POWERAMP LMP dock leveler Owner's/User's Manual

LMP-Series
Dock Leveler
Owner’s/User’s Manual
POWERAMP • Division of Systems, Inc. • W194 N11481 McCormick Drive • Germantown, WI 53022
800.643.5424 • fax: 262.255.5917 • www.docksystemsinc.com • [email protected]
Printed in U.S.A.
Copyright © 2015
Manual No. 4111-0013
May 2015
Table of Contents
Page
Safety
Recognize Safety Information..............................................................
General Operational Safety Precautions.............................................
Operational Safety Precautions............................................................
Maintenance Safety Precautions..........................................................
Safety Decals..........................................................................................
Owner’s/User’s Responsibilities..........................................................
1
1
2
4
5
6
Introduction
General Information............................................................................... 7
Dock Leveler Stock Specifications...................................................... 7
Component Identification...................................................................... 8
Installation
Prepare Pit.............................................................................................. 9
Prepare Dock Leveler........................................................................... 10
Install Dock Leveler............................................................................. 12
Operation
Theory...................................................................................................
Operating Instructions........................................................................
Ramp Loading/Unloading Instructions........................................
End Loading/Unloading Instructions...........................................
17
18
19
20
Maintenance
Service Dock Leveler Safely............................................................... 21
Periodic Maintenance.......................................................................... 22
Adjustments
Adjust Lift Arm Spring and Lip Assist Spring Tension................... 24
NON-Adjustable Lip Stop ................................................................... 26
Troubleshooting
Troubleshooting................................................................................... 27
Parts
Hold-Down Mechanism.......................................................................
Frame Components.............................................................................
Platform Components.........................................................................
Toe Guard/Weather Seal—Optional...................................................
Miscellaneous
29
30
32
34
Customer Information......................................................................... 37
Warranty................................................................................. Back Cover
SAFETY
Recognize Safety Information
General Operational Safety
Precautions
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.
Read and understand the Owner’s/Users’s manual
and become thoroughly familiar with the equipment
and its controls before operating the dock leveler.
Never operate a dock leveler while a safety device or
guard is removed or disconnected.
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.
The use of the word WARNING signifies the
presence of a serious hazard or unsafe practice
which may result in serious injury or death.
The use of the word CAUTION signifies possible
hazard or unsafe practice which could result in
personal injury.
NOTICE
The use of the word NOTICE is to draw attention
to a procedure that needs to be followed to prevent
machine damage.
Never remove DANGER, WARNING, or CAUTION
signs or decals on the equipment unless replacing
them.
on
Z
ng
ati
e
r
e
Op
era
Op
g
tin
ne
Zo
DO NOT activate the equipment until all unauthorized
personnel in the area have been warned and have
moved outside the operating zone.
Remove any tools or foreign objects from the operating
zone before starting.
Keep the operating zone free of obstacles that could
cause a person to trip or fall.
4111-0013 — May 2015
1
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 transport
vehicle is entering or leaving area.
Chock/restrain all freight carriers. Never remove
the wheel chocks until loading or unloading is
finished and transport vehicle driver has been given
permission to drive away.
Do not move or use the dock leveling device if
anyone is under or in front of it.
Do not use a broken or damaged dock leveling
device. Make sure proper service and maintenance
procedures have been performed before using.
Keep hands and feet clear of pinch points. Avoid
putting any part of your body near moving parts.
Make sure lip overlaps onto transport vehicle at
least 4 in. (102 mm).
Keep a safe distance from both side edges.
2
4111-0013 — May 2015
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.
4111-0013 — May 2015
3
SAFETY
Maintenance Safety Precautions
DO NOT grind or weld if hydraulic fluid or other
flammable liquid is present on the surface to be
ground or welded
Always post safety warnings and barricade the
work area at dock level and ground level to prevent
unauthorized use of the unit before maintenance is
complete.
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 result in
serious personal injury or death.
ALWAYS stand clear of dock leveler lip when
working in front of the dock leveler. Failure to do this
may result in serious personal injury or death.
A maintenance prop permanently attached and
hinged to the unit with means for lock out/tag out
requirements (per OSHA 1910.147) is included
with each pit style dock leveler. In addition, it is
recommended and good safety practice to use an
additional means to support the dock platform and
lip anytime when physically working in front of or
under the dock leveler. This additional means may
include, but not limited to a boom truck, fork truck,
stabilizing bar or equivalent.
PLACARD 1751-0875 MUST PLACED
IN CLOSE PROXIMITY AND IN CLEAR
VIEW OF THE LEVELER
O P E R AT I N G
! DANGER
•
•
•
•
•
•
•
•
•
•
•
INSTRUCTIONS
Read
and
follow
all
instructions, warnings, and
maintenance schedules in
the manual and on placards.
Operation and servicing of
dock leveler is restricted to
authorized personnel.
Always chock transport vehicle wheels or engage vehicle restraint
and set parking brakes before operating dock leveler or beginning
to load or unload.
Before activating dock leveler, ensure lip avoids contact with
transport vehicle sides and cargo. If lip does not lower to transport
vehicle bed, reposition transport vehicle.
Ensure the transport vehicle floor supports extended lip or the
leveler frame (lip keepers or below dock endload supports) supports
the ramp before driving on ramp.
Stay clear of hinges and front and sides of moving dock leveler.
Never use hands or equipment to move the ramp or lip.
Never use damaged or malfunctioning dock leveler. Report problems
immediately to supervisor.
Always store dock leveler and remove people, material, and
equipment from ramp before vehicle leaves the dock.
DO NOT ENTER PIT unless dock leveler is securely supported by
the maintenance prop.
Disconnect power and follow proper lockout/tagout procedures for
the dock leveler before entering the dock leveler pit or doing any
repair or inspection under the dock leveler.
FAILURE TO FOLLOW THESE INSTRUCTIONS COULD
RESULT IN DEATH OR OTHER SERIOUS INJURY.
Scan to view our owner’s/user’s
manuals online.
www.DockSystemsInc.com
1.800.643.5424
Call for additional placards, or manuals, or with questions
regarding proper use, maintenance, and repair of dock leveler.
4
1751-0875 Rev A
MECHANICAL DOCK LEVELERS
NORMAL OPERATION
1. Raise the platform by pulling and holding
the platform release ring.
2. Hold the platform release ring until the lip
is fully extended, then release the platform
release ring. Walk out onto the platform.
The platform will lower until lip is resting
on the transport vehicle.
STORING LEVELER
1. Pull the platform release ring. Slowly walk
the platform down allowing enough time
for the lip to fold, clearing the transport
vehicle. Once lip clears transport vehicle,
continue to walk leveler to the cross-traffic
position.
BELOW DOCK ENDLOADING
•
Pull and hold the platform release ring until
the platform is at the fully-raised position.
Slowly walk the platform down allowing
enough time for the lip to fold. Just before
the platform reaches the cross-traffic
position, pull and hold the safety leg
retract pull ring located in a recess at front
of the platform. The platform will continue
lowering to the full below dock position.
4111-0013 — May 2015
SAFETY
Safety Decals
5.06"
DANGER
1751-0727
CRUSH HAZARD
Maintenance prop must
support leveler behind bar.
Do not force maintenance
prop forward of bar to
support lip. Failure to
comply will result in death or
serious injury. Refer to
owner’s/user’s manual for
proper use.
