HNL SERIES Hydraulic EOD Dock Leveler Owner’s/User’s Manual DLM • Division of Systems, Inc. • W194 N11481 McCormick Drive • Germantown, WI 53022 800.643.5424 • fax: 262.257.7399 • www.docksystemsinc.com • techservices@docksystemsinc.com Printed in U.S.A. Copyright © 2009 Manual No.
Table of Contents Safety Page Recognize Safety Information.............................................................. General Operational Safety Precautions............................................. Operational Safety Precautions............................................................ Maintenance Safety Precautions.......................................................... Safety Decals..........................................................................................
SAFETY 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. 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.
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 carrier is entering or leaving area. 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.
SAFETY Do not use 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. Manual No.
SAFETY Maintenance Safety Precautions ALWAYS disconnect electrical power source and ground wire before welding on dock leveler. DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler. Always ground to the dock leveler frame. Failure to follow these instructions may result in damage to dock leveler and/or serious personal injury or death. Hydraulic and electrical power must be OFF when servicing the equipment.
SAFETY Safety Decals SAFETY INFORMATION DANGER Unsupported dock leveler ramps can lower unexpectedly. 2 Before allowing vehicle to leave the dock always: Ensure that no equipment, material 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. Unsupported dock leveler ramps can lower unexpectedly.
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. Effective operator training should also focus on the owner’s/user’s company policies and operating conditions.
INTRODUCTION General Information Congratulations on your choice of a DLM Edge-ofDock leveler. This manual covers the HNL series Edge-of-Dock levelers. Designed by DLM to be a marvel of simplicity and 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.
INTRODUCTION Component Identification A B E C G F D J K H A — Lip Plate D — Powerpack (Motor/Pump/Reservoir) B —Center Plate E — Hinge Area C — Extended Link Arm F — Platform Cylinder G — Spring Assembly J —Raise Button H — Bumper Blocks (2 used) K —Lower Button THEORY The HNL Edge-of-Dock leveler uses a pressure operated valve block and two push‑button controls for ease of use.
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INSTALLATION INSTALLATION DETAILS 50 PREFERRED 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 leveler, the facilities, and/ or serious personal injury or death. Only trained installation professionals with the proper equipment should install this product.
INSTALLATION IMPORTANT DO NOT connect the dock leveler electrical wiring and ground connections until all welding has been completed. DO NOT ground welding equipment to any hydraulic or electrical components of the dock leveler. Always ground welding equipment to the dock leveler frame, NEVER to the platform. Failure to follow these instructions may damage the motor, hoist cylinder, wiring, and/or control panel. IMPORTANT DO NOT weld continuously along the full length of the rear hinge frame angle.
INSTALLATION E.O.D. Installation Instructions Flush Mount - Weld On A flush mount weld on application is used when an 8” wide (minimum) embed channel is securely anchored into the concrete at the dock edge, and the dock height is adequate. Installation Steps: 1. Remove all existing bumper material and protruding objects from dock edge. Clean and sweep dock edge free of debris and flammable chemicals before installing unit. 2.
Manual No. 4111-0029 November 2009 May 2012 DESCRIPTION Top of base plate and bumper cover plate to be flush with top of dock floor and embedded channel Apply continuous bevel weld across both bumpers and length of base plate. NOTE 1 2 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.
INSTALLATION E.O.D. Installation Instructions Ramp Mount - Weld/Bolt On A ramp mount weld on application is used when adequate dock steel is securely anchored in the concrete at the dock edge, but the existing dock height is too low and the dock leveler must be installed above this height to correct this situation. Installation Steps: 1. Remove all existing bumper material and protruding objects from dock edge. Clean and sweep dock edge free of debris and flammable chemicals before installing unit.
Manual No. 4111-0029 November 2009 May 2012 DESCRIPTION Top of base plate and bumper cover plate to be flush with top of ramp plate. Apply continuous bevel weld across both bumpers and length of base plate. To figure ramp plate length, need 12” ramp for every 1-1/2” of rise to ramp. NOTE 1 2 3 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.
INSTALLATION E.O.D. Installation Instructions Flush Mount - Bolt On A flush mount bolt on application is used when there is no steel on dock edge, and the dock height is adequate. Additional steel ramp plate and bolting is required with this type of installation. Installation Steps: 1. Remove all existing bumper material and protruding objects from dock edge. Clean and sweep dock edge free of debris and flammable chemicals before installing unit. 2.
INSTALLATION ground in front of lever, with the unit raised and secured in the maintenance position, loosen jam nut on the underside of the linkage pin. To start allow about 3/4” to 1” of threads between top of jam nut and linkage pin. Using an open faced wrench, hold locknut on inside of spring while tightening threaded bolt until washer on top side of spring closes up tight to ram nut. Test operation of unit.
