NMS Mechanical Dock Leveler
Contents
1. 22 Adjustments Adjust Lift Arm Spring and Lip Assist Spring Tension 24 Adjust Lip Stop Bolt 00 cee ees 26 Troubleshooting Troubleshooting 27 Parts Hold Down Mechanism 29 Frame Components 30 Platform Components 32 Toe Guard Weather Seal Optional 36 Miscellaneous Customer Information 37 Warranty Back Cover 4111 0019 Nov 2010 Recognize 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 of 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 prevent2. 3 Chock the truck trailer wheels or use truck restraint if present End Loading Unloading Platform at Cross Traffic Position 4 f truck trailer bed is at or above dock floor level leave leveler at the cross traffic position and proceed with loading or unloading When finished perform steps 9 and 10 If truck trailer bed is below the dock floor level perform steps 5 10 a 7 Tara 5 Pull and hold the platform release ring A until the platform is at the fully raised position 20 6 Slowly walk the platform down allowing enough time for the lip to fold Just before the platform reaches the cross traffic position pull and hold the safety leg retract pull ring B located in a recess at front of the platform The platform will continue lowering to the full below dock position End Loading Unloading Platform at Below Dock Position 7 Proceed with loading or unloading NOTE When end unloading is finished and additional access to the truck trailer requires that the platform lip be extended see Ramp Loading Unloading Instructions on page 19 for further instructions 8 When loading or unloading is finished raise the platform to the full raised position by pulling and holding the platform release ring Slowly walk the platform down allowing enough time for the lip to fold The platform will lower to the cross traffic position lip engages in the lip keepers 9 Remove chocks fr
3. 9515 5000 9515 5004 9515 5008 25K 9515 5012 9515 5016 9515 5020 25K 9515 5024 9515 5028 9515 5032 1 9515 5001 9515 5005 9515 5009 9515 5013 9515 5017 9515 5021 9515 5025 9515 5029 9515 5033 1 35 9515 5002 9515 5006 9515 5010 35 9515 5014 9515 5018 9515 5022 35K 9515 5026 9515 5030 9515 5034 1 40 9515 5003 9515 5007 9515 5011 40K 9515 5015 9515 5019 9515 5023 40 9515 5027 9515 5031 9515 5035 1 45 9515 5036 9515 5038 9515 5040 45K 9515 5042 9515 5044 9515 5046 45 9515 5048 9515 5050 9515 5052 1 55 9515 5037 9515 5039 9515 5041 55 9515 5043 9515 5045 9515 5047 55 9515 5049 9515 5051 9515 5053 32 4111 0019 2010 PARTS Platform Components 2 1 DPLA 0338 LIP BANGER ASSY 3 2 DPLA 0341 BAR 4 1 DPLA 0353 BELOW DOCK PULL CHAIN 9 1 DPLA 0343 BELOW DOCK CONTROL ASSY 10 2 DOTH 2382 PIN COTTER 11 1 DOTH 2074 BOLT HEX 5 8 11 X 2 00 12 1 DOTH 2160 NUT HEX 5 8 11 17 1 DPLA 0360 BDC PUSH ROD ASSY 18 1 DOTH 2060 BOLT SHOULDER 19 1 DOTH 2131 LOCK NUT 20 1 DOTH 6406 LIP ASSIST ROD 23 1 DOTH 2550 SPRING LIP ASSIST STD CONSULT FACTORY 24 1 DOTH 2546 SPRING LIP ASSIST HEAVY CONSULT FACTORY 25 1 DOTP 2006 LIP PROP BAR 26 1 DOTH 2062 SHOULDER BO
4. ADJUSTMENTS Adjust Lift Arm Spring and Lip Assist Spring Tension IW 1 Jam Nut 3 Lip Assist Spring 5 Lift Spring Bolt 2 Adjustable Nut 4 Lift Springs 6 Hold Down Mechanism Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before The platform maintenance prop MUST be in the maintenance is complete Failure to do this may service position when working under the dock result in serious personal injury or death leveler For maximum protection use an OSHA approved locking device to lock the maintenance prop in the service position supplied by others Only the person servicing the equipment should have the key to unlock the maintenance prop Always stand clear of the dock leveler lip when Failure to follow these instructions may result in working in front of the dock leveler Failure to do serious personal injury or death this may result in serious personal injury or death 24 4111 0019 Nov 2010 ADJUSTMENTS NOTE Adjusting the tension of lift springs 4 usually 3 After lift spring adjustment is completed check requires that the lip assist spring 3 also be operation of the lip adjusted If the lip folds before the platform can be If the platform does not rise fully and or lip does not walked down tension of lip assist spring 3 extend fully the lift spring tension may be set too low may be set too low
5. CONSULT FACTORY 4111 0019 NOV 2010 35 36 This page intentionally left blank 4111 0019 Nov 2010 Customer Information MISCELLANEOUS NOTE Refer to illustration for leftright anentation ol dock leveler Tha modal seral number decal AJ is located on the right platform jorst near the front ip Of deck fevetar When you receive your NMS series dock leveler write down the dock leveler model and serial number in the form provided This will help ensure safe keeping of the numbers in the event the model serial number decal A becomes lost or damaged Also write down NOVA s job number the company that installed the dock leveler and the original owner s name This will all help to identify the specific dock leveler if more information is required When ordering use part numbers and description to help identify the item ordered Do not use item numbers These are only for locating the position of the parts Always give dock leveler MODEL NUMBER and or SERIAL NUMBER For service call or contact NOVA Technology N90W14507 Commerce Drive Menomonee Falls WI 53051 Phone 800 236 7325 Fax 262 502 1511 4111 0018 NOV 2030 Deck Leveler Information Model Serial No NOVA Job No Original Mame _ Address Installer Information Date of Installation STANDARD PRODUCT WARRANTY NOVA Technology warrants that its products will be free from defects i
