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APS Resource HTC Kit, Installation And Owner'S Manual

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APS Resource HTC Kit Installation And Owner'S Manual Download Page 4

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©2010 4Front Engineered Solutions, Inc. - APS Resource 

    

             

AP4047 RA 11/10

               

sAFETY PRACTICEs/TOOLs

Read these safety practices before installing, 

operating or servicing the dock leveler. Failure to 

follow the safety practices could result in serious 

injury or death.

READ AND FOLLOW THE INSTRUCTIONS 

CONTAINED IN THIS MANUAL BEFORE INSTALLING, 

OPERATING OR SERVICING THE HYDRAULIC 

CONVERSION KIT.
Place barricades on the dock floor around the dock 

leveler pit and in the driveway in front of the pit while 

installing, maintaining or repairing the dock leveler.
SAFELY SECURE MAINTENANCE STRUT before 

climbing into the dock leveler pit or doing any 

maintenance or repair under the dock leveler. 
Disconnect the power and properly tag or lock off 

before climbing into the dock leveler pit or doing any 

maintenance or repair under the dock leveler. 
All electrical troubleshooting or repair must be done by 

a qualified technician and must meet applicable codes.
Disconnect the power and properly tag or lock off 

before doing any electrical work. If it is necessary to 

make troubleshooting checks inside the control box with 

the power on, USE EXTREME CAUTION! Do not place 

fingers or non-insulated tools inside the control box. 

Touching wires or other parts inside the control box 

could result in electrical shock, serious injury or death.

 

Do not operate the dock leveler with equipment, 

material or people on the ramp or lip.
Do not operate the dock leveler when anyone is in front 

of it unless they are securing the maintenance strut.
Stay clear of the dock leveler when it is moving.
KEEP HANDS CLEAR OF HINGES AT ALL TIMES. 

Do not use hands to position dock leveler ramp or lip in 

truck or to store dock leveler.
Always use full range toe guards on dock levelers 

converted with hydraulic conversion. Failure to use toe 

guards could result in serious shearing injuries from a 

descending dock leveler.
Do not use the dock leveler if it looks broken or does 

not seem to work right. Tell your supervisor it needs 

repair right away.
Do not use a fork truck or other material handling 

equipment to lower the ramp.

TOOL LIsT

List of tools and equipment needed to field install the 

HTC Kit. This job would typically require two service 

technicians. 
Service truck should be equipped with the following: 
• Safety markers to secure work area around the dock
• “Boom” crane or hoist 
• Cutting torch 
• Welder 
• Soap stone or paint marker 
• Tape measure 
• Drill and drill bit kit, magnet, & hammer
• Miscellaneous hand tools.
• 1-1.5 gallons of Mil H - 5606 hydraulic fluid
• Teflon plumbers tape
• Touch up paint
• Shim stock
• Electrical wire / conduit

sAFETY PRACTICEs

Summary of Contents for HTC Kit

Page 1: ...nless you have read and understand the Safety Practices Warnings and Installation and Operating Instructions contained in this manual Failure to do so could result in death or serious injury 6219 West Eastwood Court Mequon Wisconsin 53092 TEL 262 518 1000 FAX 1 800 827 7491 AP4047 RA 11 10 2010 4Front Engineered Solutions Inc APS Resource APS Resource Your Aftermarket Solution ...

Page 2: ...horized replacement parts or modification of the HYDRAULIC CONVERSION KIT APS Resource s sole ob ligation with regard to a HYDRAULIC CONVERSION KIT that proves to be defective in material or workmanship shall be as set forth in its standard warranty above i e APS Resource will at its option repair or replace the HYDRAULIC CONVERSION KIT or portion thereof without charge to the purchaser This limit...

Page 3: ...TROUBLESHOOTING GUIDE 21 Parts LIST 22 SAFETY SIGNAL WORDS You may find safety signal words such as DANGER WARNING CAUTION or NOTICE throughout the owners manual Their use is explained below This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous...

Page 4: ... control box Touching wires or other parts inside the control box could result in electrical shock serious injury or death Do not operate the dock leveler with equipment material or people on the ramp or lip Do not operate the dock leveler when anyone is in front of it unless they are securing the maintenance strut Stay clear of the dock leveler when it is moving KEEP HANDS CLEAR OF HINGES AT ALL ...

Page 5: ... must be limited to only rotational If the rear hinge moves vertically or horizontally STOP do not install the Hydraulic conversion kit 3 Visually check that the retaining clips for the lip rods are in place 4 Visually check that all cotter pins hardware and other fasteners are not excessively worn and are in place to function properly 5 Verify that all welds are intact and that all structural mem...

Page 6: ...sition it must be safely secured with the proper hoists and safety struts before work can begin Failure to do so could allow the ramp to fall resulting in serious injury or death 2 Mount and wire push button station See Figure 1 and pit mounted receptacle See Figure 2 See wiring diagram located on the inside cover of the control box or wiring diagrams in this manual for wiring information Follow t...

