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17

Manual No. 4111-0025

March 2011

May 2012

INSTALLATION

NOTE

DESCRIPTION

1

Top of base plate and bumper cover plate to be flush with top of ramp plate.

2

Apply 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.

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.

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Summary of Contents for DL Series

Page 1: ...ormick Drive Germantown WI 53022 800 643 5424 fax 262 257 7399 www docksystemsinc com techservices docksystemsinc com Printed in U S A Copyright 2011 Manual No 4111 0025 March 2011 May 2012 DL NL TS SERIES EOD Dock Leveler Owner s User s Manual ...

Page 2: ...h Mount Bolt On 14 Ramp Mount Weld On w Formed Angle 16 Formed Angle 18 Ramp and Face Plate 20 Installation Check List 22 Operation Operating Instructions DL 23 Operating Instructions NL TS 24 Maintenance Periodic Maintenance 25 Troubleshooting Troubleshooting 26 Parts DL X Series 27 NL X Series 28 TS Series 30 Extension Spring Components 32 Torsion Spring Components 34 Current vs 2005 and Older 3...

Page 3: ... 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 be alert to the possibility of p...

Page 4: ...s 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 procedures have been performed before using Make sure lip overlaps onto trailer at least 4 in 102 mm Keep a safe distance from both side edges L...

Page 5: ...ling 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 Operational Safety Precautions ...

Page 6: ...rop position remove bolt and locknut at base of handle assembly Pull handle out of roller arm assembly and place into maintenance prop receiver if equipped Post safety warnings and barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before installation has been completed Failure to follow the installation instructions can result in damage to dock ...

Page 7: ...ck always Ensure no equipment material or people are on dock leveler Return 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 Control Box Size Decal Size 9 12 x 3 25 File Name 1751 0730 Rev A DANGER OPERATION 7 Stay clea...

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: ...7 Manual No 4111 0025 March 2011 May 2012 NOTES This page intentionally left blank ...

Page 10: ...m performance and longest possible use a simple program of preventive maintenance is recommended Once again thank you and congratulations on your purchase of a DLM mechanical Edge of Dock leveler Dimensions and Capacities Model Deck Total Unit Width Width Comparative Industry Rating DL 66 66 104 DL 72 72 110 DL 78 78 116 20 000 25 000 30 000 N A for DL 78 Dimensions and Capacities Model Deck Total...

Page 11: ...nd barricade the work area at dock level and ground level to prevent unauthorized use of the dock leveler before installation has been completed Failure to follow the installation instructions can result in damage to dock leveler the facilities and or serious personal injury or death Only trained installation professionals with the proper equipment should install this product 50 INCH PREFERRED ...

Page 12: ...nnel 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 bumper and base plate to dock steel Skip welding is acceptable to prevent warpage but complete weld across the top must be completed B Weld vertically along each end of base plate and on both inboard and ou...

Page 13: ... top of dock floor and embedded channel 2 Apply continuous bevel weld across both bumpers and length of base plate INSTALLATION 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 ...

Page 14: ...ve 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 slide ramp plate back into position with the top of the ramp plate flush with the top of the base plate Tack weld each end and center of ramp plate to base plate 10 Drill 5 8 dia by 5 deep holes through ramp plate at back edge Install anchor bolts per manufacturers sp...

Page 15: ...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 INSTALLATION 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 ...

Page 16: ...ck level Note that this placement will vary with ramp plate thickness Mark centers of holes in bump block flanges 9 Drill 5 8 dia by 5 deep holes at center marks Reposition bump blocks 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 base edge of ramp plate Slide ramp plate forwa...

Page 17: ... operation is achieved tighten jam nut to outer washer on spring Springs must be adjusted alternately to have equal spring tension 18 Before install is complete installer must make a final operation check of dock leveler to verify all phases of install are correct Installer must complete sign and return the Installation Checklist up on completion reference page 22 INSTALLATION NOTE DESCRIPTION 1 T...

Page 18: ...ing 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 10 Break tack welds holding ramp in place slide ramp plate back into position with the top of the ramp plate flush with the top of the base plate Tack weld each end and center of ramp plate to base plate 11 Drill 5 8 dia by 5 deep holes through ramp plate at...