6. 3 X 114 9 mm to support the full width of the frame and lo provide a shell Tor a Met weld Use the thickest shim stock possible for stability and weld penelralon purposes DO NOT use mulbgle 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 pil loor al locations B Build each shim stack using the pyramid method preferred or stepped method M wilh fie top shim having a minimum ste of 4 1 2 X 4 1 2 in 114 2 x 114 3 mm and each successive lower shim being larger so the shims be welded together using a fillet weld D HOT use P or straight method NOTE assist ir ablanung arr accurate measurement of distance LI use a string pulled tight moras the opening dinscly over lhe shim locaton that each ahim stack at the height by measuring distance J lop of shim slack K dock Distance J must equal the dock leveler halght 4111 0019 70710 lege Make sure shims are langer than frame front Nat o pyramid or stepped stacking method can be used NOTE A 1 4 in 6 6 mm Ben shim at mentions C is usad only starting paint The final Shim stack wil be determined alter Ihe eveler iz verde into fe pit The dock levelar is heavy Use chains and bing device with the appropriate lifting capa
7. 4 57 4 58 4 57 4 58 4 57 4 58 4 57 4 58 8 58 8 58 20 4 57 4 58 4 57 4 58 4 57 4 58 4 57 4 58 8 58 8 58 7 0 FOOT 16 4 57 4 58 4 57 4 58 4 57 4 58 8 58 8 58 8 58 18 4 57 4 58 4 57 4 58 4 57 4 58 8 58 8 58 8 58 20 4 57 4 58 4 57 4 58 4 57 4 58 8 58 8 58 8 58 34 4111 0019 Nov 2010 Toe Guard Weather Seal Optional 6 FOOT PARTS T 8 FOOT 10 FOOT 1 1 0014 0062 TOE GUARD LH MIDDLE 0014 0070 TOE GUARD LH MIDDLE 0014 0078 TOE GUARD LH MIDDLE 2 1 0014 0066 GUARD LH LOWER 0014 0074 GUARD LH LOWER 0014 0082 TOE GUARD LH LOWER 3 1 0014 0064 GUARD RH MIDDLE 0014 0072 TOE GUARD RH MIDDLE 0014 0080 TOE GUARD RH MIDDLE 4 1 0014 0068 TOE GUARD RH LOWER 0014 0076 GUARD RH LOWER 0014 0084 TOE GUARD RH LOWER 5 2 2041 SCREW SAME SAME 6 4 OTH 2207 WASHER SAME SAME 7 2 OTH 2131 LOCK NUT SAME SAME 4 pkrre179 FRTG COMPLETE R amp L DKIT 9180 FRTG COMPLETE R amp L DKIT 9181 FRTG COMPLETE R amp L 9 2 DOTH 2841 CHANNEL WEATHER SEAL DOTH 2840 CHANNEL WEATHER SEAL DOTH 2843 CHANNEL WEATHER SEAL 10 2 DOTH 2824 RUBBER WEATHER SEAL DOTH 2824 T RUBBER WEATHER SEAL CONSULT FACTORY 11 2 DOTH 2822 BRUSH WEATHER SEAL 2822 BRUSH WEATHER SEAL CONSULT FACTORY 12 2 DOTH 2821 EXTRUSION ALUM DOTH 2820 EXTRUSION ALUM
8. 4111 0019 Nov 2010 SAFETY Safety Decals Every 90 days quarterly inspect all safety labels and tags to ensure they are on the dock leveler and are easily legible If any are missing or require replacement please call 1 800 236 7325 for replacements ik DANGER 1751 0329 2 decal n same am bolfr args 1751 0330 Pad Teu 7 090110 VI III 1751 0728 Dod 1751 0731 1751 0726 E 4771 0018 MOV 2010 OWNER S USER S RESPONSIBILITIES 1 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 Before operation of the equipment all operators shall read understand and be familiar with all functions of equipment as described in the owner s user s manual The manufacturer shall provide to the initial purchaser all necessary information with regards to Safety Information Operation Installation and Safety Precautions Recommended lnitial and Periodic Inspections Procedures Planned Maintenance Schedule Product Specifications Troubleshooting Guide Parts Break Down Warranty Information and Manufacturers Contact Information The owner user shall be respons
9. If the platform cannot be walked down or is difficult to If the lip does not fold fully or takes too long to walk down the lift spring tension may be set too high fold tension of lip assist spring 3 may be set too high 4 Adjust lip assist spring tension as follows If the platform does not rise fully on its own it may be necessary to use an external lifting device Use NOTE Use two turn increments when adjusting lip a lifting device with the appropriate lifting capacity assist spring 3 Check lip operation after to safely raise the platform Make sure to engage each adjustment Repeat until proper and pin the platform maintenance prop after raising operation is obtained the platform Failure to do this may result in serious personal injury or death a Loosen jam nut 1 b To increase spring compression turn nut 2 IMPORTANT clockwise When using an external lifting device to raise the c To decrease spring compression turn nut 2 platform make sure hold down mechanism 6 is counterclockwise disengaged Pull and hold platform release ring during the lifting process to avoid shearing the d Tighten jam nut ratchet pawl and ratchet bar teeth 5 Recheck operation of platform and lip Readjust lift spring tension and lip assist spring tension until 1 Raise the platform and engage the platform proper operation is obtained maintenance prop Pin the maintenance prop in the service position using attached pin d
10. 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 DO NOT activate the dock leveler until the truck trailer is positioned squarely against the bumpers and the truck wheels are chocked Never remove the wheel chocks until loading and unloading is finished and truck driver has been given permission to leave DO NOT use the dock leveler if the freight carrier is too high or too low NEVER use a fork truck or any other material handling equipment to lower the dock leveler DO NOT drive any equipment onto the dock leveler until platform lip is resting on the truck trailer with at least 4 in 102 mm of overlap Always maintain a safe distance from side edges of leveler during the loading and unloading process NEVER attempt to walk on an unsupported lip in 305 mm The MP series mechanical dock leveler is designed to compensate for 12 in 305 mm of height difference between the loading dock and the truck bed DO NOT use the dock leveler if the truck trailer bed is more than 12 in 305 mm higher or lower than the dock floor DO NOT overload the dock leveler DO NOT operate any equipment while under the influence of alcohol or drugs DO NOT leave store equipment or material unattended on the dock leveler Failure to follow these instructions may result in personal in
