER J BOX AT REAR OF PIT WALL BY OTHERS FLEX CONDUIT W WIRES BY POWERAMP DOCK LEVELER BY POWERAMP INSTALLED BY OTHERS Note 1 Phase control box show jumper will be the same for 3 phase control box s 48 4111 0003 May 2014 Customer Information MISCELLANEOUS NOTE Hefer 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 DH 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
18. ainst rear pit curb angle G perform check the following 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 e Gap D must exist equally along both sides of leveler so weather seal if equipped will not bind during dock leveler operation 14 E Pry Locations F Rear Hinge Frame INNA G Rear Pit Curb Angle H Flare Bevel Weld Typical Angle To Fit Spacing 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 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 DLM Technical Services 4111 0003 May 2014 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
19. bjects from the operating zone before starting Keep the operating zone free of obstacles that could cause a person to trip or fall SAFETY Operational Safety Precautions Learn the safe way to operate this equipment Read and understand the a manufacturer s instructions If you have any questions ask your supervisor ee _ Stay clear of dock leveling device when transport vehicle is entering or leaving area Do not move or use the dock leveling device if anyone is under or in front of it Keep hands and feet clear of pinch points Avoid putting any part of your body near moving parts EE 7 Chock restrain all transport vehicles Never remove the wheel chocks until loading or unloading is finished and driver has been given permission to drive away INT Tee Do not use a broken or damage dock leveling device Make sure proper service and maintenance procedures have been performed before using _ or Make sure lip overlaps onto the transport vehicles trailer at least 4 in 102 mm Keep a safe distance from both side edges 4111 0003 May 2014 SAFETY wer Do not use dock leveling device if transport vehicle is too high or too low Do not overload the dock leveling device Do not operate any equipment while under the influence of alcohol or drugs Do not leave equipment or material unattended on dock leveling device 4111 0003 May 2014 3 SAFETY Maint
20. conditions will exist for a normally operating ARTD Proximity switch senses target Proximity switch ON closed signal sent to the control panel Proximity switch indicator light is ON Platform will automatically rise after approximately a six second delay then returns to the cross traffic position 32 Lip Fully Extended Position Whenever the platform lip is at the fully extended position the following conditions will exist for a normally operating ARTD Target not in the sensing area of proximity switch Proximity switch OFF open no signal sent to the control panel Proximity switch indicator light is OFF If the platform lip is resting on the truck bed the platform will stay at this position unless the operator activates the leveler 4111 0003 May 2014 TROUBLESHOOTING Troubleshooting When service under the dock leveler is required Always stand clear of the dock leveler lip when always lock all electrical disconnects in the OFF working in front of the dock leveler position after raising the platform and engaging the maintenance prop Failure to do this may result in The maintenance prop MUST be in the service serious personal injury or death 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 maintenanc
21. contact Systems Inc P O Box 309 Germantown WI 53022 Phone 800 643 5424 Fax 262 255 5917 4111 0003 May 2014 Dock Leveler Information Model Serial No Systems Inc Job No Original Owner Information Name Address Installer Information Name Address Date of Installation 49 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 b
22. curb steel 13 With leveler welded into place remove the shipping bands from around lip and leveler frame If the platform is raised using an external lifting device or the hydraulic system is opened to atmosphere air will enter into the hydraulic system Whenever this happens always cycle the leveler at least 4 times using the leveler s own hydraulic power system before allowing the leveler to be put into service This is to make sure all air is purged from the hydraulic cylinders Failure to do this may result in serious personal injury or death INSTALLATION A Platform Joists B Shim Locations Under Platform Cylinder Trunnions C Removable Clean Sweep Frame Section 14 Using an external lifting device i e crane or fork truck attached to the platform lifting brackets slowly raise the platform Check for binding as platform is being raised 15 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 DLM Technical Services for further instructions 16 All DH models a Install shims under maintenance prop D where prop attaches to leveler frame Make sure prop is solidly shimmed b Using the appropriate lifting device attached to the platform lifting lugs slowly raise the dock to the fully open position 16 C Clean Sweep Removable Frame Section D Maintenance Prop Two people are
