DLM HED Series, Owner & User Manual

Page 1: ... User s Manual 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 Copyright 2009 Manual No 4111 0027 Sept 2010 May 2012 ...

Page 2: ...2 Ramp Mount Weld Bolt On 14 Flush Mount Bolt On 16 Ramp Mount Weld On w Formed Angle 18 Formed Angle 20 Ramp and Face Plate 22 Installation Check List 24 Install Control Panel and Wiring 26 Put New Dock Leveler Into Service 27 Operation Operating Instructions 28 Maintenance Periodic Maintenance 30 Adjustments Adjust Main Pressure Relief 33 Adjust Lip Function 34 Electrical Single Phase 36 Three P...

Page 3: ...ore starting Keep the operating zone free of obstacles that could cause a person to trip or fall 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 Safety Alert Symbol The Safety Alert Symbol identifies important safety messages on equipment safety signs in manuals or elsewhere When you see this symbol b...

Page 4: ...ling 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 Chock restrain all freight carriers Never remove 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 damage dock leveling device Make sure proper service and maintenance p...

Page 5: ...dock leveling device if freight carrier 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 SAFETY ...

Page 6: ...ent 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 re...

Page 7: ...rial or people are on the dock leveler Return the dock leveler to its stored position at dock level Failure to follow posted instructions will result in death or serious injury SAFETY INFORMATION Call 262 255 1510 for replacement placards warning labels or owner s user s manuals Operation 1 Read and follow all instructions and warnings in the owner s user s manual 2 Use of dock leveler restricted ...

Page 8: ...rnings and place the same in view of the operator or maintenance personnel for whom such warnings are intended for Contact manufacturer for any replacements 5 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 da...

Page 9: ...ur purchase of a Poweramp hydraulic Edge of Dock leveler Dimensions and Capacities Model Deck Total Unit Width Width Comparative Industry Rating HED 66 66 104 HED 72 72 110 HED 78 78 116 HED 84 84 122 20 000 25 000 30 000 35 000 The HED series Edge of Dock leveler comes equipped with an electrical control panel which allows push button operation of the dock leveler functions Each HED dock leveler ...

Page 10: ... Platform B is raised by pushing and holding the RAISE button J This activates an electric motor D which in turn drives a hydraulic pump The hydraulic pump forces oil into the platform cylinder G causing the platform to rise Hold J until lip fully extends Releasing the raise button will allow the platform to float down to the bed of the truck trailer bed The lip will stay extended until the platfo...

Page 11: ...9 Manual No 4111 0027 Sept 2009 May 2012 9 INTRODUCTION This page intentionally left blank ...

Page 12: ... personal injury or death Only trained installation professionals with the proper equipment should install this product 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 t...

Page 13: ...his can put unnecessary stress on the leveler components causing the leveler to malfunction and shorten the lifespan of the affected components 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 syst...

Page 14: ...he base plate This will allow for vertical welding of both the base plate and the bump block flange back to the dock steel Top of the bump block cover plate should be flush with the top of the embed channel Tack weld bump blocks to dock steel 6 Check the positioning of the base plate and the bump blocks 7 Complete welding of tacked parts as follows A Apply a continuous weld across top of each bump...

Page 15: ...h with top of dock floor and embedded channel 2 Apply continuous bevel weld across both bumpers and length of base plate Securely block or support ramp and lip when in vertical positions Lack of proper bracing can result in ramp dropping during adjustment or installation causing personal injury or damage to unit 2X Junction Box ...

Page 16: ...marked line at each end of ramp to ensure proper alignment at both ends and tack weld ramp plate to dock leveler to hold ramp plate in place while bushing A Skil Roto Hammer 736 or similar tool is recommended 8 Using the back edge of the ramp plate as a guide groove concrete approximately 3 4 deep by 2 wide and should be the entire length of ramp plate 9 Break tack welds holding ramp in place slid...

Page 17: ...pply continuous bevel weld across both bumpers and length of base plate 3 To figure ramp plate length need 12 ramp for every 1 1 2 of rise to ramp Securely block or support ramp and lip when in vertical positions Lack of proper bracing can result in ramp dropping during adjustment or installation causing personal injury or damage to unit Weld Junction Box ...

Page 18: ... insert anchor bolts with washers and tighten securely to dock face 10 Place steel ramp plate in position flush with top backside of base plate Mark along full length of back edge of ramp plate Slide ramp plate forward over dock leveler the width of bushing tool approximately 2 11 Place bushing tool on marked line at each end of ramp to ensure proper alignment at both ends and tack weld ramp plate...

Page 19: ...e to be flush with top of ramp plate 2 Apply continuous bevel weld across both bumpers and length of base plate Securely block or support ramp and lip when in vertical positions Lack of proper bracing can result in ramp dropping during adjustment or installation causing personal injury or damage to unit Junction Box ...

