HED Series

A Division of Systems, LLC Dock Leveler

Owner’s/User’s Manual

McGuire • Division of Systems, LLC • W194 N11481 McCormick Drive • Germantown, WI 53022
800.624.8473 • fax: 262.255.5917 • www.wbmcguire.com • techservices@loadingdocksystems.com
Printed in U.S.A. Manual No. 4111-0020
© 2020 Systems, LLC - All Rights Reserved Sep. 2020
 Table of Contents
Page
Precautions
Recognize Precautionary Information................................................. 1
General Operational Precautions......................................................... 1
Operational Precautions....................................................................... 2
Safety Decals.......................................................................................... 4
Placard.................................................................................................... 5
Owner’s/User’s Responsibilities.......................................................... 6

Introduction
General Information............................................................................... 8
Component Identification...................................................................... 9

Installation
Installation Precautions....................................................................... 10
Installation Overview............................................................................ 11
Flush Mount - Weld On......................................................................... 12
Ramp Mount - Weld/Bolt On................................................................ 14
Flush Mount - Bolt On.......................................................................... 16
Ramp Mount - Weld On w/Formed Angle........................................... 18
Formed Angle........................................................................................ 20
Ramp and Face Plate............................................................................ 22
Install Control Panel and Wiring......................................................... 24
Placard Installation Instructions......................................................... 26
Put New Dock Leveler Into Service..................................................... 27

Operation
Operational Precautions...................................................................... 28
Operating Instructions......................................................................... 29

Maintenance
Maintenance Precautions..................................................................... 30
Periodic Maintenance........................................................................... 32

Adjustments
Adjust Main Pressure Relief................................................................ 34
Adjust Lip Function.............................................................................. 35

Troubleshooting
Troubleshooting.................................................................................... 36

Parts
Danfoss Control Box............................................................................ 40
Optional Electrical Parts...................................................................... 41
Leveler Components............................................................................ 42
Powerpack Assembly........................................................................... 44
Bumper Components........................................................................... 46

Miscellaneous
Customer Information.......................................................................... 49
Warranty................................................................................. Back Cover
 PRECAUTIONS
Recognize Precautionary Information General Operational Precautions

Safety-Alert Symbol

The Safety-Alert Symbol is a graphic representation

intended to convey a safety message without the
use of words. When you see this symbol, be alert
Read and understand the Owner’s/User’s Manual and
to the possibility of death or serious injury. Follow
become thoroughly familiar with the equipment and
the instructions in the safety message panel.
its controls before operating the dock leveling device.

Never operate a dock leveler or transport vehicle

restraint while a safety device or guard is removed or
The use of the word DANGER signifies the disconnected.
presence of an extreme hazard or unsafe practice
which will most likely result in death or severe Never remove DANGER, WARNING, or CAUTION
injury. signs, Placards or Decals on the equipment unless
replacing them.

Z one
ng
ra ti
pe
The use of the word WARNING signifies the O
presence of a serious hazard or unsafe practice
which could result in death or serious injury.

The use of the word CAUTION signifies possible

hazard or unsafe practice which could result in
minor or moderate injury. ne
g Zo
r at i n
Ope
Figure 1
The use of the word NOTICE indicates information
considered important, but not hazard-related, to
Do not start the equipment until all unauthorized
prevent machine or property damage.
personnel in the area have been warned and have
moved outside the operating zone (Figure 1).

Remove any tools or foreign objects from the

operating zone before starting.
Indicates a type of safety sign, or separate panel on
a safety sign, where safety-related instructions or
Keep the operating zone free of obstacles that could
procedures are described.
cause a person to trip or fall.

WARNING: This product can expose you to chemicals including lead, which are known to the State of California to
cause cancer or birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov

4111-0020 — Sep. 2020

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1
PRECAUTIONS
Operational 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 Chock/restrain all transport vehicles. Never
vehicle is entering or leaving area. remove the wheel chocks or release the
restraining device until loading or unloading is
finished, and transport 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 or restraining 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 bed

at least 4 in. (102 mm).

Keep a safe distance from both side edges.

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2 © 2020 Systems, LLC
 PRECAUTIONS
Operational Precautions

Do not use dock leveling device if transport vehicle

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.

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PRECAUTIONS
Safety Decals

2.43"
OPERATION 7. Stay clear of hinges and front and
1. Read and follow all instructions and sides of moving dock leveler.
PROUDLY

Unsupported dock leveler

warnings in owner’s/user’s manual. 8. N e v e r u s e d a m a g e d o r MADE
2. Use of dock leveler restricted to malfunctioning dock leveler. Report

2
IN USA

1.28"
trained operators problems immediately to supervisor.
ramps can lower unexpectedly. 3. Always chock trailer wheels or
engage truck restraint before MAINTENANCE/SERVICE SYSTEMS, INC.
operating dock leveler or beginning to 1. Read and follow all instructions, GERMANTOWN, WI
Before allowing vehicle to leave load or unload. warnings and maintenance MALVERN, AR

1
4. Never use hands or equipment to
the dock always: move ramp or lip
schedules in the owner‘s/user‘s
manual.

• Ensure no equipment,
5. Before activating dock leveler:
• Ensure trailer is backed in against
2. Maintenance/Service of dock leveler
restricted to trained personnel. 1751-0735
bumpers. 3. Place barriers on the driveway and
material or people are on • Remove any end loads if required. dock floor to indicate service work is
dock leveler. • Check trailer alignment to avoid lip being performed.
interference. If lip does not lower to 4. DO NOT ENTER PIT unless dock
trailer bed, reposition vehicle. leveler is securely supported by
• Return dock leveler to its 6. Ensure truck bed supports extended maintenance prop. Control Box Size:
lip or leveler frame supports the ramp 5. If electrically powered turn off and use Decal Size: 2.75 x 1.25
stored position at dock level. before driving on ramp. OSHA lockout/tagout procedures. File Name: 1751-0735
Failure to follow posted instructions will result in death or serious injury. Call 262.255.1510 for replacement placards, warning labels, or owner’s/user’s manuals. 1751-0730 Rev B

OPERATION 7. Stay clear of hinges and front and

1. Read and follow all instructions and sides of moving dock leveler.
warnings in owner’s/user’s manual. 8. N e v e r u s e d a m a g e d o r
Unsupported dock leveler Rev B 2. Use of dock leveler restricted to
5
malfunctioning dock leveler. Report
File Name: 1751-0730 trained operators problems immediately to supervisor.
ramps canSize:
Decal lower9.12
unexpectedly.
x 3.25
CRUSH HAZARD
3. Always chock trailer wheels or
engage truck restraint before MAINTENANCE/SERVICE
operating dock leveler or beginning to 1. Read and follow all instructions,
Before allowing vehicle to leave
the dock always:
load or unload.
4. Never use hands or equipment to
warnings and maintenance
schedules in the owner‘s/user‘s DO NOT REMOVE hydraulic cylinder until leveler is
1 safely supported by maintenance prop. Refer to
move ramp or lip manual.
5. Before activating dock leveler: 2. Maintenance/Service of dock leveler
• Ensure no equipment, • Ensure trailer is backed in against
owner’s/user’s manual for proper maintenance
restricted to trained personnel.
bumpers. 3. Place barriers on the driveway and
material or people are on • Remove any end loads if required. dock floor to indicate service work is
dock leveler. • Check trailer alignment to avoid lip
interference. If lip does not lower to
being performed.
4. DO NOT ENTER PIT unless dock procedure. Failure to comply will result in death or
serious injury.
trailer bed, reposition vehicle. leveler is securely supported by
• Return dock leveler to its 6. Ensure truck bed supports extended maintenance prop.
lip or leveler frame supports the ramp 5. If electrically powered turn off and use 1751-0138 Rev B
stored position at dock level. before driving on ramp. OSHA lockout/tagout procedures.
Failure to follow posted instructions will result in death or serious injury. Call 262.255.1510 for replacement placards, warning labels, or owner’s/user’s manuals. 1751-0730 Rev B 1751-0138
1751-0730

File Name: 1751-0138 Rev B

File Name: 1751-0730 Rev B Decal Size: 4 x 2
www.DockSystemsInc.com 1.800.643.5424

TM
Decal Size: 9.12 x 3.25
MHED SERIES
4

3
1751-0644 Decal Size: 6 x 2.4
File Name: 1751.0644

Left Bumper
3

1751-0763 Rev A

4
1751-0763
1
File Name: 1751-0763 Rev A
Decal Size: 4.3215 x 7.25 Serial Tag
2

Right Bumper
5

1 Decal Placement
for M-HED

Figure 2

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 PRECAUTIONS
Placard

O P E R AT I N G
DANGER INSTRUCTIONS
• Read and follow all HED EDGE-OF-DOCK LEVELERS
instructions, warnings, and
maintenance schedules in NORMAL OPERATION
the manual and on placards.
• Operation and servicing of
dock leveler is restricted to 1. Raise the platform by pressing and holding
authorized personnel. the RAISE button.

