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DL-NL-TS SERIES
EOD Dock Leveler
Owner’s/User’s Manual
DLM • Division of Systems, Inc. • W194 N11481 McCormick Drive • Germantown, WI 53022
800.643.5424 • fax: 262.257.7399 • www.docksystemsinc.com • [email protected]
Printed in U.S.A.
Copyright © 2011
Manual No. 4111-0025
March 2011
May 2012
Table of Contents
Page
Safety
Recognize Safety Information..................................................................1
General Operational Safety Precautions.................................................1
Operational Safety Precautions...............................................................2
Maintenance Safety Precautions.............................................................4
Safety Decals...........................................................................................5
Owner’s/User’s Responsibilities...............................................................6
Introduction
General Information.................................................................................8
Dock Leveler Stock Specifications...........................................................8
Installation
Installations Details..................................................................................9
Flush Mount-Weld On............................................................................ 10
Ramp Mount-Weld/Bolt On.................................................................... 12
Flush Mount-Bolt On.............................................................................. 14
Ramp Mount-Weld On w/Formed Angle................................................ 16
Formed Angle........................................................................................ 18
Ramp and Face Plate............................................................................ 20
Installation Check List............................................................................ 22
Operation
Operating Instructions DL...................................................................... 23
Operating Instructions NL & TS............................................................. 24
Maintenance
Periodic Maintenance............................................................................ 25
Troubleshooting
Troubleshooting..................................................................................... 26
Parts
DL-X Series............................................................................................ 27
NL-X Series............................................................................................ 28
TS Series............................................................................................... 30
Extension Spring Components.............................................................. 32
Torsion Spring Components................................................................... 34
Current vs. 2005 and Older.................................................................... 35
Handle Options...................................................................................... 36
Operating Link Options.......................................................................... 37
Bumper Components............................................................................. 38
Sliding Bumper Components................................................................. 39
Notes
Customer Information............................................................................ 41
Warranty.................................................................................. Back Cover
SAFETY
Recognize Safety Information
Safety-Alert Symbol
The Safety-Alert Symbol identifies important safety
messages on equipment, safety signs, in manuals,
or elsewhere. When you see this symbol, be alert to
the possibility of personal injury or death. Follow the
instructions in the safety message.
General Operational Safety
Precautions
Read and understand the operating instructions and
become thoroughly familiar with the equipment and its
controls before operating the dock leveler.
Never operate a dock leveler while a safety device or
guard is removed or disconnected.
The use of the word CAUTION signifies possible
hazard or unsafe practice which could result in
personal injury.
IMPORTANT
The use of the word IMPORTANT is to draw
attention to a procedure that needs to be followed to
prevent machine damage.
O
p
ng
ati
er
Zo n
e
e
The use of the word WARNING signifies the
presence of a serious hazard or unsafe practice
which may result in serious injury or death.
Never remove DANGER, WARNING, or CAUTION
signs or decals on the equipment unless replacing
them.
Zo
n
The use of the word DANGER signifies the presence
of an extreme hazard or unsafe practice which will
most likely result in severe injury or death.
in
at
er
p
O
g
Do not activate the equipment until all unauthorized
personnel in the area have been warned and have
moved outside the operating zone.
Remove any tools or foreign objects from the operating
zone before starting.
Keep the operating zone free of obstacles that could
cause a person to trip or fall.
Manual No. 4111-0025
March 2011
May 2012
1
SAFETY
Operational Safety Precautions
Learn the safe way to operate this equipment. Read and understand the
manufacturer’s instructions. If you have any questions, ask your supervisor.
Stay clear of dock leveling device when freight
carrier is entering or leaving area.
Chock/restrain all freight carriers. Never remove
the wheel chocks until loading or unloading is
finished and truck driver has been given permission
to drive away.
Do not move or use the dock leveling device if
anyone is under or in front of it.
Do not use a broken or damage dock leveling
device. Make sure proper service and maintenance
procedures have been performed before using.
Keep hands and feet clear of pinch points. Avoid
putting any part of your body near moving parts.
Make sure lip overlaps onto trailer at least 4 in.
(102 mm).
Keep a safe distance from both side edges.
2
Manual No. 4111-0025
March 2011
May 2012
SAFETY
Operational Safety Precautions
Do not use dock leveling device if freight carrier is
too high or too low.
Do not overload the dock leveling device.
Do not operate any equipment while under the
influence of alcohol or drugs.