23. e OFF prior to electrical 1219 2 mm installation For maximum protection use an OSHA approved locking device to lock out all power 2 Install electrical disconnect panel A if not already sources Only the person installing the equipment installed should have the key to unlock the power source 3 Install and connect the control wiring Failure to follow these instructions may result in serious personal injury or death 4 Connect the dock leveler power cable to the field wires in the pit junction box Refer to the electrical drawings supplied with the dock leveler 5 After all electrical connections in the pit have been made disengage the maintenance prop and lower the platform using the external lifting device connected to the platform lifting brackets All electrical work including the installation of the disconnect panel control panel and final connections to the pit junction box must be performed by a certified electrician and conform to all local and applicable national codes 18 4111 0003 May 2014 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 DLM Technical Services for further inst
24. e Safety Information Safety Alert Symbol The Safety Alert Symbol identifies important safety messages on equipment safety signs in manuals or elsewhere When you see this symbol be alert to the possibility of personal injury or death Follow the instructions in the safety message The use of the word DANGER signifies the presence of an extreme hazard or unsafe practice which will most likely result in severe injury or death The use of the word WARNING signifies the presence of a serious hazard or unsafe practice which may result in serious injury or death The use the word CAUTION signifies possible hazard or unsafe practice which could result in personal injury IMPORTANT The use of the word IMPORTANT is to draw attention to a procedure that needs to be followed to prevent machine damage 4111 0003 May 2014 SAFETY General Operational Safety Precautions Read and understand the operating instructions and become thoroughly familiar with the equipment and its controls before operating the dock leveler Never operate a dock leveler while a safety device or guard is removed or disconnected Never remove DANGER WARNING or CAUTION signs or Decal s on the equipment unless replacing them Ca hy oe LLG i Do not start the equipment until all unauthorized personnel in the area have been warned and have moved outside the operating zone Remove any tools or foreign o
25. e prop Always post safety warnings and barricade the Unless the dock leveler is equipped with a tethered work area at dock level and ground level to prevent remote two people are required to engage the unauthorized use of the dock leveler before maintenance prop one person to operate the unit maintenance IS complete Failure to do this may the other person to engage the maintenance prop result in serious personal injury or death 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 inside the control panel s Replace Make sure the correct voltages are present at the any blown fuse s with a fuse of equal specification proper locations inside the control panel s Platform does not rise Motor overload device Reset overload relay three phase or replace Motor does not energize tripped or fuse blown fuse s single phase Determine cause of overload NOTE When replacing fuse s the new fuse must have the same specification as the old fuse Motor starter three Check voltage at starter or relay coil phase or motor relay single phase not e f voltage is present and starter or relay does not energizing energize replace starter or relay If voltage is not present check all components in series with the starter or relay coil 4111 0003 May 2014 33 TROUBLESHOOTING Three
26. earing the cost for the parts labor and transportation This shall be exclusive remedy for all claims whether based on contract negligence or strict liability WARRANTY LIMITATIONS THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES WHETHER EXPRESSDH OR IMPLIDH INCLUDING BUT NOT LIMITDH TO ANY IMPLIDH 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 LIMITDH TO BREACH OF WARRANTY LOSS OF USE LOSS OF PROFIT INTERRUPTION OF BUSINESS OR LOSS OF GOODWILL PRODUCT SPECIFIC WARRANTY DH SERIES LEVELER In addition to the Standard Product Warranty provided with all DLM Products Systems Inc 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 Systems Inc sole discretion and expense including reasonable labor materials freight and travel If Systems Inc determines replacement is necessary it will provide the original purchaser with a credit toward the
27. enance Safety Precautions 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 barricade the work area at dock level and ground level to prevent unauthorized use of the unit before maintenance is complete The maintenance prop must be in the upright 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 device 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 extin
28. 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 any replacements Manufacturers 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
29. er 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 4111 0003 2014 INSTALLATION 4 For all DH models put a 1 4 in 6 6 mm thick shim at locations C and D NOTE A 1 4 in 6 6 mm thick shim at locations C and 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 For all DH models add shims at front shim locations C and D so front of dock leveler will stay level with dock floor when leveler is resting fully on shims INSTALLATION 3 8 in 6 in 152 mm 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 ag