• Always chock transport vehicle wheels or engage vehicle restraint 2. Hold the RAISE button until the lip is fully
and set parking brakes before operating dock leveler or beginning extended, then release the RAISE button.
to load or unload. The platform will lower until lip is resting
• Before activating dock leveler, check to make sure the transport on the transport vehicle.
vehicle is positioned squarely against dock bumpers. Ensure lip will
avoid contact with transport vehicle frame, sides and cargo during
dock leveler activation. If contact is likely or observed, reposition
transport vehicle.
• Ensure the transport vehicle floor supports extended lip or the
leveler frame (lip keepers or below dock endload supports) supports STORING LEVELER
the ramp before driving on ramp. 1. Press the RAISE button until the lip folds
• Stay clear of hinges and front and sides of moving dock leveler. enough to clear the transport vehicle, then
• Never use hands or equipment to move the ramp or lip. release the RAISE button. The lip will fold
• Never use damaged or malfunctioning dock leveler. Report problems and the platform will lower returning to the
immediately to supervisor. stored position.
• Always store dock leveler and remove people, material, and
NOTE: If transport vehicle departs before
equipment from ramp before vehicle leaves the dock. leveler is stored, leveler will automatically
• DO NOT ENTER PIT unless dock leveler is securely supported return to stored position.
and proper lockout/tagout procedures have been completed. See
“Maintenance Precautions” in Owner’s/User’s Manual.
FAILURE TO FOLLOW THESE INSTRUCTIONS WILL RESULT
IN DEATH OR OTHER SERIOUS INJURY. BELOW DOCK ENDLOADING
• Remove any endloads while leveler is in
Scan to view our owner’s/user’s manuals online. the stored position.
www.LoadingDockSystems.com
1.800.643.5424
Call for additional placards, or manuals, or with questions
regarding proper use, maintenance, and repair of dock leveler.
WARNING: CANCER AND REPRODUCTIVE HARM
www.P65Warnings.ca.gov 1751-0877 Rev D

1751-0877

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OWNER’S/USER’S RESPONSIBILITIES
1) The manufacturer shall provide to the initial the owner’s/user’s company policies, operating
purchaser and make the following information conditions and the manufacturer’s specific
readily available to the owners/users and their instructions provided with the dock leveling
agents, all necessary information regarding device. Maintaining, updating and retraining all
Safety Information, Operation, Installation and operators on safe working habits and operation of
Safety Precautions, Recommended Initial and the equipment, regardless of previous experience,
Periodic Inspections Procedures, Planned should be done on a regular basis and should
Maintenance Schedule, Product Specifications, include an understanding and familiarity with all
Troubleshooting Guide, Parts Break Down, functions of the equipment. Owners/users shall
Warranty Information, and Manufacturers actively maintain, update and retrain all operators
Contact Information, as well as tables to identify on safe working habits and operations of the
the grade(slope) for all variations of length or equipment.
configuration of the dock leveling device and
information identifying the maximum uncontrolled 6) An operator training program should consist of,
drop encountered when sudden removal of but not necessarily be limited to, the following:
support while in the working range of the
equipment. a) Select the operator carefully. Consider the
physical qualifications, job attitude and aptitude.
2) When selecting loading dock safety equipment,
it is important to consider not only present b) Assure that the operator reads and fully
requirements but also future plans and any understands the complete manufacturer’s owners/
possible adverse conditions, environmental users manual.
factors or usage. The owners/users shall provide
application information to the manufacturer c) Emphasize the impact of proper operation
to receive recommendations on appropriate upon the operator, other personnel, material
equipment specifications and capacity. being handled, and equipment. Cite all rules and
why they are formulated.
3) The owner/user must see all nameplates,
placards, decals, instructions and posted d) Describe the basic fundamentals of the dock
warnings are in place and legible and shall not leveling device and components design as related
be obscured from the view of the operator or to safety, e.g., mechanical limitation, stability,
maintenance personnel for whom such warnings functionality, etc.
are intended for. Contact manufacturer for any
replacements. e) Introduce the equipment. Show the control
locations and demonstrate its functions.
4) Dock leveling devices may become hazardous Explain how they work when used properly and
if the manufacturer’s instructions regarding maintained as well as problems when they are
modifications or adjustments are not followed. used improperly.
Modifications or alterations of dock leveling
devices shall only be made with prior written f) Assure that the operator understands the
approval from the original manufacturer. These capacity rating, nameplate data, placards and all
changes shall be in conformance with all precautionary information appearing on the dock
applicable provisions of the MH30.1 standard leveling device.
and shall also satisfy all safety recommendations
of the original equipment manufacturer of the g) Supervise operator practice of equipment.
particular application.
h) Develop and administer written and practical
5) The owner/user should recognize the inherent performance tests. Evaluate progress during and
dangers of the interface between the loading at completion of the course.
dock and the transport vehicle. The owner/ user
should, therefore, train and instruct all operators i) Administer periodic refresher courses. These
in the safe operation and use of the loading dock may be condensed versions of the primary course
equipment in accordance with manufacturer’s and include on-the-job operator evaluation.
recommendations and industry standards.
Effective operator training should also focus on

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6 © 2020 Systems, LLC
 OWNER’S/USER’S RESPONSIBILITIES
7) Loading dock safety equipment should never instructions, labels, decals and placards or
be used outside of its vertical working range, or their equivalent. Written documentation of
outside the manufacturer’s rated capacity. It shall maintenance, replacement parts or damage
also be compatible with the loading equipment should be kept. In the event of damage,
and other conditions related to dock activity. notification to the manufacturer is required.
Please consult the manufacturer if you have any
questions as to the use, vertical working range or 12) Loading dock devices that are structurally
capacity of the equipment. Only properly trained damaged or have experienced a sudden loss of
and authorized personnel should operate the support while under load, such as might occur
equipment. when a transport vehicle is pulled out from under
the dock leveling device, shall be removed from
8) It is recommended that the transport vehicle service, inspected by a manufacturer’s authorized
is positioned as close as practical to the dock representative, and repaired or replaced as
leveling device and in contact with both bumpers. needed or recommended by the manufacturer
When an industrial vehicle is driven on or off a before being placed back in service.
transport vehicle during loading and unloading
operations, the transport vehicle parking brakes
shall be applied and wheel chocks or a restraining
device that provides equal or better protection of
wheel chocks shall be engaged. Also, whenever
possible, air-ride suspension systems should have
the air exhausted prior to performing said loading
and unloading operations.

9) When goods are transferred between the loading

dock and a trailer resting on its support legs/
landing gear instead of a tractor fifth wheel
or converter dolly, it is recommended that an
adequate stabilizing device or devices shall be
utilized at the front of the trailer.

10) In order to be entitled to the benefits of the

standard product warranty, the dock safety
equipment 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.

11) Manufacturer’s recommended maintenance and

inspection of all dock leveling devices shall be
performed in conformance with the following
practices: A planned maintenance schedule
program must be followed, only trained and
authorized personnel shall be permitted to
maintain, repair, adjust and inspect dock leveling
devices, and only the use of original equipment
manufacturer parts, manuals, maintenance

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INTRODUCTION
General Information

Figure 3

This manual provides current information on the HED- Dimensions and Capacities
series dock leveler (Figure 3). Due to ongoing product
Model # - Deck - Total Unit
improvement, some parts may have changed, along Width Width
Comparative Industry Rating
with operation and troubleshooting methods. This HED-66 66” 104” 20,000 lb
manual describes these changes where applicable.
25,000 lb
HED-72 72” 110”
The HED series dock leveler comes equipped 30,000 lb
with an electrical control panel, which allows push HED-78 78” 116” 35,000 lb
button operation of the dock leveler functions. Each
HED dock leveler unit and control panel has been HED-84 84” 122”
factory prewired and tested to ensure satisfactory
operation. Call McGuire to discuss available voltages, phases
and options to meet your specific needs.
To illustrate which connections are to be made in the
field at installation, electrical drawings are included
with each order or by contacting Systems, LLC
Technical Services.

HED dock levelers are available in the following sizes,

weight capacities, and options:

Technical Service at 800-643-5424 or techservices@loadingdocksystems.com

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8 © 2020 Systems, LLC
 INTRODUCTION
Component Identification
Inspect package and all components. Report any missing or damaged items immediately
and note on the shipping Bill Of Lading (BOL).

E
B

H G

Figure 4

A — Lip Plate D — Powerpack (Motor/Pump/Reservoir) G — Hoist Cylinder*

B — Center Plate E — Hinge Area H — Bumper Blocks (2 used)
C — Maintenance Prop F — Lip Cylinder* J — Control Box**

* Some high-capacity models are equipped with multiple cylinders.

**Control box appearance may vary depending on options.

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INSTALLATION
Installation Precautions

It is recommended and good safety practice to use DO NOT connect the dock leveler electrical wiring
an additional means to support the dock platform and ground connections until all welding has been
and lip anytime when physically working in front of completed.
or under the dock leveler. This additional means
may include, but is not limited to a boom truck, fork DO NOT ground welding equipment to any hydraulic
truck, stabilizing bar or equivalent. 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, hydraulics, wiring, and/or control panel.
Always post safety warnings and barricade the
work area at dock level and ground level to prevent
unauthorized use of the dock leveler before
installation is complete.