Page 7: ...veler should be blocked off and secured 2 Raise the ramp to the open position Raise the lip to its maximum open position and safely secure it 3 Please the OEM safety bar in the factory recommended position 4 Weld the maintenance strut hanger to the underside of the ramp per dimensions shown or adjust position as required for proper installation Use touch up paint as required See Figures 3 and 4 5 ...

Page 8: ...er to be converted does not have full range toe guards install the toe guard kit included with the HTC Kit Insure the full range toe guards cover the entire dock leveler operating range Re adjust if necessary 3 Install full range sliding toe guards if applicable In some applications it may be necessary to create holes in the stationary toe guards for clearance of the pivot and slider bolts See Fig...

Page 9: ...cribed in step 4 This 13 area of the deck plate should be ground flat enough to allow you to flush mount the platform bracket assembly See Figure 12 5B Serco 24 pit levelers Measure the height of the center support channel and subtract In the same 13 area described in step 4 locate the next left and right of center support channels and mark this measurement to the inboard sides This is where the 2...

Page 10: ...ided 3 Full extend the cylinder rod and allow the clevis pit floor bracket to lie flat on the pit floor Mark the location where the bracket makes contact with the pit floor is the pit floor bracket mounting location 4 Temporarily secure the pit floor bracket in place 5 With a hoist lower the ramp slowly to make sure the cylinder will not bottom out at the full below dock position Adjust the pit fl...

Page 11: ...he lip spool or close to the lip rod See Figures 10 and 14 IF APPLICABLE 5 Position the lip cylinder ramp lug rear cylinder lug beneath the deck plate so that it is in line with the front cylinder lug The distance between the mounting holes from the front cylinder lug to the rear cylinder lug should be approx 17 See Figure 10 6 Tack weld the rear cylinder lug in position and attach the lip cylinde...

Page 12: ...loor This step is important to determine the resting or pendant position of the leveler when it is not in use 4 With the deck even to the dock floor level and the lip closed in the pendant position tack weld the lip supports on to the front of the frame The lip supports must be positioned in such a way as to allow the fully closed lip and deck to rest evenly on both lip supports See Figure 15 5 Wi...

Page 13: ...arts List 5 Install the velocity fuse and adapter to the main lifting cylinder 6 Install the smaller hose from the lip cylinder to the pump 7 Install the larger hose from the pump to the velocity fuse on the main lifting cylinder 8 Install the breather to the cylinder 9 With the ramp resting on the maintenance strut and the lip pendant fill the oil reservoir near the top with MIL 5606 oil This loc...

Page 14: ...ON 110 115V 1 PHASE 50 60HZ LEVELER MOTOR WIRING DETAILS 110 115V SINGLE PHASE 60HZ NOTE VISUALLY CONFIRM MOTOR TAG M BLK GRN WHT BRN ORG RED BLU WHT YEL BLK INCOMING POWER AND MOTOR WIRES TO BE STRANDED 14 GA 75 C COPPER TORQUE TO 9 LBS IN GROUND WIRES TO BE STRANDED 14 GA 75 C COPPER TORQUE TO 35 LB IN MOTOR 3 4HP MOTOR HAS AUTOMATIC THERMAL OVERLOAD WIRING PROVIDED BY CUSTOMER WIRING PROVIDED B...

Page 15: ...nderside of the lip plate Locate approximately 3 behind the lip hinge area See FIGURES 18 and 20 4 Fasten junction box to the subframe Mount approximately 29 measured from the rear of the pit Use self tapping screws provided See Figure 21 5 Install a strain relief into each end of the junction box 6 Install the power cord through the strain relief facing the rear of the pit Use a self tapping scre...

Page 16: ...k cable tie to make a loop around the switch body Leave a small amount of slack in the switch cable and tighten cable tie See Figures 22 and 23 9 At the DECK proximity switch create a strain re lief for the switch cables Use a black cable tie to make a loop around the switch body Route the LIP and DECK sensor cable through this loop Leave a small amount of slack in the DECK sensor cable and tighte...

Page 17: ...nts to the underside of the deck Clean the deck surface before applying the mounts Route and secure both sensor cables through the cable tie mounts towards the junc tion box See Figures 22 and 25 11 Route the proximity switch cables through the remain ing strain relief and into the junction box Shorten the cables if necessary See Figure 26 12 Use wire nuts to connect the proximity cables to the po...

Page 18: ...y store the dock leveler may leave the leveler in a position below the level of the floor This condition may result in unexpected drop of personnel or material handling equipment and result in death or serious injury Failure to follow these instructions could result in death or serious injury to operators and or bystanders Conversion System Test 1 With a hoist slowly lower the ramp and lip to the ...