INSTALLATION E.O.D. Installation Instructions Ramp Mount - Weld On w/Formed Angle A ramp mount-weld on used with a formed angle application is used when dock edge is damaged, there is no dock steel securely anchored into the concrete, and the dock height is too low and leveler must be installed above this height to correct this situation. Installation Steps: 1. Remove all existing bumper material and protruding objects from dock edge.
2X Manual No. 4111-0029 November 2009 May 2012 DESCRIPTION Top of base plate and bumper cover plate to be flush with top of ramp plate. Apply continuous bevel weld across both bumpers and length of base plate. To figure ramp plate length, need 12” ramp for every 1-1/2” of rise to ramp. To install formed angle, see formed angle installation instructions. NOTE 1 2 3 4 Securely block or support ramp and lip when in vertical positions.
INSTALLATION E.O.D. Installation Instructions Formed Angle A formed angle is used when there is no existing dock steel and concrete at the dock edge has been damaged. The formed angle is required to rebuild the damaged concrete edge for a proper installation if the dock height is adequate. Installation Steps: 1. Remove all existing bumper material and protruding objects from dock edge. Clean and sweep dock edge free of debris and flammable chemicals before installing unit. 2.
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INSTALLATION E.O.D. Installation Instructions Ramp and Face Plate A ramp mount requiring a face plate application is used when there is no existing dock steel and the concrete at the dock edge has been damaged. The dock height can be low, high, or adequate for this application, however, the face plate and ramp plate are required to rebuild the damaged concrete edge. Installation Steps: 1. Remove all existing bumper material and protruding objects from dock edge.
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INSTALLATION - CHECK LIST E.O.D. Installation Checklist Date: __________ Order No.: __________ Serial Number:______________ Installer: ____________________________ Customer Name: _____________________ Address: ____________________________ City/State: ___________________________ Zip: __________ Phone: _________________ 1. Unit is properly aligned and installed properly. 2. All welding has been fully completed. 3. Welding slag has been removed. 4.
INSTALLATION Install Control Panel and Wiring The electrical power 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.
OPERATION Ramp Loading/Unloading Instructions 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 the truck restraint if available. 4. Extend the platform lip onto truck/trailer as follows: A B A—RAISE Button Stay clear of dock leveler when freight carrier is entering or leaving dock area. B—LOWER Button A.
OPERATION OPERATING INSTRUCTIONS DURING POWER OUTAGE 1. Grasp the captured operating handle and raise to its 4. full extended length. 5. 2. Move handle toward you, rotating center plate back past vertical. Lip plate extend link arm will engage at this time. 3. Push forward on operating handle against the rivet, rotating leveler out onto truck. Return handle to stored position. To remove leveler from truck repeat step number one until the lip clears the bed of the trailer.
MAINTENANCE Periodic Maintenance A B D E S C Y S T E M S L o a d i n g D o c k E q HNL-MAINTENANC DRAWN BY SR TOLERANCES (UNLESS OTHERWISE NOTED) FRACTIONAL: `1/32" DECIMAL: .00 = `.01" .000 = `.005" CHECKED BY DRAWING NO.
MAINTENANCE Periodic Maintenance When maintenance is to be performed in front of the dock leveler, support the lip with the handle in the maintenance prop position. Put handle into maintenance prop position by removing bolt and locknut at base of handle assembly. Pull handle out of roller arm assembly and place into maintenance prop receiver. (If equipped) Note: Failure to lubricate the dock leveler will cause abnormal operation of the leveler.
ELECTRICAL Wiring Diagram 3 4 C A Loose B 4 4 3 T1 3 30 RED WHITE T2 Manual No.
ELECTRICAL Hydraulic Schematic NOTE BC DESCRIPTION Connect to base end of release cylinder Connet to rod end of release RC cylinder NOTE PSI relief is not adjustable. Manual No.
TROUBLESHOOTING Symptom The unit raises slowly, the motor is extremely noisy, and the hydraulic hoses are vibrating. Solution Check the fluid level in power unit reservoir, if low, add fluid and operate leveler several times to remove any air from the system. 1. Incorrect wire capacitor or faulty capacitor The motor runs but the unit will not raise. Unit raises very slow. Unit will not raise to full dock height. 2. Coil should be energized to lower leveler and de-energized to raise leveler.