2.40"
Every 90 days (quarterly) inspect all safety labels and tags to
ensure they are on the dock leveler and are easily legible. If any
are missing or require replacement, please call 1-800-643-5424
for replacements.
1751-0730 (x2)
1751-0727 Rev A
Control Box Size:
9.12" 5.06 x 2.40
Decal Size:
File Name: 1751-0727 Rev A
SAFETY INFORMATION
DANGER
3.25"
Unsupported dock leveler
ramps can lower unexpectedly.
Before allowing vehicle to leave
the dock always:
Ensure no equipment,
material or people are on
dock leveler.
Return dock leveler to its
stored position at dock level.
OPERATION
1. Read and follow all instructions and
warnings in owner’s/user’s manual.
2. Use of dock leveler restricted to
trained operators
3. Always chock trailer wheels or
engage truck restraint before
operating dock leveler or beginning to
load or unload.
4. Never use hands or equipment to
move ramp or lip
5. Before activating dock leveler:
Ensure trailer is backed in against
bumpers.
Remove any end loads if required.
Check trailer alignment to avoid lip
interference. If lip does not lower to
trailer bed, reposition vehicle.
6. Ensure truck bed supports extended
lip or leveler frame supports the ramp
before driving on ramp.
Failure to follow posted instructions will result in death or serious injury.
7. Stay clear of hinges and front and
sides of moving dock leveler.
8. N e v e r u s e d a m a g e d o r
malfunctioning dock leveler. Report
problems immediately to supervisor.
MAINTENANCE/SERVICE
1. Read and follow all instructions,
warnings and maintenance
schedules in the owner’s/user’s
manual.
2. Maintenance/Service of dock leveler
restricted to trained personnel.
3. Place barriers on the driveway and
dock floor to indicate service work is
being performed.
4. DO NOT ENTER PIT unless dock
leveler is securely supported by
maintenance prop.
5. If electrically powered turn off and use
OSHA lockout/tagout procedures.
Call 262.255.1510 for replacement placards, warning labels, or owner’s/user’s manuals.
(decal placed in same position on both sides)
Control Box Size:
Decal Size: 9.12 x 3.25
File Name: 1751-0730 Rev A
1751-0329 (x2)
DO NOT
FORK THIS SIDE
(decal placed in same position on both sides)
Control Box Size:
Decal Size: 13 x 2
File Name: 1751-0329
FORK
HERE
1751-0330 (x2)
(decal placed in same position on both sides)
Control Box Size:
Decal Size: 6 x 2
File Name: 1751-0330 REV A
1.43"
1751-0728
5.93"
DANGER
CRUSH HAZARD
Do not remove main springs until leveler is securely supported by a
suitable lifting device. Main springs contain stored energy. Be sure springs
are fully unloaded and ends are loose before removal. Failure to comply
will result in death or serious injury. Refer to owner’s/user’s manual for
proper maintenance procedure.
1751-0728 Rev A
1751-0788
1.02"
8.72"
Control Box Size:
DANGER
Decal Size: 5.93 x 1.40
CRUSH HAZARD
File
Name:
1751-0728
Rev
Do not work under dock leveler
unless
this maintenance
prop
hasAbeen secured in the upright
position. Failure to comply will result in death or serious injury. See owner’s/user’s manual for proper
1751-0788 Rev A
procedures.
5.05"
1751-0789
2.40"
Control Box Size:
Decal Size: 8.72 x 1.02
File Name: 1751-0788 Rev A
DANGER
CRUSH HAZARD
Open the pin latch and insert
through the maintenance
prop housing and prop
completely. Close the pin latch
to secure prop. Use every
time dock leveler is serviced.
Failure to comply will result
in death or serious injury.
1751-0789
Control Box Size:
Decal Size: 5.05 x 2.40
5.92"
File Name: 1751-0789
DANGER
2.36"
1751-0726
CRUSH HAZARD
DO NOT ENTER PIT unless dock leveler is
safely supported by maintenance prop. Place
barriers on driveway and dock floor to indicate
service work being performed. Failure to comply
will result in death or serious injury. Refer to
owner’s/user’s manual for proper maintenance
procedures.
1751-0726 Rev A
Control Box Size:
Decal Size: 5.92 x 2.36
File Name: 1751-0726 Rev A
4111-0013 — May 2015
5
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. Maintaining, updating and re training all operators on safe working
habits and operation of the equipment, regardless of previous experience, should be done on a regular
basis and should include an understanding and familiarity with all functions of the equipment. Owner’s/
user’s shall actively maintain, update and retrain all operators on safe working habits and operations of
the equipment.
2. The manufacturer shall provide to the initial purchaser all necessary information regarding Safety
Information, Operation, Installation and Safety Precautions, Recommended Initial and Periodic
Inspections Procedures, Planned Maintenance Schedule, Product Specifications, Troubleshooting
Guide, Parts Break Down, Warranty Information, and Manufacturers Contact Information, as well as
tables to identify the grade(slope) for all variations of length or configuration of the dock leveling device
and information identifying the maximum uncontrolled drop encountered when sudden removal of support
while in the working range of the equipment.
3. It is recommended that when the transportation vehicle is positioned correctly in the dock opening and
in contact with both bumpers, there shall be a minimum of 4.00 inches (100mm) overlap of the leveling
device and the transportation vehicle at all times during the loading and unloading process.
4. The Owner/User must review all name plates, placards, decals, instructions and posted warnings 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 damage notification to the manufacturer is required.
6. Loading dock equipment that has been structurally damaged or has experienced a sudden loss of main
support while under load (such as what might occur when a transport vehicle pulls out from under the
leveling device) shall be removed from service, inspected by a manufacturer’s authorized representative,
and repaired or replaced as needed before being placed back in service.
7. Any modifications or alterations of loading dock equipment shall only be done with prior written approval
from the manufacturer and the same shall be at least as safe as the original equipment was prior to
the modification and shall also satisfy all safety requirements of the manufacturer for the particular
application of the leveling device.
8. When industrial moving devices are being used in the loading or unloading of product from the
transportation vehicle, this vehicle shall have the brakes and wheel chocks applied appropriately or all
other positive restraining device shall be fully utilized. It is recommended that transport vehicles with airride suspension systems shall have its air exhausted prior to performing loading and unloading operation
to minimize transport vehicle bed drop.
9. Loading dock safety equipment should never be used outside of its intended use, vertical working range,
or capacity. Please consult the manufacturer if you have any questions as to the use, vertical working
range or capacity of the equipment. Only properly trained and authorized personnel should operate the
equipment.
10.When selecting loading dock safety equipment, it is important to consider not only present requirements
but also future plans and any possible adverse conditions, environmental factors or usage.
6
4111-0013 — May 2015
INTRODUCTION
General Information
Dock Leveler Stock Specifications
LMP-Series dock levelers are available in the following
sizes, weight capacities, and options:
Width
6 ft (1828.8 mm)
6-1/2 ft (1981.2 mm)
7 ft (2133.6 mm)
Length
5 ft
6 ft
8 ft
10 ft
Congratulations on your choice of a Poweramp
dock leveler. This manual covers the LMP-series
mechanical dock leveler.
Designed by Poweramp 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.