A hard hat or other applicable head protection

should always be worn when working under or
around a dock leveler.

Always stand clear of platform lip when working in

front of the dock leveler.

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.

Only trained installation professionals with the

proper equipment should install this product.

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 INSTALLATION
Installation Overview

Securely block or support ramp and lip when in DO NOT connect the dock leveler electrical wiring
vertical positions. Lack of proper bracing can result and ground connections until all welding has been
in ramp dropping during adjustment or installation. completed.

Note: This is a generic overview of the installation steps required. See full installation
instructions on pages 12-27 for different installation types and all steps.

ANCHOR BOLT
OR PLUG WELD

Figure 5

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INSTALLATION
Flush Mount - Weld On
A flush mount weld on application is used when 9. Drill 5/8” dia. by 5” deep holes in concrete
an 8” wide (minimum) embed channel is securely through holes in lower cylinder mount, and
anchored into the concrete at the dock edge, and the install anchor bolts with washers and tighten per
dock height is adequate. manufacturers specifications.

1. Remove all existing bumper material and 10. Proceed to page 24 for control panel and wiring
protruding objects from dock edge. Clean and installation instructions.
sweep dock edge free of debris and flammable
chemicals before installing unit.

2. At chosen location for Edge-of-Dock leveler,

locate the center of space and mark a point half
of the base plate width to the left and right.

3. Using a proper lifting device, raise and position

leveler on dock face with the top of the base
plate 1/4” below the top of the embedded
channel. See Figure 6. Position ends of base
plate to match up with marks made previously.

4. Tack weld base plate to dock steel on left hand

end of the leveler. Check right hand end of base
plate, ensure that end is against dock steel and
that the top of the base plate is still 1/4” below
the top of the embedded channel. Tack right
hand end to dock steel.

5. Position bump blocks out approximately 5/8”

from the edge of the inside flange of the bump
block to the end of the base plate. This will allow
for vertical welding of both the base plate and
the bump block flange back to the dock steel.
Top of the bump block cover plate should be
flush with the top of the embed channel. Tack
weld bump blocks to dock steel.

6. Check the positioning of the base plate and the

bump blocks.

7. Complete welding of tacked parts as follows:

a. Apply a continuous weld across top of each

bumper and base plate to dock steel. Skip
welding is acceptable to prevent warping.

b. Weld vertically along each end of base plate

and on both inboard and outboard flanges
of bump blocks.

c. Fully plug weld all holes in base plate.

8. Installer must remove all welding slag, and

repaint welded areas.

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 INSTALLATION
Flush Mount - Weld On (continued)

Securely block or support ramp and lip when in DO NOT connect the dock leveler electrical wiring
vertical positions. Lack of proper bracing can result and ground connections until all welding has been
in ramp dropping during adjustment or installation. completed.

Base Plate mounted

1/4” below finished
floor/ top of channel.

Note:
1. Top of base plate to be 1/4” below top of dock
floor and embedded channel to to provide a
smooth transition. Bumper is to be flush with floor.
See Figure 6

2. Apply continuous bevel weld across both bumpers

and length of base plate.

Figure 6

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INSTALLATION
Ramp Mount - Weld/Bolt On
A ramp mount-weld on application is used when 9. Break tack welds holding ramp in place, slide ramp
adequate dock steel is securely anchored in the concrete plate back into position with the top of the ramp
at the dock edge, but the existing dock height is too low plate 1/4” higher than top of base plate. See Figure
and the dock leveler must be installed above this height 7. Tack weld each end and center of ramp plate to
to correct this situation. base plate.

1. Remove all existing bumper material and protruding 10. Drill 5/8” dia. by 5” deep holes through ramp plate
objects from dock edge. Clean and sweep dock at back edge. Install anchor bolts per manufacturers
edge free of debris and flammable chemicals before specifications, and tighten securely. Weld anchor bolt
installing unit. nuts to ramp plate using a ¼” fillet weld all the way
around the nut. Cut off any portion of the anchor bolt
2. At chosen location for Edge of Dock leveler, locate exposed through the nut, and plug weld around the
the center of space and mark a point half of the base top of the nut to the anchor bolt. Ensure the top of
plate width to the left and right. the nuts are well rounded for smooth rollover.

3. At the points marked to each side of center, measure 11. Complete welding of tacked parts as follows:
and mark points 8” below the desired dock level,
subtracting the height the unit is to be raised to a. Apply continuous weld across top of each
locate bottom of base plate. This will locate the top of bumper and base plate to ramp plate. Skip
the base plate X” above dock level. See Figure 7. welding is acceptable to prevent warping.

4. Using a proper lifting device, raise and position b. Weld vertically along each end of base plate
the leveler base plate to marked position. While and on both inboard and outboard flanges of
holding base plate tight against dock face, tack weld bump blocks.
securely to dock steel on left hand end of leveler.
Check right hand end of base plate, ensure that end c. Fully plug weld all holes in base plate.
is against dock steel and that the bottom of the base
plate is even with the marks made previously. Tack 12. Installer must remove all welding slag and repaint
right hand end to dock steel. Support unit until final welded areas.
welding is ready to complete.
13. Drill 5/8” dia. by 5” deep holes in concrete through
5. Position bump blocks out approximately 5/8” out holes in lower cylinder mount, and install anchor
from the edge of the inside flange of the bump block bolts with washers and tighten per manufacturers
to the end of the base plate. Position the top of the specifications.
tread cover plate on the bump blocks to be flush with
the top of the base plate. Tack weld bump blocks to 14. Proceed to page 24 for control panel and wiring
dock steel. installation instructions.

6. Place steel ramp plate in position flush with the top

backside of base plate. Mark along full length of back
edge of ramp plate. Slide ramp plate forward over
dock leveler the width of bushing tool, approximately
2”.

7. Place bushing tool on marked line at each end of

ramp to ensure proper alignment at both ends, and
tack weld ramp plate to dock leveler to hold ramp
plate in place while bushing. A Skil Roto Hammer
#736 or similar tool is recommended.

8. Using the back edge of the ramp plate as a guide,

groove concrete approximately 3/4” deep by 2” wide,
and should be the entire length of ramp plate.

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 INSTALLATION
Ramp Mount - Weld/Bolt On (continued)

Securely block or support ramp and lip when in DO NOT connect the dock leveler electrical wiring
vertical positions. Lack of proper bracing can result and ground connections until all welding has been
in ramp dropping during adjustment or installation. completed.

Base Plate
mounted 1/4”
Note: below top of
1. Top of base plate to be 1/4” below the top ramp plate.
of ramp plate to provide a smooth transition.
Bumper is to be flush with top of ramp plate. 3/8” Ramp Plate
See Figure 7.

2. Apply continuous bevel weld across both

bumpers and length of base plate.
EOD Base Plate

3. To figure ramp plate length, need 12” ramp for

every 1-1/2” of rise to ramp.

3/4” x 2” grove in
concrete for entire
width of ramp plate.

Figure 7

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INSTALLATION
Flush Mount - Bolt On
A flush mount bolt on application is used when there is 10. Place steel ramp plate in position, flush with top
no steel on dock edge, and the dock height is adequate. backside of base plate. Mark along full length of back
Additional steel ramp plate and bolting is required with this edge of ramp plate. Slide ramp plate forward over
type of installation. dock leveler the width of bushing tool, approximately
2”.
1. Remove all existing bumper material and protruding
objects from dock edge. Clean and sweep dock 11. Place bushing tool on marked line at each end of
edge free of debris and flammable chemicals before ramp to ensure proper alignment at both ends, and
installing unit. tack weld ramp plate to dock leveler to hold ramp
plate in place while bushing. A Skil Roto Hammer
2. At chosen location for Edge of Dock leveler, locate #736 or similar tool is recommended.
the center of space and mark a point half of the base
plate width to the left and right. 12. Using the back edge of the ramp plate as a guide,
groove concrete approximately 5/8” deep by 2” wide,
3. At the points marked to each side of center, measure and should be the entire length of ramp plate.
and mark points 7-3/4” below dock level (for ¼” ramp
plate) to locate position for bottom of base plate. This 13. Break tack welds holding ramp in place, slide ramp
position will place the top of the base plate flush with plate back into position with the top of the ramp plate
the dock floor. The base plate should be 1/4” below 1/4” higher than top of base plate. See Figure 8.
the top of the ramp plate. See Figure 8. Tack weld each end and center of ramp plate to base
plate.
4. Mark line connecting these points and position support
angles. Position angles as shown in installation 14. Drill 5/8” dia. by 5” deep holes through ramp plate
drawing provided. Mark center of holes in each of the at back edge. Install anchor bolts per manufacturers
support angles. specifications, and tighten securely. Weld anchor bolt
nuts to ramp plate using a ¼” fillet weld all the way
5. At center marks, drill holes 5/8” dia. by 5” deep in around the nut. Cut off any portion of the anchor bolt
concrete. Install anchor bolts with washers through exposed through the nut, and plug weld around the
support angles into holes in concrete. Tighten bolts top of the nut to the anchor bolt. Ensure the top of the
until support angles are secure. Follow anchor nuts are well rounded for smooth rollover.
manufacturers installation instructions for proper
installation. 15. Complete welding of tacked parts as follows:

6. Using a proper lifting device, raise and position the a. Apply continuous weld across top of each
leveler base plate to marked position, while resting bumper and base plate to ramp plate. Skip
on the support angles. While holding base plate tight welding is acceptable to prevent warping.
against dock face, tack weld securely to support
angles. b. Weld bottom of base plate to support angles
using a ¼” fillet weld.
7. Drill 5/8” dia. by 5” deep holes in concrete through
holes in base plate, and install anchor bolts with 16. Installer must remove all welding slag and repaint
washers and tighten securely. welded areas.

