DoorHan DS Series Bedienungsanleitung

DOCK LEVELER

WITH TELESCOPIC LIP SERIE DS/DSI

Original installation and operation instruction

MANUFACTURER’S DECLARATION

OF CONFORMITY 2

GENERAL INFORMATION 2

SAFETY RULES 3

SAFETY FEATURES 4

GENERAL VIEW 5

PACKAGE 6

INSTALLATION 6

OPERATION 10

MAINTENANCE 11

TROUBLESHOOTING 12

APPENDIXES

CONTENTS

1. MANUFACTURER'S DECLARATION OF CONFORMITY ...................... 2

2. GENERAL INFORMATION ............................................ 2

3. SAFETY RULES ................................................... 3

4. SAFETY FEATURES ................................................ 4

5. GENERAL VIEW ................................................... 5

6. PACKAGE ........................................................ 6

7. INSTALLATION .................................................... 6

8. OPERATION ..................................................... 10

9. MAINTENANCE .................................................. 11

10. TROUBLESHOOTING .............................................. 12

11. APPENDIXES .................................................... 13

Appendix 1. Spare parts ........................................... 13

Appendix 2. Hydraulic components for dock leveller series ................ 17

Appendix 3. Pits for dock levellers ................................... 23

1. MANUFACTURER’S DECLARATION OF CONFORMITY

Manufacturer: LLC StoreHan, 143002, Russia, Moskovskaya obl., Odintsovskij r-n, s. Akulovo, ul. Novaya, d. 120

Trademark: DoorHan

Dock levellers serie DS/DSI

fulfil the stipulations of the Machinery Directives

2006/42/EC Machinery, 2006/95/EC Low-voltage, 2004/108/EC Electromagnetic compatibility and harmonized

to the following standarts

EN ISO 12100:2010, EN 1398:2009, EN 60204-1:2006/А1:2009/Cor.Feb.:2010, EN 61000-6-2:2005/Corr.Sep.:2005, EN

61000-6-4:2007/A1:2011

This declaration of conformance is not applied if:

ythe Product is operated in the extreme climatic conditions, in the magnetic action environment etc, and in case of special

requirements, e.g. explosion hazard;

ythe Product is operated for loading/unloading of hazardous substances e.g. acids, radiation-emitting materials, molten

metal, fragile freights;

2. GENERAL INFORMATION

The purpose of this manual is to give information to the operating personnel on correct procedures for installation, operation

and maintenance of telescopic lip dock leveler. The manual contains rules to observe for safe operation and maintenance of the

dock leveller. The manufacturer does not handle the operation, maintenance and placement of the equipment. The operator is

responsible for safe operation and maintenance of the equipment. It is the operator’s responsibility to study this manual prior

to installation. The manufacturer assumes no liability for interpretation of the contents of this manual.

Dock levellers with hinged lip is designed to act as bridge between warehouse and truck body and to enable quick and

unimpeded movement of forklift during loading/unloading.

Only qualified personnel can make installation, operation and maintanace for dock leveller.

We reserve the right to make design modifications without preliminary notice.

LIFTING EQUIPMENT

Fork lift: minimum carrying capacity 35 kN, fork length 2000 mm.

Crane: minimum carrying capacity 20 kN at the given radius.

EQUIPMENT FOR INSTALLATION

Before installation you should have following equipment:

welding machine (5-200 A) or similar;

welding electrodes 3,0 mm.

Control unit

Dock leveller serie DS, DSI compatible with DCUT-1/2/3 control units.

CONTENTS

3. SAFETY RULES

The improper use is not allowed.

Provide good lighting and visibility when operating the dock leveler.

When operating the dock leveler, keep the operating zone free from people and obstacles.

Watch closely when handling outsized, unstable or dangerous loads, and when the operating zone is not

free from obstacles.

When operating the dock leveler, be sure that the door is fully opened.

Make sure that the truck has stopped in the required position. If there is a risk of truck departure fix it using

a wheel block.

Before loading/unloading, make sure that the dock leveller lip lies in the truck body correctly. The lip must

overlap the truck bed by at least 85 mm.

The dock leveller control unit must be placed so that the operator has full view of the operating zone and is

able always to keep under control the whole process of loading/unloading.