Page 19: ... 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 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 ...

Page 20: ... 5 Place bushing 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 drill 5 8 dia by 5 deep holes t...

Page 21: ...19 Manual No 4111 0025 March 2011 May 2012 INSTALLATION NOTE DESCRIPTION 1 Secure formed angle with 18 anchor bolts 9 each side ...

Page 22: ... 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 the ramp plate as a guide groove concre...

Page 23: ...21 Manual No 4111 0025 March 2011 May 2012 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 24: ...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 ___________________________ Sig...

Page 25: ...personnel should operate 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 Truck trailer wheels must be chocked unless the truck restraint is used Never remove the wheel chocks until loading unloading is finished and truck driver has been given permission to leave Make sure platform lip rests...

Page 26: ... will engage at this time 3 Push forward on operating handle against the rivet rotating leveler out onto truck 4 Return handle to stored position 5 To remove leveler from truck repeat step number one until the lip clears the bed of the trailer Return leveler and handle to the stored position OR When the truck departs the unit will automatically return to the stored position OPERATING INSTRUCTIONS ...

Page 27: ...th Securely block or support ramp and lip when in vertical position Lack of proper bracing can result in ramp dropping during maintenance causing personal injury or damage to unit Quarterly Maintenance 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 Look for cracks or d...

Page 28: ...lubrication Lubricate leveler Excessive weight on top of deck Remove weight from deck Main springs need more tension or less tension Adjust main spring tension as needed Damaged or missing parts Repair of replace as needed Extended link arm does not latch out lip or unlatch Debris impacted in extended link arm Clean out debris from extended link arm Extended link arm needs lubrication Lubricated e...

Page 29: ... DOTH 2400 6 2 All Rivet Flat DOTH 2398 7 1 6620 25 30 7220 25 Spring Linkage Assy X Regular DOTH 3618 1 7230 7820 25 Spring Linkage Assy X Hvy Duty DOTH 3630 8 1 All Lifting Hook DOTH 3342 9 2 All Extra Hvy Duty Bumper Blocks DBBS 3500 10 2 All X Gusset DOTH 3589 11 All Secondary Gussets DOTH 3319 TOLERANCES UNLESS OTHERWISE NOTED FRACTIONAL 1 32 DECIMAL 00 01 000 005 ANGULAR 1 DRAWN BY CHECKED B...

Page 30: ...28 Manual No 4111 0025 March 2011 May 2012 PARTS NL X Series ...

Page 31: ...e Hinge Assembly DOTH 3923 1 8420 25 Center Plate Hinge Assembly DOTH 3242 1 8430 Center Plate Hinge Assembly DOTH 3241 3 1 ALL Base Plate Hinge Assembly Consult Factory 4 2 6620 25 30 Hinge Pin DOTH 3104 2 6635 Hinge Pin DOTH 4312 2 7220 25 30 Hinge Pin DOTH 3122 2 7235 Hinge Pin DOTH 4313 2 7820 25 30 Hinge Pin DOTH 3946 2 8420 25 30 Hinge Pin DOTH 3920 5 2 All Rivet Button DOTH 2400 6 2 All Riv...

Page 32: ...ACTIONAL 1 32 DECIMAL 00 01 000 005 ANGULAR 1 DRAWN BY SR NL RR MO S Y S L o a d i n This print is the property of Systems I patent and other rights including exclu not convey any permission to reprodu granted only by written authorization s 11 1 4 12 14 15 16 5 6 2 7 10 17 8 13 4 3 9 18 19 20 21 ...

Page 33: ... DOTH 4094 1 7830 Center Plate Hinge Assembly DOTH 4095 1 8420 25 Center Plate Hinge Assembly DOTH 4096 1 8430 Center Plate Hinge Assembly DOTH 4097 3 1 ALL Base Plate Hinge Assembly Consult Factory 4 2 6620 25 30 Hinge Pin DOTH 3104 2 6635 Hinge Pin DOTH 4312 2 7220 25 30 Hinge Pin DOTH 3122 2 7235 Hinge Pin DOTH 4313 2 7820 25 30 Hinge Pin DOTH 3946 2 8420 25 30 Hinge Pin DOTH 3920 5 2 All Rivet...