30. eration of the dock leveler use only aircraft hydraulic fluid designed to meet Before performing any maintenance under the or exceed military specification MIL H 5606 G It is dock leveler lock the electrical power source in recommended that the following hydraulic fluids be OFF position and lock the maintenance prop in the used service position using an approved locking device See Service Dock Leveler Safely in this section e ULTRA VIS HVI 15 Aero Shell Fluid 4 or Fluid 41 Failure to follow these instructions may result in Mobile Aero HFA Mil HS606A or Aero HF serious personal injury or death Texaco Aircraft Hydraulic Oil 15 or 5606 Exxon Univis J13 These fluid brands can be mixed together Mixing IMPORTANT with fluids that do not meet or exceed MIL H 5606 G Use of fluids that do not have equivalent may damage the equipment and WILL void warranty specifications to those in the following list will result Use of hydraulic fluids with equivalent specifications in abnormal operation of the dock leveler and to those listed here are acceptable voiding of warranty 24 4111 0003 May 2014 Regular maintenance must be performed a weekly and quarterly schedule 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
31. eveler s are designed with 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 IMPORTANT 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 frame rail and to provide a shelf for a fillet weld 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 Q or straight method R NOTE To assist in obtaining an accurate measurement of distance K use a string G pulled tight across the pit opening directly ov
32. f loading and vehicles bed with at least 4 in 102 mm of overlap unloading Maintain a safe distance from side edges of leveler For ramp loading and unloading see Ramp during the loading unloading process Loading Unloading Instructions on page 21 Failure to follow these instructions may result in e For end loading and unloading see End serious personal injury or death Loading Unloading Instructions on page 22 20 4111 0003 May 2014 Operating Instructions Continued Ramp Loading Unloading Instructions NOTE If end unloading is required see End Loading Unloading Instructions on page 22 For ramp loading or unloading the DH dock leveler can be operated by using the RAISE button on the control panel 1 Check to make sure the 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 vehicles wheels or use the vehicle restraint if available A RAISE Button 4 Extend the platform lip onto transport vehicle as follows a Raise the platform by pushing 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 pla
33. f maintenance Its revolutionary hydraulic system efficiently controls and operates every function To obtain maximum performance and longest possible use a simple program of preventive maintenance is recommended The DH series dock leveler comes equipped with an electrical control panel which allows pushbutton operation of the dock leveler functions Each DH 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 included with each order or by contacting DLM Technical Services Once again thank you and congratulations on your purchase of a DLM hydraulic dock leveler 4111 0003 May 2014 INTRODUCTION Dock Leveler Stock Specifications DH dock leveler s are available in the following sizes weight capacities and options Width DH 6 ft 1828 8 mm 6 1 2 ft 1981 2 mm ft 2133 6 mm Length 6 ft 1828 8 mm 8 ft 2438 mm 10 ft 3048 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 60 000 Ib 27 216 kg CIR Comparative Industry Rating Call DLM to discuss available voltages phases and options to meet your specific needs INTRODUCTION Component Identification A Lip E Powerpack Motor Pump Reservoi
34. get if necessary then recheck for interference 4111 0003 May 2014 ADJUSTMENTS Turn ON electrical power to the dock leveler Disengage the maintenance prop Turn the ARTD switch on control panel to the ON position Raise the platform until the lip is fully extended then allow the platform to drift to the below dock position After approximately 6 seconds the platform must return to the cross traffic position 10 Adjust the proximity switch and target as necessary Make small adjustments then operate the dock leveler to check results Do this until satisfied with the ARTD operation Use the following illustrations to assist in fine tuning and or diagnosing the ARTD operation Cross Traffic Position Lip Keeper NOTE The platform lip is fully folded when the platform is at the cross traffic stored position lip engaged with keepers or when platform is resting on the maintenance prop Whenever the platform lip is at the cross traffic position the following conditions will exist for a normally operating ARTD Target not in the sensing area of proximity switch Proximity switch OFF open no signal sent to control panel Proximity switch indicator light is OFF Platform stays at this position unless the operator activates the leveler 31 ADJUSTMENTS Full Below Dock Position Lip Keeper Whenever the platform lip is at the full below dock position the following