Page 20: ...ng tool approximately 2 8 Place bushing tool on marked line at each end of ramp to ensure proper alignment at both ends and tack weld ramp plate to dock leveler to hold ramp plate in place while bushing A Skil Roto Hammer 736 or similar tool is recommended 9 Using the back edge of the ramp plate as a guide groove concrete approximately 3 4 deep by 2 wide and should be the entire length of ramp pla...

Page 21: ... both bumpers and length of base plate 3 To figure ramp plate length need 12 ramp for every 1 1 2 of rise to ramp 4 To install formed angle see formed angle installation instructions Securely block or support ramp and lip when in vertical positions Lack of proper bracing can result in ramp dropping during adjustment or installation causing personal injury or damage to unit 2X Junction Box ...

Page 22: ...ushing tool approximately 2 5 Place brushing tool on marked line at each end of formed angle to ensure proper alignment at both ends A Skil Roto Hammer 736 or similar tool is recommended 6 Using the back edge of the formed angle as a guide groove concrete approximately 5 8 deep by 2 wide and should be the entire length of the formed angle 7 Slide formed angle back until tight against dock face dri...

Page 23: ...21 Manual No 4111 0027 Sept 2009 May 2012 21 INSTALLATION NOTE DESCRIPTION 1 Secure formed angle with 18 anchor bolts 9 each side ...

Page 24: ... edge of ramp plate should be flush with dock face 6 Mark along full length of back edge of ramp plate Slide ramp forward the width of bushing tool approximately 2 7 Place bushing tool on marked line at each end of ramp to ensure proper alignment at both ends A Skil Roto Hammer 736 or similar tool is recommended 8 Tack weld ramp to face plate on each end to secure in place 9 Using the back edge of...

Page 25: ...3 Manual No 4111 0027 Sept 2009 May 2012 23 INSTALLATION NOTE DESCRIPTION 1 Secure formed angle with 18 anchor bolts 9 each side 2 Apply continuous fillet weld across entire length of face plate and ramp ...

Page 26: ... 2 All welding has been fully completed 3 Welding slag has been removed 4 Welds and other affected areas have been painted 5 Springs have been properly adjusted 6 Unit is functioning properly without fault I hereby certify that all installation and or repair work has been inspected and approved by Company ________________________ Date Completed _________________ Name ___________________________ Si...

Page 27: ...25 Manual No 4111 0027 Sept 2009 May 2012 25 INSTALLATION This page intentionally left blank ...

Page 28: ...ower must be OFF prior to electrical installation For maximum protection use an OSHA approved locking device to lock out all power sources Only the person installing the equipment should have the key to unlock the power source Failure to follow these instructions may result in serious personal injury or death DO NOT make any final electrical connections until all welding has been completed Failure...

Page 29: ...he dock the platform will lower to the full below dock position as the lip folds NOTE If a truck is present the platform will lower until the lip rests on the truck trailer bed See Operating Instructions in Operation section 6 Perform steps 4 5 at least four times to purge any air that may be in the hydraulic system and to ensure proper operation Put New Dock Leveler Into Service Always stand clea...

Page 30: ...river has been given permission to leave Make sure platform lip rests on the truck trailer bed with at least 4 in 102 mm of overlap Maintain a safe distance from side edges of leveler during the loading unloading process Failure to follow these instructions may result in serious personal injury or death The HED hydraulic Edge of dock leveler is designed to compensate for a maximum 5 in 127 mm of h...

Page 31: ... Figure 2 Figure 3 Figure 4 3 Always remove any end load while leveler is in stored position Figure 1 4 Press and hold RAISE A button until leveler extends fully Figure 3 5 Release button Leveler will lower to truck bed Figure 4 6 To remove leveler from truck before departure operate leveler RAISE A button until lip clears truck bed folds up and returns Figure 2 then release button Leveler will th...

Page 32: ...ilitary specification MIL L 5606 It is recommended that the following hydraulic fluids be used ULTRA VIS HVI 15 Flomite 530 ZF Aero Shell Fluid 4 or Fluid 41 Mobile Aero HFA Mil HS606A or Aero HF Texaco Aircraft Hydraulic Oil 15 or 5606 Exxon Univis J13 These fluid brands can be mixed together Mixing with fluids that do not meet or exceed MIL L 5606 may damage the equipment and WILL void warranty ...

Page 33: ... Zerk fittings on both lip and platform hinge lines Check reservoir fluid level Q 1 Put the dock leveler platform at the full above dock position engage prop 2 Turn OFF all electrical power to the leveler 3 Measure fluid level The fluid level should be approximately 3 in 76 5 mm N from top of reservoir M with platform raised on the maintenance prop 4 Add hydraulic fluid if necessary Use only recom...