11. 10 The ratchet disengages only when the platform release ring is pulled AND held Spring leneion from paw spring causes the ratchet to engage the ratchet bar when the release ring is let go When the platform nses 10 approximately 2 3 inches 51 76 mim from its full raised height the lip snubber spring 13 and a chain pulls the lip link 4 down This in conjunction with the lip assist spring 5 causes the lip linkage to push the lip out and up The lip assist spring also helps control the amount of time required for the lip te fully feld To lower the platform the operator walks out onto the platform The platform will lower until the extended lip rests on the truck bed If the lip did not fully extend or there is no truck at the dock the platform wall lower Until one of the following conditions occur Lip is resting on lip keepers cross traffic position Lip did not fully fold causing the platform io rest on safety legs below dock position Lip d not fully fold and safety legs are retracted causing the platform te rest on the safety stops Tull below dock position The hold down ratchet assembly will keep the platform at the desired position until the platform release ring is pulled again 17 OPERATION Operating Instructions Stay clear of dock leveler when freight carrier is entering or leaving dock area DO NOT raise or lower the dock leveler if anyone is under or in front
12. 6820 58 SEE CHART DOTH 2578 SPRING MAIN 6835 6 FOOT LONG 6 0 FOOT 25K 30K 35K 40K 45K 55K 16 4 55 4 55 4 55 4 55 4 55 1 55 2 56 18 4 55 4 55 4 55 4 55 4 55 1 55 2 56 20 4 55 4 55 4 55 4 55 4 55 1 55 2 56 6 5 FOOT 16 4 55 4 55 4 55 4 55 4 55 1 55 2 56 18 4 55 4 55 4 55 4 55 4 55 1 55 2 56 20 4 55 4 55 4 55 4 55 4 55 1 55 2 56 7 0 FOOT 16 4 55 4 55 4 55 4 55 2 55 2 56 2 55 2 56 18 4 55 4 55 4 55 4 55 2 55 2 56 2 55 2 56 20 4 55 4 55 4 55 4 55 2 55 2 56 2 55 2 56 8 FOOT LONG 6 0 FOOT 25K 30K 35K 40K 45K 55K 16 4 55 4 57 4 57 4 57 4 57 4 57 18 4 55 4 57 4 57 4 57 4 57 4 57 20 4 55 4 57 4 57 4 57 2 57 2 58 2 57 2 58 6 5 FOOT 16 4 57 4 57 4 57 4 57 2 57 2 58 2 57 2 58 18 4 57 4 57 4 57 2 57 2 58 2 57 2 58 2 57 2 58 20 4 57 4 57 4 57 2 57 2 58 2 57 2 58 2 57 2 58 7 0 FOOT 16 4 57 4 57 4 57 4 57 2 57 2 58 4 58 18 4 57 4 57 4 57 4 57 2 57 2 58 4 58 20 4 57 4 57 4 57 2 57 2 58 2 57 2 58 4 58 10 FOOT LONG 6 0 FOOT 25K 30K 35K 40K 45K 55K 16 8 57 4 57 4 58 4 57 4 58 4 57 4 58 8 58 8 58 18 8 57 4 57 4 58 4 57 4 58 4 57 4 58 8 58 8 58 20 8 57 4 57 4 58 4 57 4 58 4 57 4 58 8 58 8 58 6 5 FOOT 16 4 57 4 58 4 57 4 58 4 57 4 58 4 57 4 58 8 58 8 58 18
13. IES SHALL NOT IN ANY EVENT BE LIABLE TO ANYONE INCLUDING THIRD PARTIES FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO BREACH OF WARRANTY LOSS OF USE LOSS OF PROFIT INTERUPTION OF BUSINESS OR LOSS OF GOODWILL PRODUCT SPECIFIC WARRANTY NMS SERIES LEVELER In addition to the Standard Product Warranty provided with all NOVA Products NOVA Technology guarantees materials components and workmanship to be free of defects for the following extended periods Structural Warranty For a period of five 5 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 at NOVA s sole discretion and expense including reasonable labor materials freight and travel If NOVA determines replacement is necessary it will provide the original purchaser with a credit toward the purchase of the new replacement NOVA product in the amount equal to the original purchase price of the warranted product F O B point of manufacture discounted on a five year straight line basis by the number of years of use prior to replacement
14. LT 27 1 2131 LOCK NUT 28 2 2214 WASHER 29 1 DOTH 2547 SPRING COMPRESSION 30 1 2582 SHOCK GAS 31 1 DOTH 2351 BOLT CLEVIS 32 2 DOTH 2374 PIN COTTER 33 4 DOTH 2210 WASHER FLAT 34 2 DOTH 2163 LOCK NUT LIP SHAFTS 35 2 DPLA 2101 6 0 FOOT 2 DPLA 2102 6 5 FOOT 2 DPLA 2103 7 0 FOOT 36 2 DOTH 2355 CLEVIS 37 2 DOTH 2373 PIN COTTER 39 2 2101 0079 WASHER FLAT 38 LIPS 6 0 FOOT 25K 30K 35K 40 45K 55K 1 16 0595 5000 0595 5009 0595 5018 0595 5027 0595 5036 1 18 0595 5001 0595 5010 0595 5019 0595 5028 0595 5037 1 20 0595 5002 0595 5011 0595 5020 0595 5029 0595 5038 6 5 FOOT 1 16 0595 5003 0595 5012 0595 5021 0595 5030 0595 5039 1 18 0595 5004 0595 5013 0595 5022 0595 5031 0595 5040 1 20 0595 5005 0595 5014 0595 5023 0595 5032 0595 5041 7 0 FOOT 1 16 0595 5006 0595 5015 0595 5024 0595 5033 0595 5042 1 18 0595 5007 0595 5016 0595 5025 0595 5034 0595 5043 1 20 0595 5008 0595 5017 0595 5026 0595 5035 0595 5044 1Must provide dock leveler serial number platform size capacity any options and lip size when calling or faxing orders 33 4111 0019 NOV 2010 PARTS Platform Components 55 SEE CHART DOTH 2570 SPRING MAIN 6620 56 SEE CHART DOTH 2574 SPRING MAIN 6635 57 SEE CHART DOTH 2576 SPRING MAIN
15. NOVA NMS TECHNOLOGY Mechanical Dock Leveler Owner s User s Manual NOVA Technology International Inc N90W14507 Commerce Drive Menomonee Falls WI 53051 Phone 262 502 1591 800 236 7325 fax 262 502 1511 www novalocks com Manual No 4111 0019N Printed in USA June 2010 2010 November 2010 Table of Contents Page Safety Recognize Safety Information 1 General Operational Safety Precautions 1 Operational Safety Precautions 2 Maintenance Safety Precautions 4 Safety Decals 2e RR RR E cd Seeley ee 63 5 Owner s User s Responsibilities 6 Introduction General Information 7 Dock Leveler Stock Specifications 7 Component Identification 8 Installation Prepare ss gc ee AR 9 Prepare Dock Leveler 10 Install Dock Leveler 12 Operation I _ _ _ _ _ an En 17 Operating Instructions 18 Ramp Loading Unloading Instructions 19 End Loading Unloading Instructions 20 Maintenance Service Dock Leveler Safely 21 Periodic Maintenance
