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PAGE 17

AP4047 RA 11/10

OPERATION

DOCK LEVELERs WITH AuTO-RETuRN TO

DOCK OPTION

Before operating the dock leveler, read and follow

Safety Practices.
Use of dock leveler restricted to trained operators.

Follow procedures on placard posted near 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.
Before pressing button, ensure lip avoids contact with

vehicle sides and cargo. If lip does not lower to vehicle

bed, reposition vehicle.
Stay clear of leveler unless lip is supported by vehicle

bed or the leveler is stored at dock level. visually

check that the lip is supported by the vehicle bed or

the ramp is supported by both dock level supports

before driving or walking on the ramp. Unsupported

dock levelers can lower unexpectedly.
Before chocking wheels or engaging vehicle restraint,

dump air from air ride suspensions and set parking

brakes.
Always be certain that the vehicle wheels are chocked,

or that the vehicle is locked in place by a vehicle

restraining device and the brakes are set before

loading or unloading. vehicles pulling away from the

dock unexpectedly can cause uncontrolled drop of

the dock leveler which can result in death or serious

injury.
visually check that the lip is supported by the vehicle

platform or the ramp is supported by both front lip

keepers before driving or walking on the ramp.
Always return the dock leveler to its dock level (stored)

position before allowing vehicle to leave dock. If

vehicle pulls away from dock before dock leveler is

stored, the lip will fall to its pendant position and the

ramp will drop. In addition, failure to properly 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

full below dock position. Check clearances to be

sure the cylinders do not bottom out and that the

power unit does not come in contact with the deck.

2.  Disconnect and remove the hoist from the ramp.
3.  Turn the "ON/OFF" switch to the "OFF" position.
4.  Connect the electrical power to the dock leveler.
5.  Turn the "ON/OFF" switch to the "ON" position.

Ramp will automatically return to the stored

position.

6. Press the "RAISE" Button. The ramp will rise

and the lip will extend once the ramp reaches the

highest position.

7. Release the "RAISE" button. Ramp will lower and

lip will remain extended.

8. Once the leveler reaches the full below dock

position, the lip will fall pendent. The ramp will then

automatically return to the stored position.

9. Repeat Steps 6-8 several times until all of the air

has been purged from the hydraulic system.

10. After the air has been purged from the hydraulic

system, raise the leveler and secure it using both

safety struts.

11. Check the entire hydraulic system for leaks or loose

fittings. Fix all leaks and make any necessary

repairs or adjustments.

12. Check to be sure that the hydraulic reservoir is filled

to the proper level. Add if required. See Figure 28.

13. Double check all welds and paint exposed metal to

prevent rust.

The oil level will drop as the system is run for the

first time. After the system has been purged of air,

oil should be filled to the level shown in Figure 28.

3"- 4"

Use Type 5606 (Low Temp.)

Hydraulic Oil.

Check Oil Level With Ramp

Resting on the Matienance Strut

And Lip Pendant.

Figure 28

Содержание HTC Kit

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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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