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PARTS ITEM 1 34 QTY SIZE/CAPACITY DESCRIPTION PART NUMBER (15”) LIP PART NUMBER (17”LIP) 1 6620/25 Lip Plate & Hinge Assembly DOTH-4047 DOTH-4048 1 6630 Lip Plate & Hinge Assembly DOTH-4049 DOTH-4050 1 6635 Lip Plate & Hinge Assembly DOTH-4051 DOTH-4052 1 7220/25 Lip Plate & Hinge Assembly DOTH-4053 DOTH-4054 1 7230 Lip Plate & Hinge Assembly DOTH-4055 DOTH-4056 1 7235 Lip Plate & Hinge Assembly DOTH-4057 DOTH-3167 1 7820/25 Lip Plate & Hinge Assembly DOTH-4058 DOT
PARTS ITEM 2 3 4 QTY SIZE/CAPACITY DESCRIPTION PART NUMBER (15”) LIP 1 6620/25 Center Plate & Hinge Assembly DOTH-4062 1 6630 Center Plate & Hinge Assembly DOTH-4063 1 6635 Center Plate & Hinge Assembly DOTH-4064 1 7220/25 Center Plate & Hinge Assembly DOTH-4065 1 7230 Center Plate & Hinge Assembly DOTH-4066 1 7235 Center Plate & Hinge Assembly DOTH-3258 1 7820/25 Center Plate & Hinge Assembly DOTH-4067 1 7830 Center Plate & Hinge Assembly DOTH-3923 1 8420/25 Center
PARTS DKIT-9300 Torsion to Extension Spring Kits (Includes all parts listed below) Item Quantity Part Number Description 1 1 DOTH-3620 Bar - Lip linkage 2 2 DOTH-2061 1-1/2” Shoulder Bolt 3 4 DOTH-2131 Nylon Lock Nut 4 2 DOTH-3621 Bar - Base Linkage 5 1 DOTH-2347 Pin - Linkage 6 2 DOTH-2390 Roll Pin 7 2 DOTH-2520 Spring, Extension, Reg.
PARTS DKIT-9301 Torsion to Extension Spring Kits (Includes all parts listed below) Item Quantity Part Number Description 1 1 DOTH-3620 Bar - Lip linkage 2 2 DOTH-2061 1-1/2” Shoulder Bolt 3 4 DOTH-2131 Nylon Lock Nut 4 2 DOTH-3621 Bar - Base Linkage 5 1 DOTH-2347 Pin - Linkage 6 2 DOTH-2390 Roll Pin 7 2 DOTH-2521 Spring, Extension, Reg.
PARTS Power Pack Assembly Amp Draw 4.8- 5.2 38 Manual No.
PARTS Power Pack Assembly Item Quantity Part Number Description 1 1 1431-0011 Connector-2 Screw, 3/8 2 3 1431-0086 Insulated Terminals, 16-14 AWG 3 2 2101-0017 HHCS-Grad 2-Zinc Plated, 3/8-16 UNC X 1 4 2 2101-0140 Lock Washer, 3/8 5 2 2401-0001 Grommet, 1-3/8 OD X 3/4 ID 6 1 2751-0016 J-Box Cover, 4 X 4 7 1 3051-0058 Capacitor-Motor Start, 66-77mf-330V 8 1 9301-0164 Fitting Connector Straight Thread, #4 ORB #4 JIC Powerpack-PStop, 1PH-115V-1/4HP-1GPM 9 1 9391-0040 10
PARTS HANDLE OPTIONS 40 ITEM QTY PART NO. 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 5 1 DOTH-3833 NL PIPE HANLDE ASSEMBLY Manual No.
PARTS CURRENT VS PRE-2005 PARTS Manual No. 4111-0029 November 2009 May 2012 ITEM QTY PART NO.
DBBS-3500 Complete 15” Projection Bumper Assembly Quantity Part Number Description 1 1 DOTH-3537 12” BB Weldment 2 1 DOTH-3505 Rubber - Tuf-Cord 3 4 DOTH-2056 Hex Head Cap Screw 4 4 DOTH-2210 Wahser - Flat - Zinc Plated 5 4 DOTH-2208 Washer - Flat 6 4 DOTH-2129 Nylon Lock Nut 2 DBBS-3506 15” Projection x 18” high (option) 1 4 6 5 4 3 2 1 IT EM 1 Q TY P D AR O T D T 4 D OT H-3 NO 4 O H 5 D T -3 3 .
QT Y PA 1 DO RT N 2 O T DO H-35 .
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MISCELLANEOUS Customer Information A NOTE: The model/serial number decal (A) is located on the right platform joist near the front (lip) of dock leveler. When you receive your HNL-series Edge-of-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 Systems, Inc.
STANDARD PRODUCT WARRANTY SYSTEMS, INC. warrants that its products will be free from defects in 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.