16. UP FRONT PICK UP 11 4111 0019 NOV 2010 INSTALLATION Install Dock Leveler Shim Stacking Methods A Distance Leveler Frame F String G Height G Rear Hinge Frame Angle B Shim Locations Under H Distance Dock Floor to Rear Vertical Supports Pit Floor 4 5 Places TYP J Distance Top of Shim C Shim Locations Under Stack to Dock Floor Lip Keepers Lifter Arm K Shim Stack and Prop L Dock Leveler Frame D Dock Floor M Pyramid Preferred E Rear Pit Curb Angle N Stepped Acceptable P Offset Not Acceptable Q Straight Not Acceptable 12 4111 0019 Nov 2010 INSTALLATION NOTE NOVA dock levelers are designed with a nominal 1 2 in 12 7 mm shimming distance to allow for pit inconsistencies 4 Puta 1 4 in 6 6 mm thick shim at locations C under lip keeparsimmalntenance prop and safety 1 Determine height of shim stack K lor each shim location B by performing the following a Measure leveler frame height distance A b dock flaar te pit distance Hj at each shim location B Write down the dimensions obtained at each locaton c Subtract distance from distance H to obtain the shim height Repeat for each shim location IMFORTANT The minimum size of the shim that contacts the leveter frame 1 6 Ihe top shim of sach shim shack must be atleast 4 T 2 x 4 T Z im 114
17. city and reach t do so may result in damage to dock lgvelar and or serious personal injury or death amp Using an appropriate lifting cannacted to the lifting brackets lower dock leveler into he pit 50 fear hinge frame angle G is ight against rear MI eurb E acasa full width of the lavalar frame amp Allow mar of dock lavalar to reat on the rear shims while keeping the front of fhe dock leveler level with the dock floor 7 Add chime at front chim locations C eo front of dock leveler will stay level with floor when lavalar fully on ah ma 13 INSTALLATION 474 47 4 4 17 44 47 4 4 44 47 47 ys 1 8 5 mm A Front of Dock Pit C Sida Curb Angie E Pry Locations G Rear Curb Angle B Doch Leveler Frame D 344 in 19 mm F Rear Hinge Frame Angle H Flare Bevel Weld Typical Minimum To Fit Spacing 8 With rear hinge frame angle tight against near 10 Allow the dock leveler to rest fully on the shim pit curb angle G pertorm check the following sincks Make sure the leweler is in ihe cross traffic stored position with lip resting on lip Pry between the platlorm and rear hinge frame Keepers angle at locations 18 make sure rear edge of platform is parallel to the rear hinge frame 11 Check thal a smooth and level transition exists angle F between the dock floor and the dock leveler pla
18. d shimming method Page 12 The lift arm pivot must be solidly shimmed the entire length of the lift arm pivot Make sure the lift arm pivot is level from side to side 23 Finish weld all shims using a fillet weld Weld all shims within each shim stack to each other then weld the shim stack to the leveler frame Weld the front leveler frame shim stacks to the front pit curb steel if not done previously 24 When all welding has been completed remove all slag then paint all the welds and shims 16 25 26 27 28 29 30 31 32 Chain Remove the lifting brackets from the platform side joists Disengage the platform maintenance prop Slowly walk out onto the platform to lower the platform until it is at the cross traffic stored position Check operation of dock leveler by cycling the leveler at least four times When the platform is at full height lip will be fully extended Lip will begin to drop after the unit begins to lower to truck bed Check below dock position by walking platform down before lip folds completely Lip will be over lip keepers Platform safety legs will be resting on frame Check full below dock position by walking the platform down Pull and hold safety leg chain E before lip folds completely If the lip does not extend fully or lip folds too quickly see appropriate symptom in the Troubleshooting section Install the dock bumpers as required c
19. d tagout device supplied by others Only the person servicing the equipment should have the capability to remove the lockout device The tagout device must inform that repairs are in process and clearly state who is responsible for the lockout condition If maintenance requires that the lip be in the extended position raise the lip by hand and support the lip with the lip maintenance prop C NOTE Make sure to disengage the lip maintenance prop and allow the lip to fold fully before disengaging the platform maintenance prop Refer to OSHA regulation 1910 147 21 MAINTENANCE Periodic Maintenance A UKS x n Wey SA 1 Lip Hinge Grease Fittings 4 Lift Arm Pivot 7 Lip Lift Assist Pin 2 Lip Maintenance Prop Pivot 5 Hold Down Pivot Pulley 8 Hold Down to Platform Pin 3 Lift Arm Roller Bushing 6 Safety Leg Linkage Pivots Always post safety warnings and barricade the The platform maintenance prop MUST be in the work area at dock level and ground level to prevent service position when working under the dock unauthorized use of the dock leveler before leveler For maximum protection use an OSHA maintenance is complete Failure to do this may approved locking device to lock the maintenance result in serious personal injury or death prop in the service position supplied by others Only the person servicing the equipment should have the ke
20. e lip overlaps onto trailer at least 4 in putting any part of your body near moving parts 102 mm Keep a safe distance from both side edges 2 4111 0019 Nov 2010 SAFETY Do not use dock leveling device if freight carrier is too high or too low Do not operate any equipment while under the influence of alcohol or drugs Do not leave equipment or material unattended on dock leveling device 4111 0019 NOV 2010 SAFETY Maintenance Safety Precautions 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 When engaging the maintenance prop ensure the bridge pin is set in place and closed before servicing or maintainning the unit DO NOT grind or weld if hydraulic fluid or other flammable liquid is present on the surface to be ground or welded DO NOT grind or weld if uncontained hydraulic fluid or other flammable liquid is present Stray sparks can ignite spills or leaks near the work area Always clean up the oil leaks and spills before proceeding with grinding or welding Always keep a fire extinguisher of the proper type nearby when grinding or welding Failure to follow these instructions may result in 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