8. Position bump blocks out approximately 5/8” out from 17. Drill 5/8” dia. by 5” deep holes in concrete through
the edge of the inside flange of the bump block to the holes in lower cylinder mount, and install anchor
end of the base plate. Position the top of the tread bolts with washers and tighten per manufacturers
cover plate on the bump blocks to be ¼” above dock specifications.
level. Note that this placement will vary with ramp
plate thickness. Mark centers of holes in bump block 18. Proceed to page 24 for control panel and wiring
flanges. installation instructions.

9. Drill 5/8” dia. by 5” deep holes at center marks.

Reposition bump blocks, insert anchor bolts with
washers and tighten securely to dock face.

4111-0020 — Sep. 2020

16 © 2020 Systems, LLC
 INSTALLATION
Flush Mount - Bolt On (continued)

Securely block or support ramp and lip when in DO NOT connect the dock leveler electrical wiring
vertical positions. Lack of proper bracing can result and ground connections until all welding has been
in ramp dropping during adjustment or installation. completed.

Base Plate mounted

1/4” below top of
ramp plate.

Note: Ramp Plate

1. Top of base plate to be 1/4” below top of ramp
plate to provide a smooth transition. Bumper is to
be flush with top of ramp plate. See Figure 8.

2. Apply continuous bevel weld across both

bumpers and length of base plate.

5/8 x 2 Groove in
concrete for
length of ramp.
Figure 8

4111-0020 — Sep. 2020

© 2020 Systems, LLC
17
INSTALLATION
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 9. Using the back edge of the ramp plate as a guide,
no dock steel securely anchored into the concrete, and groove concrete approximately 3/4” deep by 2” wide,
the dock height is too low and the leveler must be installed and should be the entire length of ramp plate.
above this height to correct this situation.
10. Break tack welds holding ramp in place, slide ramp
1. Remove all existing bumper material and protruding plate back into position with the top of the ramp plate
objects from dock edge. Clean and sweep dock 1/4” higher than top of base plate. See Figure 9.
edge free of debris and flammable chemicals before Tack weld each end and center of ramp plate to base
installing unit. plate.

2. Review and follow formed angle installation 11. Drill 5/8” dia. by 5” deep holes through ramp plate
instructions prior to leveler installation. See pages at back edge. Install anchor bolts per manufacturers
20-21. specifications, and tighten securely. Weld anchor bolt
nuts to ramp plate using a ¼” fillet weld all the way
3. At chosen location for Edge of Dock leveler, locate around the nut. Cut off any portion of the anchor bolt
the center of space and mark a point half of the base exposed through the nut, and plug weld around the
plate width to the left and right. top of the nut to the anchor bolt. Ensure the top of the
nuts are well rounded for smooth rollover.
4. At the points marked to each side of center, measure
and mark points 8” below the desired dock level, 12. Complete welding of tacked parts as follows:
subtracting the height the unit is to be raised to
locate bottom of base plate. This will locate the top of a. Apply continuous weld across top of each
the base plate X” above dock level. See Figure 9. bumper and base plate to ramp plate. Skip
welding is acceptable to prevent warping.
5. Using a proper lifting device, raise and position the
leveler base plate to marked position. While holding b. Weld vertically along each end of base plate and
base plate tight against dock face, tack weld securely on both inboard and outboard flanges of bump
to dock steel on left hand end of leveler. Check right blocks.
hand end of base plate, ensure that end is against
dock steel and that the bottom of the base plate is c. Fully plug weld all holes in base plate.
even with the marks made previously. Tack right hand
end to dock steel. Support unit until final welding is 13. Installer must remove all welding slag and repaint
ready to complete. welded areas.

6. Position bump blocks out approximately 5/8” out from 14. Drill 5/8” dia. by 5” deep holes in concrete through
the edge of the inside flange of the bump block to the holes in lower cylinder mount, and install anchor
end of the base plate. Position the top of the tread bolts with washers and tighten per manufacturers
cover plate on the bump blocks to be flush with the specifications.
top of the base plate. Tack weld bump blocks to dock
steel. 15. Proceed to page 24 for control panel and wiring
installation instructions.
7. Place steel ramp plate in position, flush with top
backside of base plate. Mark along full length of back
edge of ramp plate. Slide ramp plate forward over
dock leveler the width of bushing tool, approximately
2”.

8. Place bushing tool on marked line at each end of

ramp to ensure proper alignment at both ends, and
tack weld ramp plate to dock leveler to hold ramp
plate in place while bushing. A Skil Roto Hammer
#736 or similar tool is recommended.

4111-0020 — Sep. 2020

18 © 2020 Systems, LLC
 INSTALLATION
Ramp Mount - Weld On w/Formed Angle (continued)

Securely block or support ramp and lip when in DO NOT connect the dock leveler electrical wiring
vertical positions. Lack of proper bracing can result and ground connections until all welding has been
in ramp dropping during adjustment or installation. completed.

Base Plate mounted

Note:
1/4” below top of
1. Top of base plate to be 1/4” below top of ramp
ramp plate.
plate to provide a smooth transition. Bumpers are
to be flush with top of ramp plate. See Figure 9.
Ramp Plate
2. Apply continuous bevel weld across both
bumpers and length of base plate.

3. To figure ramp plate length, need 12” ramp for

every 1-1/2” of rise to ramp.

4. To install formed angle, see formed angle Formed Angle

installation instructions on page 21.

3/4 x 2 groove
in concrete for
length of
leveler.
Figure 9

4111-0020 — Sep. 2020

© 2020 Systems, LLC
19
INSTALLATION
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.

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. At chosen location for the formed angle, locate the

center of space and mark a point half of the angle
width to the left and right.

3. Using a proper lifting device, raise and position the

formed angle to marked position, slide formed angle
against dock face.

4. Mark along full length of back edge of formed angle.

Slide angle forward the width of brushing tool,
approximately 2”.

5. Place brushing tool on marked line at each end of

formed angle to ensure proper alignment at both
ends. A Skil Roto Hammer #736 or similar tool is
recommended.

6. Using the back edge of the formed angle as a guide,

groove concrete approximately 5/8” deep by 2” wide,
and should be the entire length of the formed angle.

7. Slide formed angle back until tight against dock face.

drill 5/8” dia. by 5” deep holes through formed angle
at back edge. Install anchor bolts per manufacturers
specifications, and tighten securely. Weld anchor
bolt nuts to formed angle using a 1/4” fillet weld all
the way around the nut. Cut off any portion of the
anchor bolt exposed through the nut, and plug weld
around the top of the nut to the anchor bolt. Ensure
the top of the nuts are well rounded for smooth
rollover.

8. Drill 5/8” dia. by 5” deep holes in dock face through

holes in formed angle. Install anchor bolts with
washers and tighten securely per manufacturers
specifications.

4111-0020 — Sep. 2020

20 © 2020 Systems, LLC
 INSTALLATION
Formed Angle (continued)

Figure 10

Note:
1. Secure formed angle with (18) anchor bolts,
(9) each side.

4111-0020 — Sep. 2020

© 2020 Systems, LLC
21
INSTALLATION
Ramp and Face Plate
A ramp mount requiring a face plate application is used 10. Break tack welds and slide ramp back until forward
when there is no existing dock steel and the concrete at edge is flush with dock face. Tack weld ramp on
the dock edge has been damaged. The dock height can each end and center to face plate. Drill 5/8” dia. by
be low, high, or adequate for this application, however, 5” deep holes through ramp plate at back edge.
the face plate and ramp plate are required to rebuild the Install anchor bolts per manufacturers specifications,
damaged concrete edge.­­­ and tighten securely. Weld anchor bolt nuts to ramp
plate using a 1/4” fillet weld all the way around the
1. Remove all existing bumper material and protruding nut. Cut off any portion of the anchor bolt exposed
objects from dock edge. Clean and sweep dock through the nut, and plug weld around the top of the
edge free of debris and flammable chemicals before nut to the anchor bolt. Ensure the top of the nuts are
installing unit. well rounded for smooth rollover.