35. grinding or welding Failure to follow these instructions may result in serious personal injury or death IMPORTANT DO NOT connect the dock leveler electrical wiring and ground connections until all welding has been completed DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler Always ground welding equipment to the dock leveler frame NEVER to the platform Failure to follow these instructions may damage the motor hoist cylinder wiring and or control panel NOTE The illustration on the previous page shows a typical weld pattern The weld pattern will vary slightly depending on size of dock leveler 4111 0003 May 2014 INSTALLATION IMPORTANT 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 components 11 With the rear hinge frame angle F tight against the rear pit 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 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 12 Weld front of dock leveler frame B to shims located under the keepers then weld the shims to the front pit
36. guisher of the proper type nearby when grinding or welding Failure to follow these instructions may result in serious 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 4 DANGER 4 Arc Flash Shock Hazard PPE Personal Protection Equipment Required De energize equipment before working on or inside Do nof open cover without appropriate PPE Refer to 70E for PPE requirements This panel may contain more than one power source Hazardous Voltage Will Cause Severe Injury or Death 4111 0003 May 2014 Safety Decal s Every 90 days quarterly inspect all safety labels and tags to ensure they are on the dock leveler and are easily leg ible If any are missing or require replacement please call 1 800 643 5424 for replacements 4111 0003 May 2014 SAFETY DANGER CRUSH HAZARD Maintenance prop must support leveler behind bar 1 75 1 0727 Do not force maintenance prop forward of bar to support lip Refer to owner s user s manual for proper use Failure to comply will result in death or serious injury 1751 0730 x2 SAFETY INFORMATION Unsupported dock leveler ramps can lower unexpectedly Before allowing vehicle to leave the dock always Ensure that no equipment material or people are on the dock leveler
37. 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 Quarterly Maintenance IMPORTANT Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler 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 C Platform hinge area apply oil to top of all platform hinges when platform is at the full below dock position E Platform cylinder to platform frame pin F Lip cylinder to platform frame pin G Lip lifter and lift cylinder pin Lubricate the following areas with white lithium grease B Lip Cylinder pivot and to lip D All platform cylinder trunnions NOTE Apply grease to lip hinge grease fittings if equipped 4111 0003 2014 MAINTENANCE M Reservoir N 2 in 51 mm From Top of Reservoir IMPORTANT A low fluid level or the use of hydraulic fluids not equivalent to the fluid types recommended will cause abnormal operation of the leveler and WILL void warranty P Breather Cap Q Fluid Level Before performing any maintenance under the dock leveler lock the electrical power source in OFF position and lock the maintenance prop in the service p
38. n 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 over tighten 3 Attach lifting chains to lifting brackets A and to a lifting device i e hoist or fork truck 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 INSTALLATION Install Dock Leveler Shim Stacking Methods Q 2 P B See page 16 for Hoist cylinder shimming H A Distance Leveler Frame G String Height H Rear Hinge Frame Angle B Shim Locations Under J Distance Dock Floor to T 1 Rear Vertical Supports Pit Floor ANT TO C Shim Location Under K Distance Top of Shim Maintenance Prop Stack to Dock Floor re ud Same as D L Shim Stack ice ae D Shim Locations Under M Dock Leveler Frame D K d i b Lip Keepers N Pyramid Preferred uS M E Dock Floor P Stepped Acceptable NONI F Rear Pit Curb Angle Q Offset Not Acceptable NL R Straight Not Acceptable 2 ld 4 12 4111 0003 May 2014 NOTE DLM dock l
39. nd If the lip does not extend turn S2 counter clockwise out small increments until lip begins to extend Once the lip is extended allow the powerpack to operate in pressure relief then allow the leveler to return below dock Raise the leveler and continue to adjust the S2 valve to allow a smooth quiet shift When adjusted properly the lip should stay extended until below dock Lip extension cycle should not take more than a few seconds 28 4111 0003 2014 NOTES This page intentionally left blank 4111 0003 May 2014 29 ADJUSTMENTS Adjust Auto Return To Dock ARTD A Cable E Target B Proximity Switch F Lip Hinge Tube C Bracket G Platform Lip D Lock Nuts H Indicator Light DH leveler s are equipped with the optional Auto Return To Dock ARTD if leveler not interlocked with a truck restraint The ARTD allows the platform to automatically return to the cross traffic stored position after the transport vehicle departs The ARTD uses a proximity switch B located under the platform and a piece of angled steel called the target E that is attached to the lip hinge tube F The proximity switch provides a six second delay after the platform has lowered to the full below dock position after which the platform will return to the cross traffic position The switch also contains an indicator light H that can be used for diagnosing and adjusting the switch NOTE Some proximity