21. eler frame at this time The shipping bands are needed to hold the leveler together during the installation process 4117 00159 Now 2010 INSTALLATION 1 Remove any bumpers that may be banded or 4 Remove wood blocks that are attached to the bolted to the frame of the dock leveler leveler frame before putting the dock leveler into the pit DO NOT remove the shipping bands B around the platform lip and leveler frame at this time 5 To pick up the unit from the rear slide forks into the fork slots and under the cross member Shown below 6 To pick up the unit from the front move forks closer IMPORTANT together and slide over the frame and under the cross DO NOT over tighten the lifting bracket hardware member It may be necessary to unband the unit to Over tightening can damage the weather seal if gain access to the front by lifting the lip up then equipped sliding the forks under the cross member 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 toa lifting device i e hoist or fork truck having the appropriate lifting capacity and reach REAR PICK
22. evice 2 Adjust tension of lift springs 4 as follows NOTE Use 1 2 turn increments when adjusting lift spring bolt 5 Turn clockwise to increase tension and counterclockwise to decrease tension Check platform operation after each adjustment Repeat until proper operation is obtained To increase lift spring tension turn lift spring bolt 5 clockwise To decrease lift spring tension turn lift spring bolt 5 counterclockwise 25 4111 0019 NOV 2010 ADJUSTMENTS Adjust Lip Stop Bolt Always post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the dock leveler lip when working in front of the dock leveler Failure to do this may result in serious personal injury or death The platform maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved locking device supplied by others to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Failure to follow these instructions may result in serious personal injury or death Check that lip E is fully resting on the lip keepers D and at the lowest part of the lip keepers If lip is not resting properly in lip
23. ible to verify that this information is available and received as well as proper instructions training and familiarity of the equipment for all operators has been completed Owner s User s shall actively maintain update and re train all operators on safe working habits and operations of the equipment It is recommended 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 Name plates placards decals instructions and posted warnings shall not be obscured from the view of the operator or maintenance personnel for whom such warnings are intended for Contact manufacturer for any replacements Manufacturer s recommended periodic maintenance and inspection procedures in effect at the date of shipment shall be followed at all times Written documentation of maintenance replacement parts or damage should be retained In the event of damage notification to the manufacturer is requested Any modifications or alterations of loading dock equipment shall only be done with prior written approval from the original equipment manufacturer 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 a
24. jury and or damage to equipment IMPORTANT When activating the leveler always pull AND hold the platform release ring until the platform is at the full raised position Releasing the ring while the platform is still rising may result in damage to the equipment The dock leveler operation instructions are divided into the two methods of loading and unloading NEVER allow untrained personnel to operate the dock leveler NEVER attempt to lift any part of the leveler by For ramp loading and unloading see Ramp hand Loading Unloading Instructions on page 19 Failure to follow these instructions may result in serious personal injury or death For end loading and unloading see End Loading Unloading Instructions on page 20 18 4111 0019 Nov 2010 Operating Instructions Continued Ramp Loading Unloading Instructions NOTE If end unloading is required see End Loading Unloading Instructions on page 20 1 Check to make sure truck trailer 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 truck trailer wheels or use truck restraint if present 4 Raise the platform by pulling and holding the platform release ring A 5 Hold the release ring until the platform is at the fully raised position and lip is fully extended 6 Walk out onto the platform The platform will lower until the lip
25. keepers perform the following adjustment 1 Fully raise platform Manually raise the lip and engage lip maintenance prop not shown 2 Loosen jam nut B 3 Adjust stop bolt C as necessary Turn stop bolt in clockwise to allow lip to fold closer to platform A Turn stop bolt out counterclockwise to hold lip further away from platform A 26 A Platform D Lip Keeper B Jam Nut E Lip C Stop Bolt Tighten jam nut B Disengage lip maintenance prop Walk platform down to cross traffic stored position Check lip position in both keepers Repeat procedure if necessary 4111 0019 Nov 2010 Troubleshooting Always post safety warnings and barcade the work ama at dock level and ground level to prevent unauthorized use of tha dock lever belore maintenance is complete Failure to do this may result in serious personal injury or death Always stand clear of the deck bevalar lip when working in front of tha dock leveler Failum te do this may result in serious personal injury or death Platform does not rise Dock III binds Heavy objects en pl ther TROUBLESHOOTING The platiorm maintenance prop MUST be in the service position when working under the dock For maximum protector uae OSHA approved lacking device te lask the maintenance prop in the service position supplied by others Only person servicing the equipment shou