(1424 mm)
(1828.8 mm)
(2438 mm)
(3048 mm)
Capacity (CIR*)
25,000 lb (11
30,000 lb (13
35,000 lb (15
40,000 lb (18
340
608
876
144
kg)
kg)
kg)
kg)
* CIR (Comparative Industry Rating)
Call Poweramp for your specific needs.
Once again, thank you and congratulations on your
purchase of a Poweramp mechanical dock leveler.
4111-0013 — May 2015
7
INTRODUCTION
Component Identification
S
C
A
F
Q
B
E
N
R
D
P
T
U
G H J M
K
L
A — Lip
B — Lip Maintenance Prop
C — Platform
D — Lip Link
E — Lip Assist Rod
8
F — Platform Release Ring
G — Ratchet Pawl
H — Ratchet Bar
J — Pawl Spring
K — Main Frame
L — Platform Maintenance Prop
M— Hold-Down Mechanism
N — Safety Leg
P — Lip (Snubber) Spring
Q — Lip Shock Absorber
R— Safety Leg Linkage
S — Safety Leg Pull Ring
T — Lift Arm Assembly
U — Lift (Main) Spring
Assembly
4111-0013 — May 2015
INSTALLATION
Prepare Pit
A
C
B
D
A— Distance (Pit Width)
(Front and Rear)
B — Distance (Dock Floor-to-Pit
Floor) (All Four Corners)
C — Distance (Pit Length)
(Both Sides of Pit)
D — Distance (Pit Corner-to-Corner)
(Top, Bottom, and Both Sides)
1. Before lowering the dock leveler into the pit, the
following must be performed:
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.
NOTICE
DO NOT remove the shipping bands around the
dock leveler lip until instructed to do so.
4111-0013 — May 2015
2. Remove all debris from the pit and sweep the pit
clean.
3. Check the entire dock leveler pit for proper
construction according to approved/certified pit
drawings. Make sure pit is square by making the
following measurements:
• Measure pit width distance (A) at both front and
rear of pit.
• Measure dock floor-to-pit floor distance (B) at all
four corners.
• Measure pit length distance (C) at both sides.
• Measure corner-to-corner (criss-cross) distance
(D) at both sides. Take measurements at dock
floor level and at pit floor level.
4. If any measurement is off by more than 1/8 in.
(3.18 mm), contact Technical Services before
proceeding.
9
INSTALLATION
Prepare Dock Leveler
A
B
A— Lifting Bracket (2 used)
The dock leveler is heavy. Use a lifting device and
chains with the appropriate lifting capacity and
reach.
Always use the lifting brackets provided with the unit
whenever lowering or lifting a dock leveler into or
out of a pit.
Failure to follow these instructions may result in
damage to the dock leveler and/or serious personal
injury or death.
1.
Remove any bumpers that may be banded, or
bolted to the frame of the dock leveler.
DO NOT remove the shipping bands (B) around
the platform lip and leveler frame at this time.
NOTICE
DO NOT over tighten the lifting bracket hardware.
Over tightening can damage the weather seal, if
equipped.
10
B — Shipping Bands
Poweramp dock levelers are designed with installation
in mind. Each unit is shipped with lifting brackets (A)
fastened to the platform side joists.
NOTICE
DO NOT remove the shipping bands (B) around
the platform lip and leveler frame at this time. The
shipping bands are needed to hold the leveler
together during the installation process.
NOTE:Overall width of platform and lifting brackets
(A) must be kept to a minimum to prevent
interference between the lifting brackets and
the pit walls as the dock leveler is lowered into
the pit.
2.Make sure the mounting hardware of lifting brackets
(A) is snug. The brackets should pivot relatively
freely on the mounting cap screw. DO NOT overtighten.
3.Attach lifting chains to lifting brackets (A) and to
a lifting device (i.e., hoist or fork truck) having the
appropriate lifting capacity and reach.
4.
Remove wood blocks that are attached to the
leveler frame before putting the dock leveler into
the pit.
4111-0013 — May 2015
INSTALLATION
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4111-0013 — May 2015
11
INSTALLATION
Install Dock Leveler
Shim
Stacking Methods
M
PLACARD
N
P
Q
R
A— Distance (Leveler Frame
Height)
B— Shim Locations (Under
Rear Vertical Supports)
C— Shim Locations (Under
Lip Keepers and Prop)
D— Dock Floor
E— Rear Pit Curb Angle
F— String
G— Rear Hinge Frame Angle
H— Distance (Dock Floor-toPit Floor)
J— Distance (Top of Shim
Stack-to-Dock Floor)
K— Shim Stack
L— Dock Leveler Frame
M — Pyramid (Preferred)
N— Stepped (Acceptable)
P— Offset (Not Acceptable)
Q — Straight (Not Acceptable)
R— Lip Keeper (Shim between
lip keeper and curb angle
as required)
12
4111-0013 — May 2015
INSTALLATION
NOTE: Systems, Inc. levelers are designed with
a nominal 1/2 in. (12.7 mm) shimming distance to
allow for pit inconsistencies.
1. Determine height of shim stack (K) for each shim
location (B) by performing the following:
a.Measure leveler frame height distance (A).
b.Measure dock floor-to-pit floor distance (H) at each
shim location (B). Write down the dimensions
obtained at each location.
c.Subtract distance (A) from distance (H) to obtain
the shim height. Repeat for each shim location.
NOTICE
The minimum size of the shim that contacts the
leveler frame (i.e., the top shim of each shim stack)
must be at least 4-1/2 x 4-1/2 in. (114.3 x 114.3
mm) to support the full width of the frame rail and to
provide a shelf for a fillet weld.
Use the thickest shim stock possible for stability and
weld penetration purposes. DO NOT use multiple
layers of 1/8 in. (3.18 mm) or thinner shim stock.
4. Put a 1/4 in. (6.6 mm) thick shim at locations (C)
(under lip keepers/maintenance prop and safety
legs). Make sure shims are larger than frame angle
iron so pyramid or stepped stacking method can be
used.
The dock leveler is heavy. Use chains and a lifting
device with the appropriate lifting capacity and
reach. Failure to do so may result in damage to dock
leveler and/or serious personal injury or death.
NOTE: A 1/4 in. (6.6 mm) thick shim at locations
(C) is used only as a starting point. The final shim
stack height will be determined after the dock leveler
is lowered into the pit.
5. Using an appropriate lifting device connected to the
lifting brackets, lower dock leveler into the pit so rear
hinge frame angle (G) is tight against rear pit curb
angle (E) across full width of the leveler frame.
6. Allow rear of dock leveler to rest on the rear shims
while keeping the front of the dock leveler level with
the dock floor.
7. Add shims at front shim locations (C) so front of dock
leveler will stay level with dock floor when leveler is
resting fully on shims.
2. Using the results obtained in step 1, create the
individual shim stacks on the pit floor at locations
(B). Build each shim stack (K) using the pyramid
method (M) (preferred) or stepped method (N)
with the top shim having a minimum size of 4-1/2 x
4-1/2 in. (114.3 x 114.3 mm) and each successive
lower shim being larger so the shims can be welded
together using a fillet weld. DO NOT use offset
method (P) or straight method (Q).
NOTE: To assist in obtaining an accurate
measurement of distance (J), use a string (F) pulled
tight across the pit opening, directly over the shim
locations.