2. At chosen location for the face plate, locate the 11. Apply a continuous fillet weld at the created joint
center of space and mark a point half of the face between the face plate and ramp. Skip welding
plate width to the left and right. should be the proper method used to avoid warping.­­­

3. Using a proper lifting device, raise and position the

face plate to marked position, and push face plate
against dock face.

4. Top of face plate should be flush with the top of

dock floor. Mark center of holes in face plate into
dock face. Drill 5/8” dia. by 5” holes into dock face.
Install anchor bolts with washers per manufacturers
specifications and tighten securely.

5. Place ramp plate to match each end of the face

plate. Leading (forward) edge of ramp plate should
be flush with dock face.

6. Mark along full length of back edge of ramp plate.

Slide ramp forward the width of bushing tool,
approximately 2”.

7. Place bushing tool on marked line at each end

of ramp to ensure proper alignment at both
ends. A Skil Roto Hammer #736 or similar tool is
recommended.

8. Tack weld ramp to face plate on each end to secure

in place.

9. Using the back edge of the ramp plate as a guide,

groove concrete approximately 5/8” deep by 2” wide,
and should be the entire length of the lamp plate.

4111-0020 — Sep. 2020

22 © 2020 Systems, LLC
 INSTALLATION
Ramp and Face Plate (continued)

Figure 11

Note:
1. Secure formed angle with (18) anchor bolts,
(9) each side.

2. Apply continuous fillet weld across entire

length of face plate and ramp.

4111-0020 — Sep. 2020

© 2020 Systems, LLC
23
INSTALLATION
Install Control Panel and Wiring

Make sure that the power source has been locked

out and tagged according to OSHA regulations and
approved local electrical codes.

B C

A hard hat or other applicable head protection D

should always be worn when working under or
around a dock leveler.

Always stand clear of platform lip when working in Dock face J-box: CL
)
30”
e(
30” off CL Lin
front of the dock leveler. 12” down Ce
nte
r
12”

All electrical work — including the installation of the Figure 12

disconnect panel, control panel, and final connections
to the pit junction box — must be performed by a A— Disconnect Panel C— Distance, 48 in. (1219 mm)
(provided by others) D— Placard
certified electrician and conform to all local and B— Control Panel
applicable national codes.
1. Mount the control panel (B) so bottom of control
panel-to-dock floor distance is 48 in. (1219 mm, C).

2. Install electrical disconnect panel (A) if not already

DO NOT connect any dock equipment electrical installed (provided by others). It is recommended to
wiring or ground connections until all welding has locate disconnect panel adjacent to control panel (B).
been completed.
3. Install and connect the control wiring as shown in
installation drawings.
DO NOT ground welding equipment to any electrical
components of the dock equipment. Always ground
4. Connect the control wiring to the field wires in the
welding equipment to the dock leveler frame, NEVER
dock equipment junction boxes. Refer to the electrical
to the platform. diagrams supplied with the dock equipment.
Failure to follow these instructions may damage the Note: When installing electrical controls in a
motor, wiring, and/or control panel. temperature-controlled environment, the installer
must determine an appropriate means to isolate/
prevent thermal and vapor transfer through electrical
conduit where conduit routing crosses temperature
zones. Systems, LLC is not responsible for any
Where indicated, all components must be connected damage due to moisture collecting inside the control
to a SAFETY EARTH GROUND that conforms to panel caused by improper isolation/prevention of
the 1999 National Electrical Code Section 250-50 thermal and vapor transfer through the conduit. Refer
section (a) or section (c) for a grounding electrode to Tech Service Bulletin 19-053 for more information.
system.
5. Install placard (D). Make sure placard is in
plain view of dock leveler and/or vehicle restraint
operations. Suggested placement of placard is near
control box attached to electrical conduit by using
nylon cable tie. See page 26.

4111-0020 — Sep. 2020

24 © 2020 Systems, LLC
 INSTALLATION
Danfoss Control Panel Wiring (1-Phase)

Jumper wire
Jumper wire (L1 to 95)
(A1 to L2)

Note: All Danfoss control boxes

require jumper wires shown to be
Danfoss Control Panel Wiring (3-Phase) added for push button to function.

Jumper wire
Jumper wire (L1 to 95)
(A1 to L2)

S Y S T E M S,
L o a d i n g D o c k E

4111-0020 — Sep. 2020

© 2020 Systems, LLC
25
INSTALLATION

Placard Installation Instructions

Placard Installation Instructions
Owner/Users are
• Owner/Users are responsible
responsible for installation and placement
for the installation placement of product
product
• placards.
Owner/Users
placards. are responsible for the installation and placement of product
placards.
•• Make
Make sure
sure placard
placard is in plain
is in plain viewview of
of dock
dock leveler
leveler and/or
and/or vehicle
vehicle restraint
restraint
operations.
• operations.
Make sure placard is in plain view of dock leveler and/or vehicle restraint
operations.
•• Suggested
Suggested placement
placement of of placard
placard is near control
is near control box
box attached
attached to
to electrical
electrical
conduit
• conduit by using
Suggested nylon cable
placement tie. If therenear
of placard is nocontrol
control box present, mount placard
by using nylon tie. If there is is no control boxbox attached
present, to electrical
mount placard
on wall tobythe
conduit immediate
using left Ifofthere
nylon tie. leveler
is at
noateye level.box present, mount placard
control
on wall to the immediate left of leveler eye level.
on wall to the immediate left of leveler at eye level.

Control Box
A
A Control Box

BPlacard
(Placard placement shown
B as example only.)

Nylon TieC Placard

(Placard placement
C shown as reference
Nylon Tie (Placard
only.) placement
shown as reference
Conduit D only.)
Conduit
D

A - Control Box B - Placard C - Nylon Cable Tie D - Conduit

Figure 13

4111-0020 — Sep. 2020

26 © 2020 Systems, LLC
 INSTALLATION
Put New Dock Leveler Into Service Note: The platform of a properly operating dock
leveler will automatically stop rising when it reaches
its maximum full raised height, at which point, the lip
extends. When the lip is fully extended, the powerpack
Unless the dock leveler is equipped with a tethered will go into pressure relief. (If the lip does not extend
remote, two people are required to engage the correctly, see Troubleshooting section.)
maintenance prop: one person to operate the unit,
the other person to engage the maintenance prop. 5. Release the RAISE button to lower the platform.
As long as there is no vehicle present at the dock, the
In addition, it is recommended and good safety platform will lower to the full below-dock position as the
practice to use an additional means to support lip folds.
the dock platform and lip anytime when physically
working in front of or under the dock leveler. This Note: If a transport vehicle is present, the platform will
additional means may include, but is not limited to a lower until the lip rests on the transport vehicle’s bed.
boom truck, fork truck, stabilizing bar or equivalent.
6. Perform steps 4-5 at least four times to purge any
air that may be in the hydraulic system and to ensure
proper operation.

A hard hat or other applicable head protection

should always be worn when working under or
around a dock leveler.

Always stand clear of platform lip when working in

front of the dock leveler.

1. Remove red shipping plug from hydraulic fluid

reservoir and install black breather cap. Discard red
shipping plug. See Figure 14.

Figure 14

2. Disconnect the external lifting device and chains

from the lifting brackets.

3. Turn the main electrical power ON.

4. Raise the leveler platform fully by pressing and

holding the RAISE button.

4111-0020 — Sep. 2020

© 2020 Systems, LLC
27
OPERATION
Operational Precautions

Stay clear of dock leveler and vehicle restraint

when transport vehicle is entering or leaving dock 5 in. (127 mm)
area.

DO NOT move or use the dock leveler or restraint if

anyone is under or in front of leveler. 5 in. (127 mm)

Keep hands and feet clear of pinch points. Avoid

putting any part of your body near moving parts. The HED hydraulic dock leveler is designed to
compensate for a maximum ± 5 in.* (127 mm) of
height difference between the loading dock and the
transport vehicles bed. DO NOT use the dock
leveler if the transport vehicles bed is more than 5
Only trained personnel should operate the dock in. (127 mm) higher or lower than the dock floor.
leveler.
*Service height may vary with design specifications
DO NOT use a broken or damaged dock leveler.
Make sure proper service and maintenance DO NOT overload the dock leveler.
procedures have been performed on leveler before
using. DO NOT operate any equipment while under the
influence of alcohol or drugs.
Transport vehicle wheels must be chocked unless
a vehicle restraint is used. Never remove the wheel DO NOT leave equipment or material unattended
chocks until loading/unloading is finished and on the dock leveler.
transport driver has been given permission to leave.

Make sure platform lip rests on the transport

vehicles bed with at least 4 in. (102 mm) of overlap.

Maintain a safe distance from side edges of leveler

during the loading/unloading process.