Page 19: ...k bumpers 2 Tell vehicle driver Your vehicle must stay at the dock 3 Chock or hitch vehicle 4 If necessary remove end loads with the ramp in the dock level stored position See Figure 29 5 To extend the dock leveler lip into the vehicle 5 1 Turn the ON OFF switch to the ON position See Figure 30 5 2 Push and hold the RAISE button The ramp will rise and the lip will extend once the ramp reaches the ...

Page 20: ... ramp without extending the lip for end loading below dock level 1 Turn the ON OFF switch to the ON position 2 Press the RAISE button and hold it until leveler is fully raised and the lip starts to extend When the lip has extended 2 to 3 inches to clear the front of the lip keepers release the button 3 Turn the ON OFF switch to the OFF position as the ramp begins to lower Leveler will float down f...

Page 21: ... dock floor around the dock leveler pit and in the driveway in front of the pit while installing maintaining or repairing the dock leveler Check all labels every 90 days See parts list for location and part numbers Replace if required Every 90 days inspect dock bumpers Four inches 4 of bumper protection is required Worn torn loose or missing bumpers must be replaced Hydraulic Fluid Level The hydra...

Page 22: ...inder and or pivot pins 2 Check for leakage in lip cylinder or hydraulic hose feeding cylinder 3 Check for binding in lip hinge 4 Check hydraulic oil level in reservoir Add if required 5 Check hydraulic bypass pressure and adjust as required 6 Check lip sequence valve pressure setting Ramp will not return to stored position from full below dock position Ramp will not raise if a lift vehicle or oth...

Page 23: ...RIPTION P N 1 1 Subframe Bracket 155 246 2 1 Maintenance Strut Hanger 155 874 3 3 Hex Head Bolt 3 8 16 x 2 3 4 131 506 4 3 Lock Nut 3 8 16 131 507 5 1 Flat Washer 3 8 000 214 6 1 Lower Strut w Decal 713 268 7 1 Upper Strut 713 267 8 1 Safety Decal Not Shown 138846 9 1 Complete Secondary Maintenance Post Kit includes Items 1 8 AP0353 ...

Page 24: ...3 1 Lip Cylinder Ramp Lug Rear Cylinder Lug C100376 4 1 Clevis Pit Floor Assembly AP4045 5 1 Clevis Assembly AP4039 6 2 Angle Support C68245 7 1 Base Plate 8 C68247 1 Base Plate 11 C68248 1 Base Plate 14 C68249 8 2 Lip Keeper Assembly SE328859 9 2 5 8 x 4 Subframe Anchor Bolt Not Shown 131 526 10 1 Motor Mounting Plate Not Shown C68058 11 6 3 4 x 6 Pit Floor Bracket Anchor Bolt Not Shown AP2815 1 ...

Page 25: ...A 1 Power Unit 3 PH 50 60 HZ 208 230 460 VAC N A C103110 8 1 Hose Assy Large C104002 C104002 9 1 Hose Assy Small C104003 C104003 10 1 Elbow C16920 AP4362 11 1 Fitting Elbow C18865 C18865 12 1 Breather C55024 C55024 13 1 Elbow C55267 C55267 14 1 Clevis Pin Ramp Cyl Base End C52649 C52649 15 1 Clevis Pin Ramp Cyl Rod End C52644 C52644 16 8 Cotter Pin 1 8 x 2 ZP 035 020 035 020 17 1 Reservoir AP5227 ...

Page 26: ... Dock Includes items 1 15 115 208 230V 1PH 60HZ 110V 1 PH 50 HZ AP4063 1 1 Enclosure 10 x 8 x 4 w holes 712 502 2 1 Panel 707 975 3 1 Relay Power 700 901 4 1 Push Button Roto 061 727 5 2 Contact Block 1 N O 061 732 6 1 Label Wiring schematic AP4064 7 1 Label Instruction AP4062 8 1 Label Caution 138 607 9 1 Label U L 10 1 Fuse Holder Single 061 492 11 1 Fuse 250V 1 2 AMP 061 152 12 1 Channel Mounti...

Page 27: ...ALITY DIMENSION TOLERANCES ARE IN INCHES UNLESS OTHERWISE SPECIFIED MATERIAL SPECIFICATION DRAWN MATERIAL PO PART DESCRIPTION DRAWN DATE JOB REF NUMBER SCALE ISSUE PART NUMBER X 0 060 XX 0 030 XXX 0 010 FRACTIONAL 1 16 DIAMETER 0 015 0 005 ANGULAR 1 DEG B 6009078 PROXIMITY SWITCH INSTALLATION KELLEY ARTD PROXY KIT NTS jaime pulido 7 11 2006 UOM N A The information contained herein is proprietary a...

Page 28: ... Engineered Solutions Inc APS Resource AP4047 RA 11 10 Your local APS Resource distributor is Please direct questions about your HTC Kit to your local distributor or to 4Front Engineered Solutions Inc APS Resource ...

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