40. osition using an approved locking device See Service Dock Leveler Safely in this section Failure to follow these instructions may result in serious personal injury or death Check reservoir fluid level Q 1 Put the dock leveler platform at the full above dock position 2 Turn OFF all electrical power to the leveler 4 Remove breather cap P 5 Measure fluid level The fluid level should be approximately 2 in 50 8 mm N from top of reservoir M 6 Add hydraulic fluid if necessary Use only recommended fluid 7 Install breather cap and inspection plate 8 Turn ON electrical power to the leveler 9 Return the platform to the cross traffic position 25 ADJUSTMENTS Valve Adjustment Procedure 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
41. p 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 4111 0003 May 2014 Whenever maintenance is to be performed under the dock leveler platform support the platform with maintenance prop A Position the maintenance prop behind front header plate while staying clear of the lip The lip will fold down after the platform has rested on the maintenance prop Lock the maintenance prop in the service upright position using an OSHA approved lockout device C and Tag Out device B Whenever servicing the dock leveler lock the electrical power disconnect in the OFF position Use only an OSHA approved lockout device B and Tag Out device C Only the person servicing the equipment should have the capability to remove the lockout 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 147 Refer to OSHA regulation 1910 146 23 MAINTENANCE Periodic Maintenance A Lip Hinge Area C Platform Hinge Area E Platform Cylinder to Platform Pin B Lip Lifter and Lip Cylinder Pin D Platform Cylinder Trunnion F Lip Cylinder to Platform Frame Pin To ensure normal op
42. phase units only Platform does not rise Motor hums but does not run Three phase units only Platform does not rise Motor runs in reverse Single phase units only Platform does not rise Motor energizes but does not run Dock leveler equipped with ARTD Platform does not automatically return to the cross traffic position or operates abnormally 34 No voltage is present on Check for blown fuses at branch circuit disconnect one line Replace fuse Determine cause of blown fuse NOTE A motor that is Check motor starter as follows missing voltage line Disconnect wires at load side of starter is said to be single phased Ep ergize the starter 3 Measure line to line voltage at line side of starter 4 Measure line to line voltage at load side of starter 5 Line side and load side voltages should be approximately the same Replace starter if voltage values are considerably different from one another Check all wiring to motor for high resistance or no connection Phase reversed Reverse any two legs at the branch circuit disconnect 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 Defective motor centrifugal Replace motor switch Defective motor capacitor Replace motor The auto return proximity Adjust proximity
43. purchase of the new replacement Systems Inc product in the amount equal to the original purchase price of the warranted product F O B point of manufacture discounted on a ten year straight line basis by the number of years of use prior to replacement Hydraulic Warranty For a period of three 3 years from date of shipment this warranty specifically applies to the hydraulic pump and motor all hydraulic cylinders hydraulic pressure lines and fittings and fluid logic control assembly only
44. r B Main Frame F Platform Cylinder C Platform G Clean Sweep Removable Section D Lip Cylinder THEORY The DH dock leveler uses hydraulic logic and one button operation for ease of use The dock leveler can be operated remotely using the RAISE button M on the control panel Platform C is raised by pushing and holding the RAISE button M This activates an electric motor E which in turn drives a hydraulic pump The hydraulic pump forces oil into the platform cylinder s F causing the platform to rise Releasing the RAISE button allows the platform to lower H Maintenance Prop Lock Out L Control Box J Maintenance Prop M Raise Button K Toe Guards 2 used N ARTD Switch option When the platform rises to the highest point of travel left in the platform cylinder a sequence valve in the Powerpack directs fluid flow to the lip cylinder extending the lip With the lip fully extended the raise button may be released allowing the leveler to float down on to the truck for loading or unloading See Operating Instructions for a complete operation guide 4111 0003 May 2014 INSTALLATION 2 installation Instructions e Owner is responsible for the installation and placement of product placards e Make sure placard is in plain view of dock leveler operations e Suggested placement of placard is near control box attached to electrical conduit by using nylon