4111-0020 — Sep. 2020

28 © 2020 Systems, LLC
 OPERATION
Operating Instructions

Figure 15

1. Before activating dock leveler, ensure lip avoids c. Make sure that the lip is fully extended and
contact with transport vehicle sides and cargo. If lip supported on the transport vehicle along the
does not lower to transport vehicle bed, reposition entire width of the platform, with at least 4 in.
transport vehicle. (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. 6. Proceed with loading or unloading.

3. Chock the transport vehicle wheels, or use a 7. When loading or unloading is finished, press and
vehicle restraint if available. hold the RAISE button until the lip clears the transport
vehicle bed and folds up, then release the button.
4. If necessary, remove any end loads with the Leveler will then return to stored position.
leveler in the stored position.
8. Remove chocks from transport vehicle wheels, or
5. Extend the dock leveler onto the transport vehicle release the vehicle restraint if used.
as follows (see Figure 15):
9. Indicate to driver that the transport vehicle may
a. Raise the platform by pressing and holding the leave the dock.
RAISE button.

b. Hold the RAISE button until the lip is fully

extended, then release the RAISE button. The
platform will lower until the lip is resting on the
transport vehicle bed.

4111-0020 — Sep. 2020

© 2020 Systems, LLC
29
MAINTENANCE
Maintenance Precautions

A B D
P O W E R A M P
D L M
S Y S T E M S, I N C.

Figure 16
L o a d i n g D o c k E q u i p m e n t

NL-X MAINTENANCE PROP

Figure 17
DRAWN BY CHECKED BY DATE
SR 8/6/2009
TOLERANCES
(UNLESS OTHERWISE NOTED) DRAWING NO.
FRACTIONAL: `1/32"

HED6620-15 Maintenance
DECIMAL:
.00 = `.01"
.000 = `.005"

A— Tag Out Device B —Lock Out Device C — Maintenance Prop D— Support Gussets
ANGULAR: `1~

patent andisother
Thisconvey
print rights, including
the permission
property of to exclusive
Systems, rights
Inc. print
and of use and/or
represents manufacture
a proprietary and/or
article sale.
in which Possession
Systems, Inc. of this print
retains does
any and
not any reproduce, or manufacture the article or articles shown therein, such permission toallbe

granted only by written authorization signed by an officer or other authorized agent of Systems,Inc. thereof.

When working with electrical or electronic controls,

make sure that the power source has been tagged (A)
and locked out (B) according to OSHA regulations*
Unless the dock leveler is equipped with a tethered
and approved local electrical codes (see Figure 16).
remote, two people are required to engage the
maintenance prop: one person to operate the unit,
Whenever maintenance is to be performed under
the other person to engage the maintenance prop.
the dock leveler, support the dock leveler with the
maintenance prop (C). Position the maintenance
In addition, it is recommended and good safety
prop in its support gussets (D). See Figure 17.
practice to use an additional means to support
the dock platform and lip anytime when physically
Only the person servicing the equipment should have
working in front of or under the dock leveler. This
the capability to remove the lockout devices. The tag
additional means may include, but is not limited to a
out devices* must inform that repairs are in process
boom truck, fork truck, stabilizing bar or equivalent.
and clearly state who is responsible for the lockout
condition.

A hard hat or other applicable head protection

should always be worn when working under or
Always post safety warnings and barricade the
around a dock leveler.
work area at dock level and ground level to prevent
unauthorized use of the unit before maintenance is
Always stand clear of platform lip when working in
complete.
front of the dock leveler.

* Refer to OSHA regulations 1910.146. Confined Space and 1910.147. Lockout/Tagout

4111-0020 — Sep. 2020

30 © 2020 Systems, LLC
 MAINTENANCE

This page intentionally left blank.

4111-0020 — Sep. 2020

© 2020 Systems, LLC
31
MAINTENANCE
Periodic Maintenance

B
C

P O

S Y S T E M S, I
L o a d i n g D o c k E q u i p

NL-X MAINTENANCE PR

DRAWN BY CHECKED BY DA
SR
TOLERANCES
(UNLESS OTHERWISE NOTED) DRAWING NO.

Figure 18
FRACTIONAL: `1/32"

HED6620-15 Ma
DECIMAL:
.00 = `.01"
.000 = `.005"
ANGULAR: `1~

A— Lip Hinge Area B —Platform Hinge Area C — Platform Cylinder Trunnions D— Lip Cylinder Trunnions
patent
not
andisother
Thisconvey
print any
rights, including
the permission
property of to exclusive
Systems, rights
Inc. print
reproduce, and of use and/or
represents manufacture
a proprietary
or manufacture
and/or
article
the article
sa
in which
or articles sh

granted only by written authorization signed by an officer or other authorized agent of

To ensure normal operation of the dock leveler, use Weekly Maintenance

only aircraft hydraulic fluid designed to meet or exceed
military specification MIL-H-5606-G. It is recommended Operate the dock leveler through the complete
that the following hydraulic fluids be used: operating cycle to maintain lubrication.

ULTRA-VIS-HVI-15 • Inspect the platform hinge and the lip hinge areas.
Aero Shell Fluid 4 or Fluid 41 The hinge areas must be kept free of dirt and
Mobil Aero HFA Mil-H5606A or Aero HF debris. Build-up of foreign material in the hinge
Texaco Aircraft Hydraulic Oil 15 or 5606 areas will cause abnormal operation.
Exxon Univis J13
Castrol Brayco Micronic 756
• Inspect warning decals and placards. Replace if
damaged or missing.
These fluid brands can be mixed together. Use of
hydraulic fluids with equivalent specifications to those
listed here are acceptable.

Use of fluids that do not have equivalent specifications

to those in the preceding list will result in abnormal
operation of the dock leveler and voiding of warranty.

4111-0020 — Sep. 2020

32 © 2020 Systems, LLC
 MAINTENANCE
Quarterly Maintenance F
G
• Complete Weekly Maintenance.
3 in.

• Inspect the following for damage/abnormal wear:

• Check welds for cracks.
• Cylinder pins and mounting holes.
• Lip hinge pins and rear hinge pins.
• Check J-box for water damage.
• Inspect hoses, cylinders, fittings and
powerpack. E
• Control box and conduit for damage. Figure 19
• Bumpers for more than 1” of wear. Replace E - Reservoir G - Fluid Level
worn, loose, damaged or missing bumpers.
F - Breather Cap

• Lubricate the following areas with light weight • Check reservoir fluid level (G, see Figure 19):
machine oil (see Figure 18):
1. Raise the platform fully and engage the
(A) — Lip hinge area unless equipped with grease maintenance prop in the service position.
fittings (apply oil to the top of the entire
length of lip hinge when platform is at the 2. Turn OFF all electrical power to the leveler.
full below-dock position and lip is folded)
(B) — Platform rear hinge area (apply oil to top of 3. Remove breather cap (F).
all platform hinges when platform is at the
full below-dock position) 4. Measure fluid level. The fluid level should be
approximately 3 in. (76.5 mm) from top of reservoir
• Lubricate the following areas with white lithium (E) with platform at the below-dock position.
grease:
5. Add hydraulic fluid if necessary. Use only
(C) — Platform cylinder pins recommended fluid (see page 32).
(D) — Lip cylinder pins
6. Install breather cap.
Note: Apply grease to lip hinge grease fittings if
equipped. 7. Turn ON electrical power to the leveler.

8. Return the platform to the stored position.

Failure to properly lubricate the dock leveler will Yearly Maintenance

cause abnormal operation of the leveler.
• Complete Quarterly Maintenance.

• Change hydraulic oil (may be required more often

depending upon conditions).

4111-0020 — Sep. 2020

© 2020 Systems, LLC
33
ADJUSTMENTS
Adjust Main Pressure Relief

Unless the dock leveler is equipped with a tethered D A

remote, two people are required to engage the
maintenance prop: one person to operate the unit,
the other person to engage the maintenance prop.
B
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 is not limited to a
boom truck, fork truck, stabilizing bar or equivalent. C

When service under the dock leveler is required,

Figure 20
always lock all electrical disconnects in the OFF
A — Sequence Valve C — Fluid Reservoir
position after raising the platform and engaging the
B — Pressure Relief Valve D — Motor
maintenance prop. (RV1)

Always post safety warnings and barricade the 1. Raise the platform fully and engage the
work area at dock level and ground level to prevent maintenance prop in the service position.
unauthorized use of the dock leveler before
maintenance is complete. 2. Turn OFF all electrical power to the dock leveler.

A hard hat or other applicable head protection 3. Attach lock out/tag out devices.
should always be worn when working under or
around a dock leveler. 4. Loosen jam nut on pressure relief valve (B).