To prevent injury during installation, keep a safe distance from the dock leveller.

Before connecting any wire be sure that the power supply is switched off.

When not in use, the dock leveller should be in the closed position.

Do not put the lip of dock leveller on the truck’s tail lift.

Do not exceed the maximum allowable working angle 12.5% or 7°.

FUNCTION

Function DCUT-1 DCUT-2 DCUT-3

Impulse AUTO button zz

400Volt zzz

Traffic light outside zz

Traffic light inside zz

Dock light zz

Interlock (door-dockleveler) zzz

Extra safety devices connection zz

Service indicator zz

Digital display zz

Door control z

Inflatable dock shelter control z

SAFETY RULES

All hydraulic components designed to resist to a pressure at least double than

declared one.

The upper sheet of the dock leveller is made of diamond steel sheet to ensure

the best bite of the forklift wheels and dock leveler’s deck.

Black/yellow safety marking allows to see that the platform is above the the

ramp

Noise level during operation of the dock leveller does not exceed 85 Db within

a radius of 1 m.

Protection rating is IP54.

3. SAFETY FEATURES

Rising/lowering speed less than 0.15 m/s.

Maintenace supports ensures safe maintenance and connection of wiring.

Burst valve immediately stops upper deck in case of hose rupture.

SAFETY FEATURES

1. Upper deck

2. Lip

3. Frame

4. Signal yellow-black stripping

5. Hydraulic pump

6. Lifting cylinder

7. Lip cylinder

8. PVC front curtain

9. Control unit

4. GENERAL VIEW

Table 1

WEIGHT OF DOCK LEVELLERS

Length, mm 2 500 3 000 3 500 4 000 4 500

Weight, kg 1 000 1 100 1 200 1 350 1 450

WARNING

Upper plate of the dock leveller is a 8-10 mm thick steel sheet with lentiform (diamond) riffling with height 0.8–3 mm. If load-

ing/unloading is performed using a standard 4-wheel forklift with inflatable tyres, the dock leveller is manufactured with 8 mm

thick sheet and riffling height 0.8–2.4 mm. If loading/unloading is performed using equipment with high point load (for example,

electric pilers), the dock leveller is manufactured with 10 mm thick steel sheet with riffling height 1–3 mm. Small deformation

of the dock leveller upper sheet is admissible, as it does not effect operation of the product. The lip is made of steel 12 mm

thick sheet with diamond riffling height 1.2–3.6 mm. The reinforcement profiles can be made of flanged beams 100/120 mm or

L-shaped profile 140404 mm, the frame is made of channel bar 100/120 mm. If the profile length exceeds 3500 mm, the rein-

forcement profiles and the frame are made of flanged beams 120 mm.

PERFOMANCE

Load capacity 6000 kg (60 kN)/10000 kg (100 kN)

Maximal point load (upper sheet 6 mm) 1.3 N/mm2

Maximal point load (upper sheet 8 mm) 6.5 N/mm2

Motor hydraulic unit 1.1 kW

Power supply 400 V, 3 phase

Control voltage 24 V

Control unit protection class IP54

Working fluid Mobil Univis HVI 26 / G-Special Hydraulic Nord-32

Class of surface cleaning before painting Sa 2

Thickness of painted layer 60–90 micron

Operation temperature range From –30 to +50°C

GENERAL VIEW

8 2 7 6 5 1 3 4

12 2а

EMBEDDED MOUNTING WITHOUT TAIL LIFT ACCESS

6. PACKAGE

1. Dock leveller . .............................. 1

2. Control unit, connection cables*................ 1

3. Operating manual ........................... 1

* Control unit is to be ordered separately depending on the required functions. For dock levellers with length up to 3 m, a 7 m long connection

cable is required (art. DKTL02 ), for dock levellrs with length exceeding 3 m, a 10.5 m long connection cable is required (art. DKTL02-1).

7. INSTALLATION

UNLOADING

GENERAL: Make the installation in accordance to all local

safety regulations! The installation of the dock leveller must

be carried out by the service department of DoorHan or by

a service department/dealer recognized by DoorHan.

When installing the dock leveler in the pit, fix the lifting belts

only in certain points.

Before installation some important point to be checked:

yIs protective pipe for cables made according to draw-

ings?

yIs the pit made according to drawing?