3. Verify that each shim stack is at the correct height
by measuring distance (J) [top of shim stack (K) to
dock floor]. Distance (J) must equal the dock leveler
height (A).
4111-0013 — May 2015
13
INSTALLATION
A— Front of Dock Pit
B— Dock Leveler Frame
C— Side Pit Curb Angle
D— Gap [3/4 in. (19 mm)
Minimum]
E— Pry Locations
F— Rear Hinge Frame
Angle
8. With rear hinge frame angle (F) tight against rear
pit curb angle (G), perform/check the following:
•Pry between the platform and rear hinge frame
angle at locations (E) to make sure rear edge of
platform is parallel to the rear hinge frame angle
(F).
•Gap (D) must exist equally along both sides of
leveler so weather seal (if equipped) will not bind
during dock leveler operation.
G— Rear Pit Curb Angle
H— Flare Bevel Weld, Typical
(To Fit Spacing)
10.Allow the dock leveler to rest fully on the shim
stacks. Make sure the leveler is in the cross-traffic
(stored) position with lip resting on lip keepers.
11.Check that a smooth and level transition exists
between the dock floor and the dock leveler
platform. Add or remove shims as necessary until
a smooth transition is obtained.
12.If leveler cannot be squared and made level
as instructed in steps 8 – 10, contact Technical
Services.
9. If gap (D) cannot be obtained equally at both sides
of leveler, grind or add material at the rear edge of
rear hinge frame angle (F) as needed.
14
4111-0013 — May 2015
INSTALLATION
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 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 result in
serious personal injury or death.
NOTICE
Always ground welding equipment to the dock
leveler frame, NEVER to the platform.
DO NOT weld continuously along the full length
of the rear hinge frame angle. This can put
unnecessary stress on the leveler components,
causing the leveler not to function correctly and
shortening the lifespan of the affected components.
NOTE: The illustration on the previous page shows
a typical weld pattern. The weld pattern will vary
slightly depending on size of dock leveler.
13.With the rear hinge frame angle (F) tight against
the rear pit curb angle (G), weld the rear hinge
frame angle (F) to the rear pit curb angle (G) using
a 3/8 in. (9.5 mm) flare bevel skip weld-each weld
being 6 in. (152 mm) long.
Start at each end with a 6 in. (152 mm) long
weld. Space all the other welds out evenly leaving
approximately 6 in. (152 mm) space between each
weld.
Alternate welding locations to distribute heat.
Welding sequentially from one end to the other
may cause warping or distortion.
14.Remove shipping bands at this time. Allow platform
to float. Add/Remove shims as necessary to bring
platform level/flush with floor.
Make sure all personnel are outside of the leveler
operating zone and stand clear of the platform lip
before removing the shipping bands. Failure to do
this may result in serious personal injury or death.
15.Weld front of dock leveler frame (B) to shims
located under the keepers, then weld the shims to
the front pit curb steel.
16.Disconnect lifting device and chains from the lifting
brackets.
Make sure all personnel are outside of the leveler
operating zone and clear of the platform lip before
activating the leveler. Failure to do this may result
in serious personal injury or death.
NOTICE
When activating the leveler, always pull AND hold
the platform release ring until the platform is at the
full-raised position. Releasing the ring while the
platform is still rising may result in damage to the
equipment.
17.Pull and hold the release ring (located in recess
at rear of platform) until the platform is fully
raised. Check for binding as platform rises.
18.Slowly walk out onto the platform to lower the
platform. Allow the platform to lower to the
cross‑traffic position. Check for binding as platform
lowers.
19.If binding occurs, reposition leveler and/or add
or remove shims as necessary. Raise and lower
platform again. If platform still binds, contact
Systems Inc. Technical Services for further
instructions.
20.Check that the leveler is flush with the dock floor
and that the platform lip contacts both lip keepers
evenly.
4111-0013 — May 2015
15
INSTALLATION
F
E
A
C
B
D
A— Safety Leg Chain Pull Ring
E— Lip Support Prop
B— Platform Maintenance Prop C — Shim Location (Under Lift Arm Pivot) D — Locking Device
F— Platform Release Ring
21.Pull the release ring to raise platform. Engage
the platform maintenance prop (B) in the service
(upright) position and lock the maintenance prop
at this position using an OSHA approved locking
device (D). Engage lip maintenance prop.
Make sure the platform is properly supported in the
raised position before entering the pit to finish weld
the shims. Failure to do this may result in serious
personal injury or death.
22.Install shims under lift arm at locations (C) using
the pyramid shimming method. The lift arm pivot
must be solidly shimmed the entire length of the lift
arm pivot. Make sure the lift arm pivot is level from
side-to-side.
23.Finish weld all shims using a fillet weld.
•Weld all shims within each shim stack to each
other, then weld the shim stack to the leveler frame.
•Weld the front leveler frame shim stacks to the front
pit curb steel if not done previously.
24.When all welding has been completed, remove all
slag then paint all the welds and shims.
25.Remove the lifting brackets from the platform side
joists.
26.Disengage the platform maintenance prop.
27.Slowly walk out onto the platform to lower the
platform until it is at the cross-traffic (stored)
position.
28.Check operation of dock leveler by cycling the
leveler at least four times.
•When the platform is at full height, lip will be fully
extended.
•Lip will begin to drop after full height is reached,
taking approximately 12 seconds to fully fold.
29.Check below-dock position by walking platform
down before lip folds completely.
•Lip will be over lip keepers.
•Platform safety legs will be resting on frame.
30.Check full below-dock position by walking the
platform down. Pull and hold safety leg chain (A)
before lip folds completely.
31.If the lip does not extend fully or lip folds too quickly,
see appropriate symptom in the Troubleshooting
section.
32.Install the dock bumpers as required.
16
4111-0013 — May 2015
OPERATION
Theory
1 — Lip
2 — Lip Maintenance Prop
3 — Platform
4 — Lip Link
5 — Lip Assist Spring
6 — Hold Down Release Ring
7— Ratchet Pawl
8— Ratchet Bar
9 — Hold down
The LMP-series mechanical dock leveler uses large
lift springs (18) to apply force to lift arm (17). The lift
arm pushes against the underside of the platform (3),
rolling on the cam (not pictured) forcing the platform to
rise. The force of the spring tension is just enough to
lift the weight of the platform.
NOTICE
When activating the leveler, always pull AND hold
the platform release ring until the platform is at the
full-raised position. Releasing the ring while the
platform is still rising may result in damage to the
equipment.
To actuate the dock leveler platform, the operator
pulls and holds the platform release ring (6) located
in the recess at the rear of the platform. This causes
ratchet pawl (7) to disengage from ratchet bar (8).
With the ratchet pawl disengaged, spring tension from
lift springs (18) forces the platform to rise.
NOTE:Ratchet pawl (7) and bar (8) are part of the
hold-down mechanism (9)
10 — Platform Maintenance Prop
11— Main Base Frame
12 — Safety Leg Assy.
13 — Snubber Spring
14 — Gas Shock
15 — Safety Leg Below Dock
Control
16— Safety Leg Retract Pull Ring
17 — Lift Arm
18 — Lift Springs
The ratchet pawl disengages only when the platform
release ring (6) is pulled AND held. Spring tension
from pawl spring causes the ratchet pawl to engage
the ratchet bar when the release ring is let go.