Always stand clear of platform lip when working in 5. Adjust hex adjusting screw as follows:
front of the dock leveler.
• To increase pressure relief, turn hex screw
clockwise in 1/4 turn increments.
Main Pressure Relief Adjustment • To decrease pressure relief, turn hex screw
counterclockwise in 1/4 turn increments.
Typically set to 2.5 turns out from dead in;
adjusting RV1 clockwise increases system pressure, 6. Tighten the jam nut on pressure relief valve (B).
and adjusting RV1 counter-clockwise decreases
system pressure. 7. Turn ON electrical power to the dock leveler.
The main pressure relief valve (RV1) may need to be 8. Remove lock out/tag out devices.
increased if the platform does not rise or rises slowly
and the system operates in pressure relief mode. 9. Disengage the maintenance prop.
The main pressure relief valve (RV1) may need to 10. Cycle leveler and verify pressure relief setting.
be decreased if the pump motor loads down when
platform reaches the full raised position. 11. Repeat steps 1– 10 as necessary.
See Troubleshooting section on pages 36-39 for
more information.

4111-0020 — Sep. 2020

34 © 2020 Systems, LLC
 ADJUSTMENTS
Adjust Lip Function Sequence Valve Adjustment

A
Typically set to 7 turns out from dead in (750 PSI);
adjusting clockwise increases pressure required to
shift valve, and adjusting counter-clockwise decreases
pressure required to shift valve.

See Troubleshooting section on pages 36-39 for more

information.

1. Raise the platform fully and engage the

maintenance prop in the service position.

B 2. Turn OFF all electrical power to the dock leveler.

3. Attach lock out/tag out devices.

A
4. Loosen jam nut.
D
5. Adjust hex adjusting screw (B) as follows:

• If the lip opens as the platform begins to rise, turn

sequence valve clockwise in 1/4 turn adjustments
until operation is satisfactory.

• If the lip will not fully retract when the platform

returns to the stored position, turn sequence valve
counterclockwise in 1/4 turn increments.

6. Tighten the jam nut.

7. Turn ON electrical power to the dock leveler.

C
8. Remove lock out/tag out devices.
Figure 21

A — Sequence Valve C — C1 Port (Hoist Cyl.) 9. Disengage the maintenance prop.

B — Pressure Relief Valve D — C2 Port (Lip Cyl.)
10. Cycle leveler and verify lip operation.

11. Repeat steps 1– 10 as necessary.

All HED-series dock levelers are factory tested, and
should not require additional adjustments in the
field. Consult Systems, LLC Technical Services if
minor adjustments do not result in proper operation.

Whenever valve adjustments are completed, record

the number of turns made to allow an undesirable
adjustment result to be reversed.

4111-0020 — Sep. 2020

© 2020 Systems, LLC
35
TROUBLESHOOTING

Unless the dock leveler is equipped with a tethered When service under the dock leveler is required,
remote, two people are required to engage the always lock all electrical disconnects in the OFF
maintenance prop: one person to operate the unit, position after raising the platform and engaging the
the other person to engage the maintenance prop. maintenance prop.

In addition, it is recommended and good safety Always post safety warnings and barricade the
practice to use an additional means to support work area at dock level and ground level to prevent
the dock platform and lip anytime when physically unauthorized use of the dock leveler before
working in front of or under the dock leveler. This maintenance is complete.
additional means may include, but is not limited to a
boom truck, fork truck, stabilizing bar or equivalent. A hard hat or other applicable head protection
should always be worn when working under or
around a dock leveler.

Always stand clear of platform lip when working in

front of the dock leveler.

Before performing the detailed troubleshooting procedures, check the following items first:

• Check all fuses inside the control panel(s). Replace • Make sure the correct voltages are present at the
any blown fuse(s) with a fuse of equal specification. proper locations inside the control panel(s).

Symptom Possible Cause Solution

Motor overload device Reset overload relay or breaker. Determine cause of

tripped. device tripping.

Platform does not rise.

Motor does not energize.

Check voltage at starter or relay coil.

Motor starter (three-
phase) or motor relay • If voltage is present and starter or relay does not
(single‑phase) not energize, replace starter or relay.
energizing. • If voltage is not present, check all components in
series with the starter or relay coil.

4111-0020 — Sep. 2020

36 © 2020 Systems, LLC
 TROUBLESHOOTING
Symptom Possible Cause Solution

Check for blown fuses at branch circuit disconnect.

Replace fuse. Determine cause of blown fuse.

Check motor starter as follows:

1. Disconnect wires at load side of starter.
No voltage is present on 2. Energize the starter.
Three-phase units only: one line. 3. Measure line-to-line voltage at line side of starter.
Platform does not rise. 4. Measure line-to-line voltage at load side of
Motor hums, but does Note: A motor that is starter.
not run. missing voltage on one line 5. Line-side and load-side voltages should be
is said to be single-phased. approximately the same. Replace starter if
voltage values are considerably different from
one another.

Check all wiring to motor for high resistance or no

connection.

Three-phase units only:

Reverse any two legs at the branch circuit
Platform does not rise. Phase reversed.
disconnect.
Motor runs in reverse

Check wiring to motor for high resistance. Check for

loose or corroded connections. Check if gauge of
Line voltage too low.
wires to motor are of correct size and specification
for load requirement. Replace if necessary.

Single-phase units only:

Platform does not rise. Faulty motor centrifugal
Replace motor.
Motor energizes, but switch.
does not run.

Faulty motor capacitor. Replace motor.

4111-0020 — Sep. 2020

© 2020 Systems, LLC
37
TROUBLESHOOTING
Symptom Possible Cause Solution

Remove object(s) from platform.

Heavy object(s) on platform.
Note: For safety reasons, the dock leveler is
designed to lift only the platform’s own weight.

Check for visible obstructions that could cause

Dock leveler binds. binding. Remove obstructions. If no obstructions
Platform does not found, contact Systems, LLC Technical Services.
rise. Pump operates in
pressure relief mode.

Increase pressure relief. See page 34 for instruction.

Note: The pressure relief valve must not be set

at a level that causes the motor operating current
Pressure relief set too low. to exceed the full load amp value* at any time,
including when operating in pressure relief.

* The full load amp value can be found on the inside cover of the
control panel.

Add fluid, see pages 32-33 for proper fluid level and
Low hydraulic fluid.
type.

Clean and inspect valves. Flush contaminated oil

Contaminated hydraulic
from hydraulic system. Fill system with new oil. See
system.
page 33.

Damage or blocked
Replace damaged hose(s). Check and remove
Platform rises slowly. hydraulic hose(s) and/or
blockage from hose(s) and/or valve(s).
valve(s).

Increase pressure relief. See page 34 for instruction.

Note: The pressure relief valve must not be set

at a level that causes the motor operating current
Pressure relief set too low. to exceed the full load amp value* at any time,
including when operating in pressure relief.

* The full load amp value can be found on the inside cover of the
control panel.

4111-0020 — Sep. 2020

38 © 2020 Systems, LLC
 TROUBLESHOOTING
Symptom Possible Cause Solution
Decrease pressure relief. See page 34 for
instruction.

Pump motor loads down Note: The pressure relief valve must not be set
when platform reaches Pressure relief set too high. at a level that causes the motor operating current
the full raised position. to exceed the full load amp value* at any time,
including when operating in pressure relief.

* The full load amp value can be found on the inside cover of the
control panel.

Platform does not rise to Add fluid, see pages 32-33 for proper fluid level and
Low hydraulic fluid.
full height. type.

Sequence Valve requires Adjust valve as necessary. See page 35 for

adjustment. adjustment instructions.
Lip does not stay
extended when leveler
lowers.

Faulty lip cylinder. Rebuild or replace lip cylinder.

Add fluid, see pages 32-33 for proper fluid level and
Low hydraulic fluid.
type.
Platform DOES rise to
full height, but lip DOES
NOT extend or extend
fully.
Sequence Valve requires Adjust valve as necessary. See page 35 for
adjustment. adjustment instructions.

Sequence Valve requires Adjust valve as necessary. See page 35 for

Lip does not extend.
adjustment. adjustment instructions.

Lip extends almost

Sequence Valve requires Adjust valve as necessary. See page 35 for
immediately when the
adjustment. adjustment instructions.
RAISE button is Pressed.

If additional troubleshooting assistance is required, contact Systems, LLC

Technical Services with equipment serial number or customer order number (CO#).
Technical Service at 800-643-5424 or techservices@loadingdocksystems.com

4111-0020 — Sep. 2020

© 2020 Systems, LLC
39
PARTS
Danfoss Control Box

Part Number Voltage Phase Description

7141-0268 110v 1-Phase Danfoss Control Box (MTR 3627A)
7141-0269 230v 1-Phase Danfoss Control Box (MTR 3627C)
7141-0270 230v 3-Phase Danfoss Control Box (MTR 3627E)
7141-0271 460v 3-Phase Danfoss Control Box (MTR 3627F)
* Provide dock leveler serial number, voltage, phase, and options when e-mailing, calling or faxing controller orders.

4111-0020 — Sep. 2020

40 © 2020 Systems, LLC
 PARTS
Optional Electrical Parts

Item Quantity Part Number Description

A 1 * Control Box w/Optional Equipment
9511-0004 J-Box, Standard (4 x 4 in. Metal Box)
B 1
2751-0042 J-Box, Cold Weather (5 x 5 in. Plastic Box)
* Provide dock leveler serial number, voltage, phase, and options when e-mailing, calling or faxing controller orders.