Page 34: ...xtension Spring Adjustment Instructions 1 Lift and secure leveler in full upright maintenance position to start 2 Loosen jam nut A by turning the nut clockwise Once jam nut is loosened use an open faced wrench to hold the locknut B inside the spring body Tighten the hex bolt C by turning clockwise 3 To start the top fender washer should be tightened until the washer is about one and a half inches ...

Page 35: ...xtension Spring Adjustment Instructions 1 Lift and secure leveler in full upright maintenance position to start 2 Loosen jam nut A by turning the nut clockwise Once jam nut is loosened use an open faced wrench to hold the locknut B inside the spring body Tighten the hex bolt C by turning clockwise 3 To start the top fender washer should be tightened until the washer is about one and a half inches ...

Page 36: ...ole 5 Insert hex bolt B through the flange on the tube assembly and tighten nut until secure 6 Test leveler operation If spring tension is not sufficient repeat the previous steps until desired tension is achieved 7 Return leveler to stored position Item Quantity Part Number Description 1 1 DOTH 3305 L R Gusset Assembly w Bearing 2 1 DOTH 3327 HL Model Gusset w Guide 3 1 DOTH 3679 HL Torsion Tube ...

Page 37: ... VS 2005 and Older Item Quantity Part Number Description 1 1 DOTH 3730 Bar NL Extended Link Arm pre 09 2005 2 1 DOTH 3744 NL SB Catch Assembly pre 09 2005 3 1 DOTH 3585 Bar NL Extend Link Arm 09 2005 present 4 1 DOTH 3586 NL SB Catch Assembly 09 2005 present ...

Page 38: ...h 2011 May 2012 PARTS HANDLE OPTIONS Item Quantity Part Number Description 1 1 DOTH 3752 NL Handle Assembly Tube 2 1 DOTH 3769 NL Handle Assembly Solid 3 1 DOTH 3691 NLII Handle Assembly Formed 4 1 DOTH 3694 NLIII Handle Assembly ...

Page 39: ...ber Description 1 1 DOTH 3726 NL Operating Link Assembly 2 1 DOTH 3696 NLIII Operating Link Assembly 3 1 DOTH 3697 Operating Link Assembly for all 35K units not shown 4 1 DOTH 2449 Roller Bearing PART NO QTY ITEM NL OPERA DOTH 3726 1 1 NLIII OPER DOTH 3696 1 2 NLIII ROLL PIPE DOTH 3834 1 3 1 2 4 ...

Page 40: ...lat 6 4 DOTH 2129 Nylon Lock Nut 2 DBBS 3506 15 Projection x 18 high option B I L L O F M A T E R I A L S I Z E D E S C R I P T I O N P A R T N O Q T Y I T E M 1 2 B B W E L D M E N T D O T H 3 5 3 7 1 1 4 X 1 2 X 1 3 R U B B E R T U F C O R D D O T H 3 5 0 5 1 2 7 1 6 1 4 U N C X 3 1 4 H E X H E A D C A P S C R E W D O T H 2 0 5 6 4 3 1 2 D I A W A S H E R F L A T Z I N C P L A T E D D O T H 2 2 ...

Page 41: ...e 12 BB Slide 3 2 DOTH 3515 Bar BB Sliding Stop 4 1 DOTH 3517 12 Sliding BB Plate w Rubber B I L L O F M A T E R I A L D E S C R I P T I O N P A R T N O Q T Y I T E M 1 2 B B W E L D M E N T D O T H 3 5 3 7 1 1 A N G L E 1 2 B B S L I D E D O T H 3 5 1 4 2 2 B A R B B S L I D I N G S T O P D O T H 3 5 1 5 2 3 1 2 S L I D I N G B B P L A T E W R U B B E R D O T H 3 5 1 7 1 4 1 2 4 3 2 1 3 4 ...

Page 42: ...40 Manual No 4111 0025 March 2011 May 2012 MISCELLANEOUS This page intentionally left blank ...

Page 43: ...wn DLM 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...

Page 44: ... 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...

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