26. latform does not stay down Lip does not fold after truck departs 28 Lip assist chain Connect or replace chain disconnected or broken Insufficient main spring Increase tension on main lift springs See Adjust Lift tension Arm Spring and Lip Assist Spring Tension in the Adjustments section Insufficient lip assist force Increase lip assist spring compression See Adjust Lift Arm Spring and Lip Assist Spring Compression in the Adjustments section Excessive main spring Reduce main spring tension See Adjust Lift Arm tension Spring and Lip Assist Spring Tension in the Adjustments section Damaged or worn Clean and inspect hold down mechanism hold down mechanism Insufficient lip assist force Increase lip assist spring compression See Adjust Lift Arm Spring and Lip Assist Spring compression in the Adjustments section Disconnected worn or Inspect shock absorber Connect or replace gas broken gas strut strut Entangled release chain Remove cause of entanglement Dirt impacted in ratchet bar Clean and inspect ratchet bar and ratchet pawl teeth teeth DO NOT lubricate the ratchet assembly Broken or damaged ratchet Replace ratchet assembly DO NOT lubricate the assembly teeth ratchet assembly Disconnected or broken Replace hold down pivot pins hold down pivot pins Damaged or worn Clean and inspect hold down mechanism hold down mechanism Lip hinge binding because Inject grease into all of
27. ld have the key t unlock the maintenance pron Failure follow these instructions may result in serious personal injury or death Remise objects from platterm NOTE For reasons Ihe dock ilaveler designed fo lit only tha platens onm Disconnected or broken Connect or raplace dhar release chain Check for visible obetructionge that could cause binding Check weather seal if equipped If no obstructions found call NOVA Technical Services See cover for phone number and address Plalform slowly or Heavy object z on platform Remove objectis from platform does not rise to the Tull position Dock leveler binds Insul ceni mein spr ng tension NOTE For safety reasons the dock lavalar is designed to lift oniy tha platforms own weight Check far obstructions that cold Gaia binding Chack weather saal if equipped If no obstructions found call NOVA Technical Services See cover for phone number and address Increase on main springs See Adjust Lilt Arm Sp ng and Lip Assist Spring Tension the Adjustments section Damaged or worn Clean and inspect hold down mechanism heid dewmn mechanism 4111 0045 2010 TROUBLESHOOTING Platform rises to full height but lip does not fully extend Platform does not lower when operator walks out onto the platform Lip folds too fast during normal walk down P
28. lean weld splatter and touch up with spray paint 4111 0019 Nov 2010 OPERATION 1 Lip Down Rebease Ring 10 Platform Maintenance Prop 15 Safety Lag Below Dock 2 Maintenance Prop 1 Pared 11 Base Frame 3 Platform Ratchet Bar 12 Safety Log Assy 16 Safety Leg Ratract Full Ring 4 Link 9 down 11 Snubber Spring 17 Arm 5 Assist Spring 14 Gas Shock 18 LIN Springs The NMS series mechanical dock leveler uses large lift springs 18 to apply force to lift arm 17 The lift arm pushes against the underside of the platform 3 rolling on the cam not pictured forcing the platform to rise The force of the spring tension is just enough to lift the weight of the platform and extend lip IMPORTANT When activating the leveler always pull AND hold platiorm release ring until the platform is at the full raised pessitian Releasing the ring while the platform is still rising may result in damage t the equipment actuate the dock leveler platform the operator Pulls and holds the platform release ring 6 located the recess al the near of the platform This causes ratchet pawl 7 disengage fram ratchet bar 81 With the ratchet pawl disengaged spring tension from lift springs 18 forces the platform to rise NOTE Ratchet paw 7 and bar 8 are part af the mechanism 8 4111 0018 NOV 20
29. ll other positive restraining device shall be fully utilized Loading dock safety equipment should never be used outside of its intended use range or capacity Please consult the manufacturer if you have any questions as to the use range or capacity of 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 environments or use 4111 0019 Nov 2010 INTRODUCTION General Information Dock Leveler Stock Specifications NMS Series Mechanical Dock Levelers dock levelers are available in the following sizes weight capacities and options 6 ft 1828 8 mm 6 1 2 ft 1981 2 mm 7 ft 2133 6 mm 6ft 18288 mm sh 2438 mm 10 ft 3048 mm 25 000 Ib 11 340 kg 30 000 Ib 13 608 kg Congratulations on your choice of a NOVA dock 35 000 Ib 15 876 kg leveler This manual covers the NMS series 40 000 Ib 18 144 kg mechanical dock leveler 45 000 Ib 20 412 kg Designed by NOVA to be a marvel of simplicity and 000 b EE BAD ko efficiency your dock leveler when properly installed will provide many years of trouble free performance with an absolute minimum of maintenance To obtain maximum performance and longest possible use a simple program of preventive maintenance is recommended CIR Comparative Industry Rating Call NOVA for your specific needs Once again thank you and c
30. machine damage 4111 0019 NOV 2010 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 decals on the equipment unless replacing them DO NOT activate the equipment until all unauthorized personnel in the area have been warned and have moved outside the operating zone Remove any tools or foreign objects from the operating zone before starting Keep the operating zone free of obstacles that could cause a person to trip or fall SAFETY Operational Safety Precautions Learn the safe way to operate this equipment Read and understand the manufacturer s instructions If you have any questions ask your supervisor Stay clear of dock leveling device when freight Chock restrain all freight carriers Never remove carrier is entering or leaving area the wheel chocks until loading or unloading is finished and truck driver has been given permission to drive away Do not use a broken or damaged dock leveling Do not move or use the dock leveling device if device Make sure proper service and anyone is under or in front of it maintenance procedures have been performed before using Keep hands and feet clear of pinch points Avoid Make sur