When the platform rises to approximately 2 – 3 inches
(51 – 76 mm) from its full raised height, the lip spring
(5) and a chain pulls the lip link (4) forward. This, in
conjunction with the lip assist spring (5), causes the lip
linkage to push the lip out and up. The lip assist spring
also helps control the amount of time required for the
lip to fully fold.
To lower the platform, the operator walks out onto the
platform. The platform will lower until the extended lip
rests on the transport vehicle bed. If the lip did not fully
extend or there is no transport vehicle at the dock, the
platform will lower until one of the following conditions
occur:
• Lip is resting on lip keepers (cross-traffic position).
•Lip did not fully fold causing the platform to rest on
safety legs (below-dock position).
•Lip did not fully fold and safety legs are retracted,
causing the platform to rest on the safety stops (full
below-dock position).
The hold-down ratchet assembly will keep the platform
at the desired position until the platform release ring is
pulled again.
4111-0013 — May 2015
17
OPERATION
Operating Instructions
Stay clear of dock leveler when transport vehicle is
entering or leaving dock area.
12 in. (305 mm)
DO NOT raise or lower the dock leveler if anyone
is under or in front of leveler.
12 in. (305 mm)
Keep hands and feet clear of pinch points. Avoid
putting any part of your body near moving parts.
Failure to follow these instructions may result in
severe personal injury or death.
DO NOT activate the dock leveler until the transport
vehicle is positioned squarely against the bumpers
and the transport vehicle wheels are chocked.
Never remove the wheel chocks until loading and
unloading is finished and transport vehicle driver
has been given permission to leave.
DO NOT use the dock leveler if the freight carrier is
too high or too low.
NEVER use a fork truck or any other material
handling equipment to lower the dock leveler.
DO NOT drive any equipment onto the dock leveler
until platform lip is resting on the transport vehicle
with at least 4 in. (102 mm) of overlap.
Always maintain a safe distance from side edges of
leveler during the loading and unloading process.
NEVER attempt to walk on an unsupported lip.
NEVER allow untrained personnel to operate the
dock leveler.
NEVER attempt to lift any part of the leveler by
hand.
Failure to follow these instructions may result in
serious personal injury or death.
18
The HM-series mechanical dock leveler is designed
to compensate for ± 12 in. (305 mm) of height
difference between the loading dock and the
transport vehicle bed. DO NOT use the dock leveler
if the transport vehicle bed is more than 12 in. (305
mm) higher or lower than the dock floor.
DO NOT overload the dock leveler.
DO NOT operate any equipment while under the
influence of alcohol or drugs.
DO NOT leave/store equipment
unattended on the dock leveler.
or
material
Failure to follow these instructions may result in
personal injury and/or damage to equipment.
NOTICE
When activating the leveler, always pull AND hold
the platform release ring until the platform is at the
full raised position. Releasing the ring while the
platform is still rising may result in damage to the
equipment.
The dock leveler operation instructions are
divided into the two methods of loading and
unloading:
•For ramp loading and unloading, see Ramp
Loading/Unloading Instructions on page 19.
•For end loading and unloading, see End
Loading/Unloading Instructions on page 20.
4111-0013 — May 2015
OPERATION
Operating Instructions — Continued
Ramp Loading/Unloading Instructions
NOTE: If end unloading is required, see End Loading/
Unloading Instructions on page 20.
1.Check to make sure transport vehicle is positioned
squarely against dock bumpers.
7.
Make sure that the lip is fully extended and
supported on the transport vehicle along the entire
width of the platform with at least 4 in. (102 mm) of
lip contacting the transport vehicle bed.
2.
Instruct driver to remain at the dock until the
loading or unloading process has been completed.
3.Chock the transport vehicles wheels or use vehicle
restraint if present.
8. Proceed with loading or unloading.
A
NOTE:If end loading is necessary, see End Loading/
Unloading Instructions on page 20.
A
4.
Raise the platform by pulling and holding the
platform release ring (A).
5.Hold the release ring until the platform is at the
fully-raised position and lip is fully extended.
9.When the loading or unloading process has been
completed, return platform to cross-traffic (stored)
position as follows:
a.Raise the platform to the full-raised position by
pulling and holding the platform release ring (A).
6.Walk out onto the platform. The platform will lower
until the lip rests on the transport vehicle.
b.Lower platform by slowly walking out onto the
platform allowing time for the lip to fully fold and
clear the transport vehicle. Continue walking
out on platform until platform lowers to the
cross‑traffic position (lip engages in the lip
keepers).
10.Remove chocks from transport vehicle wheels or
release vehicle restraint if used.
11. Indicate to driver that transport vehicle may leave the dock.
4111-0013 — May 2015
19
OPERATION
Operating Instructions — Continued
End Loading/Unloading Instructions
NOTE: End loading or unloading can be done with
the dock at the cross-traffic position or
below‑dock position depending on the height
of the transport vehicle bed.
B
1.Check to make sure transport vehicle 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 transport vehicle wheels or use vehicle
restraint if present.
End Loading/Unloading — Platform at Cross-Traffic
Position.
4.If transport vehicle bed is at or above dock floor
level, leave leveler at the cross-traffic position and
proceed with loading or unloading. When finished,
perform steps 9 and 10.
If transport vehicle bed is below the dock floor
level, perform steps 5 – 10.
A
5.Pull and hold the platform release ring (A) until the
platform is at the fully-raised position.
6.
Slowly walk the platform down allowing enough
time for the lip to fold. Just before the platform
reaches the cross-traffic position, pull and hold the
safety leg retract pull ring (B) (located in a recess
at front of the platform). The platform will continue
lowering to the full below dock position.
End Loading/Unloading — Platform at Below-Dock Position.
7. Proceed with loading or unloading.
NOTE: When end unloading is finished and
additional access to the transport vehicle
requires that the platform lip be extended,
see Ramp Loading/Unloading Instructions on
page 19 for further instructions.
8.When loading or unloading is finished, raise the
platform to the full-raised position by pulling and
holding the platform release ring. Slowly walk the
platform down, allowing enough time for the lip
to fold. The platform will lower to the cross‑traffic
position (lip engages in the lip keepers).
9.Remove chocks from transport vehicle wheels or
release vehicle restraint if used.
10.Indicate to the driver that the transport vehicle
may leave the dock.
20
4111-0013 — May 2015
MAINTENANCE
Service Dock Leveler Safely
A— Platform Release
Ring
B — Platform Maintenance
Prop
C— Lip Maintenance Prop D— Prop Pin and Clip E— Safety Leg Pull Chain
Always post safety warnings and barricade the
work area at dock level and ground level to prevent
unauthorized use of the dock leveler before
maintenance is complete. Failure to do this may
result in serious personal injury or death.
Always stand clear of the dock leveler lip when
working in front of the dock leveler. Failure to do this
may result in serious personal injury or death.
The platform maintenance prop MUST be in the
service position when working under the dock
leveler. For maximum protection, use an OSHA
approved locking device to lock the maintenance
prop in the service position. Only the person
servicing the equipment should have the key to
unlock the maintenance prop.
Failure to follow these instructions may result in
serious personal injury or death.