Page 34: ...32 Manual No 4111 0027 Sept 2009 May 2012 32 NOTES This page intentionally left blank ...

Page 35: ...oubleshooting section 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 ma...

Page 36: ...aintenance 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 o...

Page 37: ...35 Manual No 4111 0027 Sept 2009 May 2012 35 ADJUSTMENTS This page intentionally left blank ...

Page 38: ...ual No 4111 0027 Sept 2009 May 2012 36 ELECTRICAL 1 Phase Provide dock leveler serial number voltage phase and options when calling or faxing controller orders Field Wire 18 gauge min Field Wire 18 gauge min ...

Page 39: ...ual No 4111 0027 Sept 2009 May 2012 37 ELECTRICAL 3 Phase Provide dock leveler serial number voltage phase and options when calling or faxing controller orders Field Wire 18 gauge min Field Wire 18 gauge min ...

Page 40: ...ne NOTE A motor that is missing voltage on one line is said to be single phased Check motor starter as follows 1 Disconnect wires at load side of starter 2 Energize 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 conside...

Page 41: ... plate remains extended but is still yieldable to approximately thirty pounds of downward force The lip plate extends before the unit reaches full dock height Turn sequence valve clockwise in 1 2 turn increments until lip plate operates properly The motor runs but the unit will not raise Check the motor for reverse polarity wiring Consult the wiring diagram located on the motor and reverse polarit...

Page 42: ...0 Lip Plate Hinge Assembly DOTH 4104 DOTH 4195 1 6635 Lip Plate Hinge Assembly DOTH 4129 DOTH 4133 1 7220 25 Lip Plate Hinge Assembly DOTH 4106 DOTH 4166 1 7230 Lip Plate Hinge Assembly DOTH 4114 DOTH 4172 1 7235 Lip Plate Hinge Assembly DOTH 3977 DOTH 6978 1 7820 25 Lip Plate Hinge Assembly DOTH 4107 DOTH 4007 1 7830 Lip Plate Hinge Assembly DOTH 4122 DOTH 3979 1 8420 25 Lip Plate Hinge Assembly ...

Page 43: ...ALL Rivet Button DOTH 2400 6 2 ALL Rivet Flat DOTH 2398 7 2 ALL 18 Projection Bumper Block DBBS 3550 8 2 ALL HED Gusset DOTH 4309 9 1 ALL Pivot Block DOTH 3316 10 1 ALL Lip Stop DOTH 3734 11 1 ALL Safety Strut Assembly DOTH 4325 12 4 ALL Pivot Block DOTH 3113 13 2 ALL Clevis Pin DOTH 2364 14 2 ALL Cotter Pin DOTH 2374 15 2 ALL Breather Vent Plug DOTH 2717 16 1 ALL Lip Cylinder DOTH 2721 17 1 ALL H...

Page 44: ...10 4 4 WASHER FLAT DOTH 2208 4 5 NYLON LOCK NUT DOTH 2129 4 6 6 5 1 2 4 3 DBBS 3550 Complete 18 Projection Bumper Assembly PARTS ITEM QTY PART NUMBER DESCRIPTION SIZE 1 1 DOTH 3556 18 Proj x 12 BB Weldment HED 2 1 DOTH 3505 Rubber TUF Cord 4 X 12 X 13 3 4 DOTH 2056 Hex HEad Cap Screw 7 16 14 UNC X 3 1 4 4 4 DOTH 2210 Washer Flat Zinc Plated 1 2 Dia 5 4 DOTH 2208 Washer Flat 1 2 Dia 6 4 DOTH 2129 N...

Page 45: ...43 Manual No 4111 0027 Sept 2009 May 2012 43 PARTS This Page Intentionally Left Blank ...

Page 46: ...44 Manual No 4111 0027 Sept 2009 May 2012 44 MISCELLANEOUS This page intentionally left blank ...

Page 47: ...ion is required When ordering use part numbers and description to help identify the item ordered Do not use item numbers These are only for locating the position of the parts Always give dock leveler MODEL NUMBER and or SERIAL NUMBER For service call or contact Systems Inc P O Box 309 Germantown WI 53022 Phone 800 643 5424 Fax 262 255 5917 Dock Leveler Information Model ___________________________...

Page 48: ... of maintenance Periodic lubrication adjustment and inspection in accordance with all manufacturers recommendations are the sole responsibility of the Owner User In the event of a defect as determined by SYSTEMS INC covered by this warranty SYSTEMS INC shall remedy such defect by repairing or replacing any defective equipment or parts bearing the cost for the parts labor and transportation This sh...