31. n 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 manufacturer s recommen dations 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 responsi bility of the Owner User In the event of a defect as determined by NOVA Technology covered by this warranty NOVA Technology shall remedy such defect by repairing or replacing any defective equipment or parts bearing the cost for the parts labor and transportation This shall be exclusive remedy for all claims whether based on contract negligence or strict liability WARRANTY LIMITATIONS THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SYSTEMS INC AND ITS SUBSIDAR
32. om truck trailer wheels or release truck restraint if used 10 Indicate to the driver that the truck may leave the dock 4111 0019 Nov 2010 MAINTENANCE Service Dock Leveler Safely 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 Failure to do this may result in serious personal injury or death The platform maintenance prop MUST be in the service position when working under the dock leveler For maximum protection use an OSHA approved lock out tag out device supplied by others to lock the maintenance prop in the service position Only the person servicing the equipment should have the key to unlock the maintenance prop Failure to follow these instructions may result in serious personal injury or death 4111 0019 NOV 2010 Whenever maintenance is to be performed under the dock leveler platform support the platform with the platform maintenance prop Put the platform maintenance prop in the service upright position so that the prop is cradled in back of the header plate and the underside of the deck plate Secure the platform maintenance prop in this position by inserting the pin or attaching an OSHA approved lockout device an
33. ongratulations on your purchase of a NOVA mechanical dock leveler 4111 0019 NOV And INTRODUCTION Component Identification IV D 4 s 1 Lip 6 Hold Down Release Ring 11 Main Base Frame 15 Safety Leg Pull Chain 2 Lip Maintenance Prop 7 Ratchet Pawl 12 Safety Leg Assy 16 Lift Arm Assembly 3 Platform 8 Ratchet Bar 13 Lip Snubber Spring 17 Lift Main Spring 4 Lip Link 9 Hold Down 14 Lip Shock Absorber 18 Prop Pin and Clip 5 Lip Assist Spring 10 Platform Maintenance 19 Working Range Toe Prop Guards 8 4111 0019 Nov 2010 Prepare Pit A Distance Width B Distance Dock Floor to Pit Front and Rear Floor Four Corners Post safety warnings and barricade Ihe work area at dock level and ground level ta prevent unaulhorzed use of the dock leveler before installation has been completed Failure to follow the installation Instructions result in damage to dock leveler ihe facilities and or serious personal injury or death Only trained installation professionals with Ihe proper equipment should install this product IMPORTANT DO NOT remove the shipping bands around the dock leveler lip until instructed to do so 4111 0018 NOV 2010 C UDistance Pit Length INSTALLATION D Distancu Fit Cornar bo Cornerj Both Sides of Fit Top and Both Sides Befo
34. patom raleass rng untl the platform at tha lull raised position Releasing the ring while the platform is still may result in damage to the equipment 17 Pull and hold the release ring located In recess rear of platform untl the platform i fully raised Check for binding as platterm rises 18 Slowly walk out onto the platlorm to lower the Hatemi Allow the patemi te loyer la the position Check for binding platlorm lowers 19 If binding occurs reposition leveler and or add or remove shims as necessary Raise and lower platform again If platform still binds contact NOVA Technical Services for further instructions TU Check that the leweler flush wiih the dock foor and that the plationm hp contacte both lip keepers event 15 INSTALLATION A Platform Release Ring B Platform Maintenance C Lip prop support D Prop Pin and Clip E Safety Leg Pull Prop 21 Pull the release ring A to raise platform Engage the platform maintenance prop B in the service upright position and lock the maintenance prop at this position using an OSHA approved locking device supplied by others Engage lip maintenance prop C 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 22 Install shims under lift arm at locations using the pyrami
35. re lowering the dock leveler into the pit the following must be performed 1 Remove all debris from the pit and sweep the pit clean 2 Check the entire dock beveler pit for proper construction according lo appraoved certified pil drawings Make sure p Is square by making the following measurements Measure pil width distance A al both front and rear of pit Measure dock floor to pit floor distance B al all four corners Measure pit length distance C at both sides Measure criss cross 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 NOVA Technical Services before proceeding INSTALLATION Prepare Dock Leveler A Lifting Bracket 2 used chains with the appropriate lifting capacity and reach Always use the lifting brackets provided with the unit whenever lowering or lifting dock leveler into aut af a pit Failure to follow these instructions may result in damage the dock leveler and or serious personel injury or death NOTE third sling may be used to install the unit as needed 10 Shipping Bands NOVA dock levelers are designed with installation in mind Each unit is shipped with lifting brackets A fastened to the platform side joists IMPORTANT DO NOT remove the shipping bands B around the lp and lev