4111-0013 — May 2015
Whenever maintenance is to be performed under the
dock leveler platform, support the platform with the
platform maintenance prop (B).
Put the platform maintenance prop in the service
(upright) position so that the prop is cradled in the
u-bracket (C). Lock the platform maintenance prop
in this position by inserting the prop pin and clip (D)
or attaching an OSHA approved lockout device* and
tagout device*, supplied by others.
Only the person servicing the equipment should have
the capability to remove the lockout device. The
tagout device must inform that repairs are in process
and clearly state who is responsible for the lockout
condition.
If maintenance requires that the lip be in the extended
position, raise the lip by hand and support the lip with
the lip maintenance prop (A).
NOTE:Make sure to disengage the lip maintenance
prop and allow the lip to fold fully before
disengaging the platform maintenance prop.
* Refer to OSHA regulation 1910.146.
* Refer to OSHA regulation 1910.147.
21
MAINTENANCE
Periodic Maintenance
C
K
A
•
D
E
L
J
M
H
G
B
A —Lip Hinge Lug Area
B — Lip Maintenance Prop
Pivot
C — Lip Link Pivots
D — Platform Lug Area
E — Lift Arm Roller Bushing Always post safety warnings and barricade the
work area at dock level and ground level to prevent
unauthorized use of the dock leveler before
maintenance is complete. Failure to do this may
result in serious personal injury or death.
Always stand clear of the dock leveler lip when
working in front of the dock leveler. Failure to do this
may result in serious personal injury or death.
22
G — Lift Arm Pivot
K — Lip Assist Pin
H — Hold-Down Pivot/Pulley
L — Hold Down-to-Platform Pin
J — Safety Leg Linkage Pivots M — Secondary Pulley
The platform maintenance prop MUST be in the
service position when working under the dock
leveler. For maximum protection, use an OSHA
approved locking device to lock the maintenance
prop in the service position. Only the person
servicing the equipment should have the key to
unlock the maintenance prop.
Failure to follow these instructions may result in
serious personal injury or death.
4111-0013 — May 2015
MAINTENANCE
Regular maintenance must be performed on a weekly
and quarterly schedule. Follow all safety precautions
Quarterly Maintenance
Weekly Maintenance
•
Lubricate the following areas with light-weight
machine oil:
•
Operate the dock leveler through the complete
operating cycle to maintain lubrication.
(B)— Lip maintenance prop pivot
NOTE: To thoroughly inspect the platform hinge area,
position the platform in the full below‑dock
position.
(C)— Lip banger pivots
(F)— E-Z release bellcrank pivot
•Inspect the platform hinge and the lip hinge areas.
The hinge areas must be kept free of dirt and debris.
Build-up of foreign material in the hinge areas will
increase wear and cause abnormal operation.
(H)— Hold-down pivot/pulley
(J)— Safety leg linkage pivots
(L)— Hold down-to-platform pin
Failure to properly lubricate the dock leveler will
cause abnormal operation of the leveler.
DO NOT lubricate the hold-down ratchet
bar and pawl.
•
Lubricate the following areas with white lithium
grease:
(A)— Lip hinge area (inject grease into all the lip
hinge grease fittings)
(D)— Platform hinge area (inject grease into all the
platform hinge grease fittings)
(E)—Lift arm roller bushing
(G)— Lift arm pivot
(K)— Lip assist pin
A maintenance prop permanently attached and
hinged to the unit with means for lock out/tag out
requirements (per OSHA 1910.147) is included
with each pit style dock leveler. In addition, it is
recommended and good safety practice to use an
additional means to support the dock platform and
lip anytime when physically working in front of or
under the dock leveler. This additional means may
include, but not limited to a boom truck, fork truck,
stabilizing bar or equivalent.
4111-0013 — May 2015
23
ADJUSTMENTS
Adjust Lift Arm Spring and Lip Assist Spring Tension
A B
C
F
E
D
A — Jam Nut
B — Adjustment Nut
C — Lip Assist Spring
D — Lift Springs
Always post safety warnings and barricade the
work area at dock level and ground level to prevent
unauthorized use of the dock leveler before
maintenance is complete. Failure to do this may
result in serious personal injury or death.
Always stand clear of the dock leveler lip when
working in front of the dock leveler. Failure to do this
may result in serious personal injury or death.
24
E — Lift Spring Bolt
F — Hold-Down Mechanism
The platform maintenance prop MUST be in the
service position when working under the dock
leveler. For maximum protection, use an OSHA
approved locking device to lock the maintenance
prop in the service position. Only the person
servicing the equipment should have the key to
unlock the maintenance prop.
Failure to follow these instructions may result in
serious personal injury or death.
4111-0013 — May 2015
ADJUSTMENTS
NOTE: Adjusting the tension of lift springs (D) usually
requires that the lip assist spring (C) also be
adjusted.
3.
After lift spring adjustment is completed, check
operation of the lip.
•If the lip folds before the platform can be walked
down, tension of lip assist spring (C) may be set
too low.
•If the lip does not fold fully or takes too long to
fold, tension of lip assist spring (C) may be set
too high.
If the platform does not rise fully and/or lip does not
extend fully, the lift spring tension may be set too low.
If the platform cannot be walked down or is difficult to
walk down, the lift spring tension may be set too high.
4. Adjust lip assist spring tension as follows:
NOTE:Use two-turn increments when adjusting
lip assist spring (C). Check lip operation
after each adjustment. Repeat until proper
operation is obtained.
a.Loosen jam nut (A).
NOTICE
When using an external lifting device to raise the
platform, make sure hold-down mechanism (F) is
disengaged. Pull and hold platform release ring
during the lifting process to avoid shearing the
ratchet pawl and ratchet bar teeth.
1.
Raise the platform and engage the platform
maintenance prop. Lock the maintenance prop in
the service position using an appropriate locking
device.
b.To increase spring tension, turn nut (B) clockwise.
c.
To decrease spring tension, turn nut (B)
counterclockwise.
d.Tighten jam nut.(A)
5.
Recheck operation of platform and lip. Readjust
lift spring tension and lip assist spring tension until
proper operation is obtained.
NOTE: Set lip tension first with the unit about 6 inches above dock floor, fully extend the lip. Time the rate
of descent of the lip to full pendant position, this time
should be approximately 15-25 seconds.
2. Adjust tension of lift springs (D) as follows:
NOTE:
Use 1/2 turn increments when adjusting lift
spring bolt (E). Check platform operation
after each adjustment. Repeat until proper
operation is obtained.
•
To increase lift spring tension, turn lift spring
bolt (E) clockwise.
•To decrease lift spring tension, turn lift spring
bolt (E) counterclockwise.
4111-0013 — May 2015
25
ADJUSTMENTS
Adjust Lip Stop Bolt
Always post safety warnings and barricade the
work area at dock level and ground level to prevent
unauthorized use of the dock leveler before
maintenance is complete. Failure to do this may
result in serious personal injury or death.
A
B
Always stand clear of the dock leveler lip when
working in front of the dock leveler. Failure to do this
may result in serious personal injury or death.
C
The platform maintenance prop MUST be in the
service position when working under the dock
leveler. For maximum protection, use an OSHA
approved locking device to lock the maintenance
prop in the service position. Only the person
servicing the equipment should have the key to
unlock the maintenance prop.