45. rematurely adjust S1 clockwise in small increments testing each time until the motor is not spinning backwards or Leveler and or Lip may drop correctly S2 Sequence Valve 2 Controls the Lip Cylinder This valve should be set to allow a smooth quiet shift Turning S2 counter clockwise causes the lip to extend If the lip does not extend turn S2 counter clockwise out small increments until lip begins to extend Once the lip is extended allow the powerpack to operate in pressure relief then allow the leveler to return below dock Raise the leveler and continue to adjust the S2 valve to allow a smooth quiet shift When adjusted properly the lip should stay extended until below dock Lip extension cycle should not take more than a few seconds 4111 0003 2014 Controls the Down speed of the ramp cylinder Increase Down speed by turning NV1 counter clockwise Decrease Down speed by turning NV1 clockwise RV2 Relief Valve 2 Allows the lip to collapse below dock protects the lip if it is backed in to Set the RV2 valve by backing out adjustment screw as far as it goes Return leveler to keepers and begin to raise it Halfway up allow the leveler to return for a second then raise leveler The lip should not extend If lip extends turn S2 valve clockwise 1 4 turn and repeat until lip does not extend PO CHK Pilot Operated Check Valve Keeps Lip from collapsing until it is below dock This valve is not adjustable
46. rn to the cross traffic position if the ARTD is enabled When the platform is at the full below dock position there is a six second delay before the platform will automatically rise to the cross traffic position 8 Perform steps 5 7 at least four times to purge any air that may be in the hydraulic system and to ensure proper operation 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 Release the RAISE button to allow the platform to lower until it is resting on the maintenance prop 10 Secure the maintenance prop with the maintenance prop lock out 10 With the maintenance prop supporting the platform remove the lifting brackets and Clean Sweep frame section in between lip keepers if you haven t already done so 10 Release the maintenance prop by unlocking the lock out 12 Push and hold the RAISE button until the maintenance prop drops to its stored position Release the RAISE button and allow the platform to lower fully 13 Perform step 7 if not equipped with ARTD OPERATION Operating Instructions Stay clear of dock leveler when transport vehicle is entering or leaving dock area in 305
47. ructions 3 Install the dock bumpers as required 4 Turn the main electrical power ON Always stand clear of platform lip when working in front of the dock leveler Serious personal injury or death may result 5 Raise the leveler platform fully by pushing and holding the RAISE button NOTE The platform of a properly operating dock leveler will automatically stop rising when it reaches its maximum full raised height at which point the lip extends When the lip is fully extended the powerpack will go in to by pass If the lip does not extend or extend fully see Platform Rises to Full Height But Lip Does Not Fully Extend in the Troubleshooting section 6 Release the RAISE button to lower the platform As long as there is no vehicle present at the dock the platform will lower to the full below dock position as the lip folds NOTE Transport Vehicle is present the platform will lower until the lip rests on the Transport Vehicles bed See Operating Instructions in Operation section 4111 0003 May 2014 INSTALLATION 7 When the platform lowers to the full below dock position push 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 NOTE For dock leveler s equipped with the Auto Return To Dock ARTD the platform will automatically retu
48. ss Traffic Position 4 f transport vehicles bed is at or above dock floor level leave leveler at the cross traffic position and proceed with loading or unloading End Loading Unloading Platform at Below Dock Position 5 If transport vehicles bed is below the dock floor level and the dock is equipped with the optional lip out button perform steps 6 12 Whenever end loading or unloading with the platform in the below dock position make sure the ARTD switch is in the OFF position DO NOT turn the ARTD switch to the ON position until end loading or unloading is finished 22 A ARTD Switch 6 Turn the ARTD switch A on the control panel to the OFF position if equipped 7 Push the Raise button B to the platform just enough to clear the lip keepers 8 When the platform lip clears the lip keepers push the Lip Out button C just long enough to clear the lip keepers Release Lip Out button 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 vehicles is still required the platform lip will need to be extended See Hamp Loading Unloading Instructions on page 21 for further instructions 10 When the loading or unloading is finished return the dock leveler platform to the cross traffic stored position by performing one of the following Turn the ARTD switch A to the