36. rests on the truck trailer bed 4111 0019 NOV 2010 OPERATION 7 Make sure that the lip is fully extended and supported on the truck trailer along the entire width of the platform with at least 4 in 102 mm of lip contacting the truck bed 8 Proceed with loading or unloading NOTE If end loading is necessary see End Loading Unloading Instructions on page 20 9 When the loading or unloading process has been completed return platform to cross traffic stored position as follows a Raise the platform to the full raised position by pulling and holding the platform release ring A b Lower platform by slowly walking out onto the platform allowing time for the lip to fully fold and clear the truck trailer Continue walking out on platform until platform lowers to the cross traffic position lip engages in the lip keepers 10 Remove chocks from truck trailer wheels or release truck restraint if used 11 Indicate to driver that truck may leave the dock 19 OPERATION Operating Instructions Continued End Loading Unloading Instructions NOTE 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 truck trailer bed 1 Check to make sure truck trailer is positioned squarely against dock bumpers 2 Instruct driver to remain at the dock until the loading or unloading process has been completed and instructed to leave
37. tform Add or remove shims as necessary until Gap D must exist equally along both sides of a amp mooth transition is obtained loveler so wealhar seal if equipped will not bind during dock leveler operation 12 If leveler cannot be squared and made level as instructed in steps 8 10 contact NOVA 8 gap D cannot be obtained equally at both Technical Services sides of leveler grind or add material at the rear edge of rear hinge frame angle as needed 14 gt 4111 0018 Now 2010 DO NOT grind er weld it hydraulic fluid or other flammable liquid is present on the surface to ba ground or welded DO NOT gind or weld if uncontalned hydraulic fluid or other flammable liquid is present Stray sparks can ignite spills or leaks near fe work area Always clean up the oll leaks and belona proceeding wih grinding or welding Alanya keep a fine extinguisher of the proper type nearby when grinding or welding Fallura to fellow these Instructions may result In enous personal injury or death IMPORTANT Always ground welding equipment to the dock leveter frame NEVER to the OO weld continuously along the full length of the rear hinge frame angle This can put 50955 on the laer components causing ha leveler nat te lunction correctly and shorten ihe lilespan of the components NOTE The Hlustration on the previous page shows a weld pa
38. the lip hinge grease fittings of lack of lubrication See Periodic Maintenance in the Maintenance section Excessive lip assist force Decrease lip assist spring compression See Adjust Lift Arm Spring and Lip Assist Spring Compression in the Adjustments section 4111 0019 Nov 2010 PARTS Hold Down Mechanism HOUSING RELEASE LEVER 4 1 HANDLE 5 1 PAWLSPRING EXTENSION SPRING 2 035 006 1147 LG CLEVIS B EN 110 13 1 x O d CLEVISPIN 52565 a Nm 4111 0018 Nov 2006 29 PARTS Frame Components 20 171213 30 10 19 4111 0019 Nov 2010 PARTS Frame Components BASE FRAMES NVS2000AR COLD DOWN PAZ LIFTER ARM 77 IN DOTP 8424 LIFTER ARM 25 IN BWD 25 LIFTER ARM 77 all others en aj pomen ru ius eua pa fa 24 IMCM PIT I _ INCH PIT E LL Must provide dock laveler serial number platform size lip size capacity any options and pit depth when calling er faxing orders 31 4111 0019 NOV PARTS Platform Components 38 EEE 35 29 28 27 2625 37 gg 36 7155 56 57 58 19 18 17 PLATFORMS ITEM QTY 6 FOOT 8 FOOT 10 FOOT 1 6 0 FOOT 6 5 FOOT 7 0 FOOT 6 0 FOOT 6 5 FOOT 7 0 FOOT 6 0 FOOT 6 5 FOOT 17 0 FOOT 1 25
39. ttem The weld pattern wil vary alightly depanding size of dock lavalar 13 With the rear hinge frame angle F tight agalnst fhe rear pil curb angle 6 weld the rear hinge frame angle t the rear pit ours angle using a 8 In 9 5 mm flare bevel skip weld sach weld being 8 in 152 mm long Start nt each end with a 6 In 15 mm long weld Space all the other welds oul evenly leaving appreximately gt In 152 mm space betwen each wald Altemate weldng te distribute heat Welding sequentially from one end to the other may cause warping or disterbon 4111 0045 NOW 2010 INSTALLATION 14 Remove shipping bands at this time Allow platlorm to foal Add Remove shims as te bang platform levelfush with for Make sure personnel are outside of the leveler operating zone and stand dear of the platform lip before removing the shipping bands Failure te do this may result In serous personal injury or death 15 Weld front of dock leveler frame to shima located under the keepers then weld the shime te front pit curb steel 16 Disconnact lifting device and chalna from tha lifting brackets Make sure personnel are outside of the leveler operaling cone and clear of the patom lip before valen Fallure t de tus may result In serious personal injury or death IMPORTANT When activating the always pull AND hold the
40. y to unlock the maintenance prop Failure to follow these instructions may result in Always stand clear of the dock leveler lip when serious personal injury or death working in front of the dock leveler Failure to do this may result in serious personal injury or death 22 4111 0019 Nov 2010 Regular maintenance must be performed on 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 position the platform in the full below dock position Inspect the platform hinge and the lip hinge areas The hinge areas must be kept free of dirt and debris Build up of foreign material in the hinge areas will increase wear and cause abnormal operation IMPORTANT Failure to properly lubricate the dock leveler will cause abnormal operation of the leveler DO NOT lubricate the hold down ratchet bar and pawl 4111 0019 NOV 2010 MAINTENANCE Quarterly Maintenance Lubricate the following areas with light weight machine oil 2 Lip maintenance prop pivot 5 Hold down pivot pulley 6 Safety leg linkage pivots 8 Hold down to platform pin Lubricate the following areas with white lithium grease 1 Lip hinge area inject grease into all the lip hinge grease fittings 3 Lift arm roller bushing 4 Lift arm pivot 7 Lip assist pin 23
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