Failure to follow these instructions may result in
serious personal injury or death.
Check that lip (E) is fully resting on the lip keepers (D)
and at the lowest part of the lip keepers. If lip is not
resting properly in lip keepers, perform the following
adjustment.
1.
Fully raise platform. Manually raise the lip and
engage lip maintenance prop (not shown).
2. Loosen jam nut (B).
E
D
A— Platform
B— Jam Nut
C— Stop Bolt
D — Lip Keeper
E — Lip
4. Tighten jam nut (B).
5. Disengage lip maintenance prop.
6.
Walk platform down to cross-traffic (stored)
position.
7.
Check lip position in both keepers. Repeat
procedure if necessary.
3.Adjust stop bolt (C) as necessary.
•Turn stop bolt “in” (clockwise) to allow lip to fold
closer to platform (A).
•Turn stop bolt “out” (counterclockwise) to hold
lip further away from platform (A).
26
4111-0013 — May 2015
TROUBLESHOOTING
Troubleshooting
Always post safety warnings and barricade the
work area at dock level and ground level to prevent
unauthorized use of the dock leveler before
maintenance is complete. Failure to do this may
result in serious personal injury or death.
Always stand clear of the dock leveler lip when
working in front of the dock leveler. Failure to do
this may result in serious personal injury or death.
Symptom
Platform does not rise.
Possible Cause
The platform maintenance prop MUST be in the
service position when working under the dock
leveler. For maximum protection, use an OSHA
approved locking device to lock the maintenance
prop in the service position. Only the person
servicing the equipment should have the key to
unlock the maintenance prop.
Failure to follow these instructions may result in
serious personal injury or death.
Solution
Heavy object(s) on platform. Remove object(s) from platform.
NOTE:For safety reasons, the dock leveler is
designed to lift only the platform’s own
weight.
Disconnected or broken
release chain.
Connect or replace chain.
Dock leveler binds.
Check for visible obstructions that could cause
binding. Check weather seal if equipped.
If no obstructions found, call Systems Inc. Technical
Services. See inside back cover for phone number
and address.
Platform rises slowly or
does not rise to the full
raised position.
Heavy object(s) on platform. Remove object(s) from platform.
NOTE:For safety reasons, the dock leveler is
designed to lift only the platform’s own
weight.
Dock leveler binds.
Check for visible obstructions that could cause
binding. Check weather seal if equipped.
If no obstructions found, call Systems Inc. Technical
Services. See inside back cover for phone number
and address.
4111-0013 — May 2015
Insufficient main spring
tension.
Increase tension on main springs. (See Adjust Lift
Arm Spring and Lip Assist Spring Tension in the
Adjustments section.)
Damaged or worn
hold‑down mechanism.
Clean and inspect hold-down mechanism.
NOTE Never lube the ratchet bar and pawl.
27
TROUBLESHOOTING
Symptom
Platform rises to full
height, but lip does not
fully extend.
Possible Cause
Lip assist chain
disconnected or broken.
Connect or replace chain.
Insufficient main spring
tension.
Increase tension on main lift springs. (See Adjust
Lift Arm Spring and Lip Assist Spring Tension in the
Adjustments section.)
Insufficient lip assist force.
Increase lip assist spring tension. (See Adjust Lift
Arm Spring and Lip Assist Spring Tension in the
Adjustments section.)
Platform does not lower Excessive main spring
when operator walks out tension.
onto the platform.
Lip folds too fast during
normal walk-down.
Platform does not stay
down.
Lip does not fold
after transport vehicle
departs.
28
Solution
Reduce main spring tension. (See Adjust Lift
Arm Spring and Lip Assist Spring Tension in the
Adjustments section.)
Damaged or worn
hold‑down mechanism.
Clean and inspect hold-down mechanism.
DO NOT lube the ratchet bar and pawl.
Insufficient lip assist force.
Increase lip assist spring tension. (See Adjust Lift
Arm Spring and Lip Assist Spring Tension in the
Adjustments section.)
Disconnected, worn, or
broken shock absorber.
Inspect shock absorber. Connect or replace shock
absorber.
Entangled release chain.
Remove cause of entanglement.
Dirt impacted in ratchet bar
teeth.
Clean and inspect ratchet bar and ratchet pawl
teeth. DO NOT lubricate the ratchet assembly.
Broken or damaged ratchet
assembly teeth.
Replace ratchet assembly. DO NOT lubricate the
ratchet assembly.
Disconnected or broken
hold-down pivot pins.
Replace hold-down pivot pins.
Damaged or worn
hold‑down mechanism.
Clean and inspect hold-down mechanism.
Lip hinge binding because
of lack of lubrication
Spray lithium grease into all of the lip lug area. (See
Periodic Maintenance in the Maintenance section.)
Excessive lip assist force.
Decrease lip assist spring tension. (See Adjust Lift
Arm Spring and Lip Assist Spring Tension in the
Adjustments section.)
4111-0013 — May 2015
PARTS
Hold-Down Mechanism
B
B
E
D
C
C
Item
Quantity
1
B
1
C
D
E
1
1
1
4111-0013 — May 2015
Part Number
DOTH-2563
DOTH-2564
DKIT-2575
DKIT-2576
1751-0043
DOTH-2559
DOTH-2556
Description
Hold Down Assembly Complete, 31.5” Ratchet Bar
Hold Down Assembly Complete, 34.5” Ratchet Bar
Ratchet Bar and Pawl Assembly 31.5” Ratchet Bar
Ratchet Bar and Pawl Assembly 34.5” Ratchet Bar
Decal, Warning
Spring, Release Arm
Spring, Pawl
29
PARTS
Frame Components
K
J
F
F
P Q
R
G
A
AE
AF
X
L
D
AA
L
E
Z
C
AD
B
W
U
M
AB AC
V
H
S
T
30
4111-0013 — May 2015
PARTS
Frame Components
Item Quantity Part Number
Description
1
1
1
DFRA-____
DFRA-____ 1
DOTH-2555
DOTH-2418
DPLA-2128
Frame, Welded Assembly
Frame, Clean Sweep, Welded Assembly (Optional)
Spring, Snubber
Hook, S.
Chain, Lip Assist Link
1
DOTH-2416
Link,Lap
1
1
1
1
1
1
1
DPLA-1218 1
DFRA-03231
DFRA-0323 1
DOTH-2222
DOTP-6424 1
DOTP-6423 1
9201-0006
Bolt, Spring Adjuster 8 foot long
Plate, Spring Tensioner 6 foot long
Plate, Spring Tensioner 8 foot long
Washer
Lift Arm, Short, 25” All 6’ long and 6’x8’ -25K
Lift Arm, Long, 27” 6’x8’ 30K to 7’x8’ 40K
Prop Pin and Clip
J
K
L
M
P
Q
1
AR*
3
3
2
1
1
DOTH-2401
DOTH-____ 1
DOTH-2382
9202-0002
DOTH-2418
DOTH-2423
5265-0012 1
Roller Assembly, Cam
Spring, Lift
Pin, Cotter, 1/4 x 2 in.