See detailed drawing of the manufacturer.

Unloading

Check the possible damages during transportation of dock leveler. Always transport and store the dock leveller in a horizontal

position and in any case do not let it fall! At the same time allowed to pick up and unload only one dock leveller!

PIT PREPARATION

Before Installation the dock leveller, prepare the pit in strict accordance with the drawings that have been supplied by

the manufacturer. Detailed information on dimensions, types of dock levellers and pits as well as recommendations on pit

preparation is given in our engineering solution catalogue.

1. Stretch the connection wiring through the tube.

2. Install the dock leveler so that the rear corner of the dock leveller tightly adjoined to the rear upper fitting on the pit.

3. Longitudinal gaps between the pit and leveler should be 10–15 mm width.

4. Weld joints on the platform with the rear and front fittings on the pit as shown in Figure 3, 3a.

PACKAGE

12 2а

EMBEDDED MOUNTING WITH TAIL LIFT ACCESS

1. Stretch the connection wiring through the tube.

2. Install the dock leveler so that the rear corner of the dock leveller tightly adjoined to the rear upper fitting on the pit.

3. Longitudinal gaps between the pit and leveler should be 10–15 mm width.

4. Weld joints on the platform with the rear and front fittings on the pit as shown in Figure 3, 3a.

INSTALLATION

Рис. 3a

12 2а

SUSPENDED MOUNTING

Gap between the pit and the dock

leveller 10–15 mm on both sides.

Fig. 3a

INSTALLATION

Рис. 4a

Fig. 4a

1. Stretch the connection wiring through the tube.

2. Install the dock leveler in the required position.

3. Connect the dock leveller external frame with fittings of concrete floor by

welding. See Fig 3a.

4. Longitudinal gaps between the pit and leveler should be 10–15 mm width.

5. Underpour concrete.

INSTALLATION

Connect dock leveller steel

structure to the grounding of

the building!

Remove transportation bolts before use

CONTROL UNIT INSTALLATION

Control unit shall be installed so, that the dock leveller operator is always able to keep

under control the operation of the dock leveller.

8. OPERATION

Connect the control unit to the dock leveller following the instructions given in the control unit manual. Complete 4–5 full

opening/closing cycles, make sure that the dock works properly.

When operating the dock leveller, do observe the following rules:

Never operate the dock leveller when persons, goods are on it or in front of it.

The lip of the dock leveller must be placed in the truck body in full width and has sufficient support at least 85 mm.

Do not exceed declared load capacity. Load capacity agrees with total weight of the forklift with load and the driver.

It is strictly forbidden to operate the dock leveller with the load.

When not operated (after loading/unloading has been completed), the dock leveller should be back in rest position.

When loading/unloading, do not switch off control unit.

Emergency stop function integrated into the main switch. Use this function ONLY in case of emergency. It

may not be used during loading/unloading, as the dock leveller is unable to follow the vertical movements

of truck which could lead to damage of hydraulic system.

Forklifts are prohibited to move along the platform at a speed of more than 5 km/h.

Place the truck with door open correctly in front of dock leveller. Fix the track to avoid it’s unwanted departure.

OPERATION

Turn the main switch to «I» position.

Check that the control unit power indicator lights, then press up button for lifting of dockleveler.

Keep the button pressed until complete lifting of DL. Then press button lip pull out and keep it pressed untill the extension of lip

becomes required length.

Press down button briefly and wait while the lip will come down to the truck body.

WARNING! Don’t switch off power while dockleveler is being used. Only in case of emergency. Emergency stop

function integrated into the main switch. Use this function ONLY in case of emergency. It may not be used during

loading/unloading, as the dock leveller is unable to follow the vertical movements of truck which could lead to damage

of hydraulic system.

RETURN TO THE INITIAL POSITION

After finish of loading/unloading dock leveler has to back to initial position.

Press up button and lift dockleveler approx. 100mm higher from truck body.

Press and keep lip pull in button while the lip is not retract completely. Press down button briefly, dock leveler descend to park

position position. Turn off main switch to “0”.

EMERGENCY STOP

In case of emergency turn the main switch to «0»

To resume dock leveler operation, make sure that the power is on, there is nobody under the deck or close to dockleveler movable

parts. Press up button briefly.

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