4111-0020 — Sep. 2020

© 2020 Systems, LLC
41
PARTS
Leveler Components
14
9
13 11

12
15
7
16
4

10

17

6
8

7
3

15 18
S Y
23 19 L o a
21
24 20 HEOD
25 22
26 DRAWN BY
29 TOLERANCE
(UNLESS OTHERWISE

27 FRACTIONAL: C1/3
DECIMAL:

28 .00 = C.01"
.000 = C.005"
ANGULAR: C1a
This print is the property o
patent and other rights, in
not convey any permissio
granted only by written au

ITEM QTY SIZE/CAPACITY DESCRIPTION PART NUMBER (15” LIP) PART NUMBER (17” LIP)
1 6620/25 Lip Plate & Hinge Assembly 7303-0195 7303-0196
1 6630 Lip Plate & Hinge Assembly 7303-0197 7303-0198
1 6635 Lip Plate & Hinge Assembly 7303-0199 7303-0200
1 7220/25 Lip Plate & Hinge Assembly 7303-0201 7303-0202
1 7230 Lip Plate & Hinge Assembly 7303-0203 7303-0204
1 7235 Lip Plate & Hinge Assembly 7303-0205 7303-0206
1
1 7820/25 Lip Plate & Hinge Assembly 7303-0207 7303-0208
1 7830 Lip Plate & Hinge Assembly 7303-0209 7303-0210
1 7835 Lip Plate & Hinge Assembly 7303-0211 7303-0212
1 8420/25 Lip Plate & Hinge Assembly 7303-0213 7303-2014
8430 Lip Plate & Hinge Assembly 7303-0215 7303-0216
1 8435 Lip Plate & Hinge Assembly 7303-0217 7303-0218

*Provide dock leveler serial number, platform size, lip size and type of installation when e-mailing, calling or faxing orders.
Contact Technical Services for 2005 and earlier parts.

4111-0020 — Sep. 2020

42 © 2020 Systems, LLC
 PARTS
ITEM QTY SIZE/CAPACITY DESCRIPTION PART NUMBER
1 6620/25 Center Plate & Hinge Assembly 7303-0219
1 6630 Center Plate & Hinge Assembly 7303-0220
1 6635 Center Plate & Hinge Assembly 7303-0221
1 7220/25 Center Plate & Hinge Assembly 7303-0222
1 7230 Center Plate & Hinge Assembly 7303-0223
1 7235 Center Plate & Hinge Assembly 7303-0234
2
1 7820/25 Center Plate & Hinge Assembly 7303-0225
1 7830 Center Plate & Hinge Assembly 7303-0226
1 7835 Center Plate & Hinge Assembly 7303-0227
1 8420/25 Center Plate & Hinge Assembly 7303-0228
1 8430 Center Plate & Hinge Assembly 7303-0220
1 8435 Center Plate & Hinge Assembly 7303-0230
3 1 ALL Base Plate & Hinge Assembly Consult Factory
2 6620/25/30 Hinge Pin 9511-0044
2 6635 Hinge Pin DOTH-4312
2 7220/25/30 Hinge Pin 9511-0045
2 7235 Hinge Pin DOTH-4313
4
2 7820/25/30 Hinge Pin 9511-0046
2 7835 Hinge Pin DOTH-3633
2 8420/25/30 Hinge Pin 9511-0047
2 8435 Hinge Pin DOTH-4317
5 2 ALL Rivet - Button DOTH-2400
6 2 ALL Rivet - Flat DOTH-2398
7 2 ALL Bumper Block Assembly See Page 46
8 2 ALL HED Gusset DOTH-4309
9 1 ALL Pivot Block DOTH-3316
10 1 ALL Lip Stop DOTH-3734
11 1 ALL Maintenance Strut Assembly DOTH-4325
12 4 ALL Pivot Block DOTH-3113
13 2 ALL Clevis Pin DOTH-2364
14 2 ALL Cotter Pin DOTH-2374
15 2 ALL Breather Vent Plug DOTH-2717
16 1 ALL Lip Cylinder 0521-0200
17 1 ALL Hose Assembly -39” DOTH-2799
18 1 ALL Upper Cylinder Pivot DOTH-4202
19 2 ALL Main Cylinder Pin DOTH-2358
20 2 All Hitch Clip DOTH-2815
21 1 ALL Main Cylinder DOTH-2725
22 1 ALL Lower Cylinder Mount Assembly DOTH-4302
23 1 ALL 90 Degree Fitting, 1/4 NPTM, 1/4 NPTF 0521-0062
24 1 ALL Hose Assembly - 15” DOTH-2785
25 2 ALL 90 Degree Fitting, 3/8 NPTM, 1/4 NPTF 0521-0237
26 1 ALL Powerpack See Page 44
27 4 ALL Carriage Bolt 2101-0029
28 4 ALL Flange Nut 2101-0214
29 1 ALL Motor Mount Bracket DOTH-4305

4111-0020 — Sep. 2020

© 2020 Systems, LLC
43
PARTS
Powerpack Assembly

Part Number Description

DOTH-2854 Powerpack, 115/230v, 1ph, 50/60Hz
DOTH-2855 Powerpack, 230/460v, 3ph, 50/60Hz

*Provide dock leveler serial number when e-mailing, calling or faxing orders. Contact Technical Services for 2005 and earlier parts.

4111-0020 — Sep. 2020

44 © 2020 Systems, LLC
 PARTS

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4111-0020 — Sep. 2020

© 2020 Systems, LLC
45
PARTS
Bumper Components

4111-0020 — Sep. 2020

46 © 2020 Systems, LLC
 PARTS

Item Quantity Part Number Description

* * DBBS-3553 HED Bumper Assembly, 18” Proj, 12” Tall, Blue (includes A-F)
* * DKIT-3540 4” x 12” x 13” Bumper & Hardware Kit (includes A-E)
A 1 DOTH-3505 Rubber Bumper, Tuf Cord, 4” x 12” x 13”
B 4 DOTH-2056 Hex Head Cap Screw, 7/16-14 UNC x 3-1/4
C 4 DOTH-2210 Washer, Flat, Zinc Plated, 1/2”
D 4 DOTH-2208 Washer, Flat, 1/2”
E 4 DOTH-2129 Nylon Lock Nut, 7/16-14 UNC
F 1 DOTH-3846 18” Proj. x 12” BB Weldment (HED) Slate Blue

4111-0020 — Sep. 2020

© 2020 Systems, LLC
47
MISCELLANEOUS

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48 © 2020 Systems, LLC
 MISCELLANEOUS
Customer Information

P O W E R A M P
D L M
S Y S T E M S, I N C.
L o a d i n g D o c k E q u i p m e n t

Figure 23
NL-X MAINTENANCE PROP

DRAWN BY CHECKED BY DATE

SR 8/6/2009

Figure 22 TOLERANCES
(UNLESS OTHERWISE NOTED)

FRACTIONAL: `1/32"
DRAWING NO.

HED6620-15 Maintenance
DECIMAL:
.00 = `.01"
.000 = `.005"

NOTE: Refer to Figure 22 for orientation of dock leveler ANGULAR: `1~

Dock Leveler Information

patent andisother
Thisconvey
print rights, including
the permission
property of to exclusive
Systems, rights
Inc. print
and of use and/or
represents manufacture
a proprietary and/or
article sale.
in which Possession
Systems, Inc. of this print
retains does
any and toallbe

and Figure 23 for example of decal.

not any reproduce, or manufacture the article or articles shown therein, such permission

granted only by written authorization signed by an officer or other authorized agent of Systems,Inc. thereof.

The LEVELER model/serial number decal is Model ___________________________________

located on the left platform joist near the front (lip)
of dock leveler (A). Serial No. ________________________________

When you receive your new equipment, write down the Systems, LLC, Job No. ______________________
model and serial number in the form provided. This will
help ensure safe keeping of the numbers in the event
Vehicle Restraint Information
the model/serial number decal (A, B) becomes lost or
damaged.
Model ___________________________________
Also, write down Systems, LLC’s order number, the
company that installed the dock leveler, and the original Serial No. ________________________________
owner’s name. This will all help to identify the specific dock
leveler if more information is required. Systems, LLC Order No. ______________________

When ordering, use part numbers and description to help Original Owner Information
identify the item ordered. Do not use “item” numbers.
These are only for locating the position of the parts. Always
Name ___________________________________
give dock leveler MODEL NUMBER and/or SERIAL
NUMBER. Address _________________________________

For service, call or contact: ________________________________

Systems, LLC Installer Information

P.O. Box 309
Germantown, WI 53022 Name ___________________________________

Phone: (800) 643-5424 Address _________________________________

Fax: (262) 255-5917
_________________________________
www.loadingdocksystems.com Date of Installation ________________________

4111-0020 — Sep. 2020

© 2020 Systems, LLC
49
 STANDARD PRODUCT WARRANTY
SYSTEMS, LLC 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 LLC, covered by this warranty, SYSTEMS LLC 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 LLC 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.