49. switch and target as necessary switch not sensing target See Adjust Auto Return To Dock ARTD in the correctly Adjustment section Defective proximity switch Replace switch Broken wire Loose or Repair or replace wires and connections as corroded wire connections necessary 4111 0003 May 2014 TROUBLESHOOTING Platform does not Heavy object s on platform Remove object s from platform rise Pump operates in pressure relief mode Dock leveler binds Pressure relief set too low NOTE For safety reasons the dock leveler is designed to lift only the platform s own weight Check for visible obstructions that could cause binding Remove obstructions If no obstructions found call DLM Technical Services See inside back cover for phone number and address Increase pressure relief See Adjust Main Pressure Relief in the Adjustment section NOTE The pressure relief valve must not be set at a level that causes the motor operating current to exceed the full load amp value at any time including when operating in pressure relief The full load amp value can be found on the inside cover of the control panel Platform rises slowly Low hydraulic fluid Add fluid as needed See Periodic Maintenance in the Maintenance section Contaminated hydraulic system Damaged or restricted hydraulic hose s Pressure relief set too low Pump motor loads down Pressure relief set too high when platform
50. t in death or serious injury 1751 0726 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 operation of the equipment regardless of previous experience should be done on a regular basis and should include an understanding and familiarity with all functions of the equipment Owner s user s shall actively maintain update and retrain all operators 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
51. tenance schedules in the manual and on placards e Operation and servicing of dock leveler is restricted to trained personnel Always chock transport vehicle wheels or engage vehicle restraint and set parking brakes before operating dock leveler or beginning to load or unload Before activating dock leveler ensure lip avoids contact with transport vehicle sides and cargo If lip does not lower to transport vehicle bed reposition transport vehicle Ensure the transport vehicle floor supports extended lip or the leveler frame lip Keepers or below dock endload supports supports the ramp before driving on ramp Stay clear of hinges and front and sides of moving dock leveler Never use hands or equipment to move the ramp or lip Never use damaged or malfunctioning dock leveler Report problems immediately to supervisor Always store dock leveler and remove people material and equipment from ramp before vehicle leaves the dock DO NOT ENTER PIT unless dock leveler is securely supported by the maintenance prop Disconnect power and follow proper lockout tagout procedures for the dock leveler before entering the dock leveler pit or doing any repair or inspection under the dock leveler FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DEATH OR OTHER SERIOUS INJURY OPERATING INSTRUCTIONS POWERED DOCK LEVELERS NORMAL OPERATION Raise the platform by depressing and holding the RAISE button 2 Hold the RAISE button until
52. tform with at least 4 in 102 mm of lip contacting the transport vehicle bed 4111 0003 May 2014 OPERATION Tere 5 Proceed with loading or unloading the transport vehicle 6 If end loading is necessary see End Loading Unloading Instructions on page 21 A RAISE Button B ARTD Switch 7 When loading or unloading is finished raise the platform by pushing and holding RAISE button A Hold the RAISE button until the lip folds enough to clear the transport vehicles bed then release the RAISE button The lip will fold and the platform will return to the cross traffic position 8 Remove chocks from transport vehicle wheels or release the vehicle restraint if used 9 Indicate to driver that the transport vehicle may leave the dock 21 OPERATION Operating Instructions Continued End Loading Unloading Instructions NOTE If ramp loading is required see Ramp Loading Unloading Instructions on page 21 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 Vehicles bed 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 vehicles wheels or use the vehicle restraint if available Toe End Loading Unloading Platform at Cro
53. the lip is fully extended then release the RAISE button The platform will lower until lip is resting on the transport vehicle STORING LEVELER 1 Depress the RAISE button until the lip is completely folded When the lip is folded release the RAISE button The platform will lower returning to the cross traffic position BELOW DOCK ENDLOADING e HYDRAULIC ONLY Depress and hold the RAISE button until the leveler is fully raised As the lip starts to extend release the RAISE button The leveler will lower to the below dock position provided the lip extension allows the lip to clearthe lip keepers AIR POWERED ONLY Depress and hold the RAISE button until the leveler is 12 above dock level Pull the below dock level chain until the leveler passes the below dock position HYDRAULIC WITH INFINITE LIP CONTROL If equipped raise the platform by depressing and holding the RAISE button When the lip is just above the lip keepers simultaneously depress and hold the RAISE Poweramp 1 262 255 1510 or 1 800 643 5424 button and the LIP OUT button until lip has MORE Call for additional placards or manuals or with questions extended beyond the lip keepers Release regarding proper use maintenance and repair of dock leveler both buttons wwwDockSystemsInc com Loading Dock Equipment NOTE If equipped depressing E STOP button will stop platform from lowering 1751 0874 Operating Instruction 46 4111 0003 May 2