Pin, Rear Hinge
Hook, S
Ring, Chain
Chain, Hold-Down Release 6 ft/10ft
R
S
1
5265-0013 1
Chain, Hold-Down Release 8 ft
U
V
W
1
2
2
2
1
1
1
X
1
DOTP-____
8432-0983
8432-0984
8432-0985
DOTH-2356
DRFA-0350
DOTH-2375
DOTH-2563
Z
AA
AB
AC
1
1
1
1
AD
AE
AF
1
1
1
A
1
B
C
D
E
F
G
H
T
1
DOTH-2564
DOTH-2205
DFRA-1205
DOTH-2211
2101-0216
DFRA-0351
DFRA-0348
DOTH-2061
DFRA-0349
DOTH-2137
1
Prop, Maintenance
Keeper, Lip 16 inch 8’/10
(2)8432-1193 6’Long
Keeper, Lip 18 inch 8’/10’
(2)8432-1194 6’Long
Keeper, Lip 20 inch 8’/10’
(2)8432-1195 6’ Long
Pin, Clevis
Roller, Release Chain
Pin, Cotter
Hold-Down Assembly Complete, 31.5” Ratchet Bar (see page 29)6’L
Hold-Down Assembly Complete, 34.5” Ratchet Bar (see page 29)8’/10’L
Washer
Pin
Washer, Float
Link, Quick 1/8 inch
Roller Assy,6’ includes AD,AE,AF, and mounting brkt
Roller Assy,8’ includes AD,AE,AF, and mounting brkt
Bolt, Shoulder 1/2 x 1-1/2
Tube, Roller ZP
Nut, Jam 3/8-16UNC
*AR = As Required
1 Provide dock leveler serial number, platform size, lip size and pit depth when calling or faxing orders.
4111-0013 — May 2015
31
PARTS
Platform Components
AC
E
D
N P Q R S
T U V W X
AD
F
B
A
K
G H J
L M
C
PLATFORMS(2)
ITEM
QTY
AD
1
32
6 FOOT LONG
6.0 FOOT
8 FOOT LONG
6.5 FOOT 7.0 FOOT 6.0 FOOT 6.5 FOOT
10 FOOT LONG
7.0 FOOT 6.0 FOOT 6.5 FOOT 7.0 FOOT
4111-0013 — May 2015
PARTS
Platform Components
A
1
DPLA-0338
LIP BANGER ASSY.
B
1
DPLA-0341
BAR
C
1
DPLA-0343
BELOW DOCK CONTROL ASSY.
D
2
DOTH-2382
PIN, COTTER
F
1
DPLA-0353
BELOW DOCK CHAIN ASSY.
G
1
DPLA-0360
BDC PUSH ROD ASSY
H
1
DOTH-2060
BOLT SHOULDER
J
1
DOTH-2131
LOCK NUT
K
1
DOTH-6406
LIP ASSIST ROD
L
1
DOTH-2548
SPRING ,LIP ASSIST STD consult factory
M
1
DOTH-2546
SPRING ,LIP ASSIST HEAVY consult factory
N
1
DOTP-2006
LIP PROP BAR
P
1
DOTH-2061
SHOULDER BOLT
Q
1
DOTH-2131
LOCK NUT
R
2
DOTH-2214
WASHER
S
1
DOTH-2547
SPRING COMPRESSION
T
1
DOTH-2582
SHOCK GAS
U
2
DOTH-2351
BOLT CLEVIS
V
2
DOTH-2375
PIN COTTER
W
4
DOTH-2210
WASHER, FLAT
X
2
DOTH-2163
LOCK NUT
LIP SHAFTS
E
1
DPLA-0316
6.0 FOOT
1
DPLA-0394
6.5 FOOT
1
DPLA-0317
7.0 FOOT
AC
LIPS (2)
consult factory
*AR = As Required
1)Provide dock leveler serial number, platform size, and lip size when calling or faxing orders.
2)Consult Factory for Platform and Lip part numbers
4111-0013 — May 2015
33
Toe Guard/Weather Seal—Optional
Toe Guard / Weather Seal Options
C
B
CC
A
D
K
E
E
H
Item
A
B
C
CC
D
E
H
E
34
Quantity
2
2
2
2
2
4
2
Part Number
DOTH-2818
DOTH-2824
DOTH-2820
DOTH-2822
DOTH-2043
DOTH-2207
DOTH-2131
Description
Channel, Weather Seal, 84”
T-Rubber, Weather Seal, 84”
Extrusion, Brush Weather Seal, 84”
Brush Weather Seal, 1.58” x 84”
Cap Screw
Washer
Nut, Nylon Lock
1
DKIT-9178
DKIT-9179
DKIT-9180
DKIT-9181
Toe Guard / Weather Seal Options
Full Range Toe Guard Assembly, 5’
Full Range Toe Guard Assembly, 6’
Full Range Toe Guard Assembly, 8’
Full Range Toe Guard Assembly, 10’
1
DKIT-9292
KIT COMPLETE RUBBER WEATHER SEAL 6’-8’
1
DKIT-9293
KIT COMPLETE BRUSH WEATHER SEAL 6’-8’
4111-0013 — May 2015
Weather Seal—Optional
F
Item
Quantity
G
1
F
1
Part Number
0195-0045
0195-0046
0195-0047
0195-0048
G
Description
Rear Powerseal (Brush Seal)
Foam Seal Fits 6’ (self adhesive backing)
Foam Seal Fits 6-1/2’ (self adhesive backing)
Foam Seal Fits 7’ (self adhesive backing)
AR = As Required
NOTE: Brush or track can be purchased separately as replacement parts. Contact factory for part numbers.
Kits provide all parts / hardware to add Toe Guards or Weather Seal to an existing dock leveler.
Weatherseal channel must be welded to leveler
*Note, see Safety section (P.4). Pay special attention to removing grounds to motor anc control box before welding.
* Provide dock leveler serial number and size of platform when calling or faxing orders.
4111-0013 — May 2015
35
NOTES
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36
4111-0013 — May 2015
MISCELLANEOUS
Customer Information
A
NOTE: Refer to illustration for left/right orientation of
dock leveler.
The model/serial number decal (A) is located
on the right platform joist near the front (lip) of
dock leveler.
When you receive your LMP-series 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 Poweramp’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.
For service, call or contact:
Dock Leveler Information
Model
Serial No.
Systems Inc., Job
No.
Original Owner Information
Name
Address
Installer Information
Name
Address
Date of Installation
Systems, Inc.
P.O. Box 309
Germantown, WI 53022
Phone:(800) 643-5424
Fax: (262) 255-5917
4111-0013 — May 2015
37
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. In order to
be entitled to the benefits of this warranty, the product must have been properly installed, maintained
and operated in accordance with all manufacturer’s recommendations and/or specified design
parameters and not otherwise have been subject to abuse, misuse, misapplication, acts of nature,
overloading, unauthorized repair or modification, application in a corrosive environment or lack 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 shall be exclusive remedy for all claims whether
based on contract, negligence or strict liability.
WARRANTY LIMITATIONS
THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES, WHETHER
EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. SYSTEMS INC. AND
ITS SUBSIDIARIES SHALL NOT IN ANY EVENT BE LIABLE TO ANYONE, INCLUDING THIRD
PARTIES, FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND
INCLUDING BUT NOT LIMITED TO, BREACH OF WARRANTY, LOSS OF USE, LOSS OF
PROFIT, INTERRUPTION OF BUSINESS OR LOSS OF GOODWILL.
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