54. the lip stops 2 Turn OFF all electrical power to the dock leveler Attach safety lockout and Tag Out devices 4111 0003 May 2014 IMPORTANT Anytime proximity switch and target are adjusted always check for interference between target and switch before operating the leveler Damage to switch will occur if the target contacts the switch The maximum torque for proximity switch lock nuts is 10 N m 7 Ib ft Damage to switch will occur if maximum torque is exceeded A 1 4 in 6 4 mm C 1 in 25 4 mm Approximate Approximate B Target D Lock Nuts E Proximity Switch NOTE Distances A and C are typical factory settings Use these dimensions only as a starting point when adjusting the proximity switch and target especially if switch and or target have been replaced When dimensions A and C are obtained the proximity switch and target may need finer adjustments to get the ARTD to operate satisfactorily 3 Loosen lock nuts D Adjust proximity switch E to obtain distance A Tighten lock nuts 4 Bend target B as needed to obtain distance C Recheck distance A and readjust if necessary NOTE At least two people may be required to manually move the lip 5 After adjusting proximity switch and target slowly move the lip up by hand while observing the target and proximity switch The target MUST NOT contact the switch otherwise damage to switch will occur Readjust switch and or tar
55. the original equipment was prior to the modification and shall also satisfy all safety requirements of the manufacturer for the particular application of the leveling device When industrial moving devices are being used in the loading or unloading of product from the transportation vehicle this vehicle shall have the brakes and wheel chocks applied appropriately or all other positive restraining device shall be fully utilized It is recommended that trailers with air ride suspension systems shall have its air exhausted prior to performing loading and unloading operation to minimize trailer bed drop Loading dock safety equipment should never be used outside of its intended use vertical working range or capacity Please consult the manufacturer if you have any questions as to the use vertical working range or capacity of the equipment Only properly trained and authorized personnel should operate the equipment When selecting loading dock safety equipment it is important to consider not only present requirements but also future plans and any possible adverse conditions environmental factors or usage 4111 0003 May 2014 General Information Congratulations on your choice of a DLM dock leveler This manual covers the DH series hydraulic 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 o
56. tie If there is no control box present mount placard on wall to the immediate left of leveler at eye level CD SSNS NET SNS ST ER SSS SOY MESE SS 2 pum NS y up Nylon Tie T WZ SS ylon Tie lt NN NS 7 SS 4111 0003 May 2014 INSTALLATION A Distance Pit Width B Distance Dock Floor to Pit C Distance Pit Length D Distance Pit Corner to Corner Top Front and Rear Floor All Four Corners Both Sides of Pit Bottom and Both Sides Before lowering the dock leveler into the pit the following must be performed Post safety warnings and barricade the work area at dock level and ground level to prevent 1 unauthorized use of the dock leveler before installation has been completed Remove all debris from the pit and sweep the pit clean 2 Check the entire dock leveler pit for proper Failure to follow the installation instructions can result in damage to dock leveler the facilities and or serious personal injury or death IMPORTANT DO NOT remove the shipping bands around the dock leveler lip until instructed to do so 10 construction according to approved certified pit drawings Make sure pit is square by making the following measurements Measure pit width distance A at both front and rear of pit Measure dock floor to pit floor distance B at all four corners Measure pit length distance C at both sides Measure
57. ully 52 Sequence Valve 2 See Valve Adjustment Procedure Section requires adjustment 1 8 increments at a time Lip does not extend 52 Sequence Valve 2 See Valve Adjustment Procedure Section requires adjustment 1 8 increments at a time Lip extends almost 2 Sequence Valve 2 See Valve Adjustment Procedure Section immediately when the requires adjustment RAISE button is pushed Platform rises after lip is fully extended Platform locks into Platform lowering speed is See Valve Adjustment Procedure Section safety as platform too fast NV1 Needle Valve lowers Lip drops to 1 requires adjustment vertical position Velocity fuse failed Replace Velocity Fuse Incorrect fluid NOTE Extreme cold weather OH incorrect fluid may cause platform to lock Adjustment is same If adjustments and velocity fuse replacement fail to correct problem fluid replacement may be required 36 4111 0003 May 2014 PARTS Controls Standard Control Box Optional Control Box w lt Quantity Part Number Description A 0961 0085 Proximity Switch with Harness ARTD Feature Only B 1 9 Push Button Controller C 1 9511 0004 J Box Standard 4 x 4 in Metal Box 2 51 0042 J Box Cold Weather 5 x 5 in Plastic Box Provide dock leveler serial number voltage phase and options when calling or faxing controller orders 4111 0003 2014 37 PARTS Frame and Platform

DLM DH Manual May2014

Contents

Download Pdf Manuals

Related Search

Related Contents