Do not leave equipment or material unattended on
dock leveling device.
Manual No. 4111-0025
March 2011
May 2012
3
SAFETY
Maintenance Safety Precautions
To put handle into maintenance prop position,
remove bolt and locknut at base of handle
assembly. Pull handle out of roller arm assembly
and place into maintenance prop receiver, if
equipped.
Post safety warnings and barricade the work area at
dock level and ground level to prevent unauthorized
use of the dock leveler before installation has been
completed.
ALWAYS stand clear of dock leveler lip when
working in front of the dock leveler. Failure to do this
may result in serious personal injury or death.
4
Failure to follow the installation instructions can
result in damage to dock leveler, the facilities, and/
or serious personal injury or death.
Manual No. 4111-0025
March 2011
May 2012
Unsupported dock leveler
ramps can lower unexpectedly.
2
manual.
sides of moving dock leveler.
2. Use of dock leveler restricted to
8. Never use damaged or
trained operators
malfunctioning dock leveler. Report
3. Always chock trailer wheels or
problems immediately to supervisor.
engage truck restraint before
Before allowing vehicle to leave
operating dock leveler or beginning to
Maintenance/Service
load or unload.
1. Read and follow all instructions,
the dock always:
4. Never use hands or equipment to
warnings and maintenance schedules
move the ramp or lip
in the owner’s/user’s manual.
5. Before activating dock leveler:
2. Maintenance/Service of dock leveler
Ensure that no equipment, 9.12" Ensure trailer is backed in against
restricted to trained personnel.
material or people are on the
3. Place barriers on the driveway and on
bumpers.
dock floor to indicate service work is
Remove any end loads if required.
dock leveler.
being performed.
Check trailer alignment to avoid lip
4. DO NOT ENTER PIT unless dock
interference. If lip does not lower to
leveler is securely supported by
trailer bed, reposition vehicle.
Return the dock leveler to its
maintenance prop.
that truck bed supports
OPERATION
7. Stay clear
of
and front
and turn off and use
stored position at dock level. 6. Ensure
5. Ifhinges
electrically
powered
the leveler
1. Read extended
and follow lip
all or
instructions
andframe sides of moving
dock leveler.
OSHA
lockout/tagout procedures.
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
instructions will
result in death
serious injury. 2. Use of dock
Call 262.255.1510
for replacement
placards, warning
or owner’s/user’s
manuals.
leveler restricted
to
malfunctioning
docklabels,
leveler.
Report
Unsupported
dockorleveler
SAFETY
Safety Decals
SAFETY INFORMATION
DANGER
3.25"
Failure to follow posted
2
ramps can lower unexpectedly.
trained operators
problems immediately to supervisor.
3. Always chock trailer wheels or
engage truck restraint before
MAINTENANCE/SERVICE
operating dock leveler or beginning to 1. Read and follow all instructions,
load or unload.
warnings and maintenance
Supports
the ramp before driving on
4. Never use hands Operation
or equipment to
schedules in
the owner’s/user’s
move
ramp or
lip follow all instructions and
1. Read
and
manual.
ramp.
5. Before
activating in
dock
of dock
levelerand front and
warnings
theleveler:
owner’s/user’s2. Maintenance/Service
7. Stay clear
of hinges
Ensure
trailer is backed in against
restricted to trained
manual.
sidespersonnel.
of moving dock leveler.
on the driveway and
bumpers.
2. Use of dock leveler restricted 3.
to Place barriers
8.
Never
use
damaged
or
dock floor to indicate service work is
Remove any end loads if required.
trained operators
malfunctioning dock leveler. Report
being performed.
Check trailer alignment to avoid lip
3. Always chock trailer wheels or4. DO NOT ENTER
problems
immediately
to supervisor.
PIT
unless
dock
interference. If lip does not lower to
engage truck restraint before
leveler is securely supported by
trailer bed, reposition vehicle.
maintenance
prop.
operating
dock
leveler
or
beginning
to
Maintenance/Service
6. Ensure truck bed supports extended
9.12"
turnfollow
off andall
useinstructions,
load orframe
unload.
1. powered
Read and
lip or leveler
supports the ramp 5. If electrically
procedures.
4. Never
hands or equipment toOSHA lockout/tagout
before
drivinguse
on ramp.
warnings
and maintenance schedules
SAFETY INFORMATION
DANGER
Before allowing vehicle to leave
the dock always:
Ensure no
equipment,
Unsupported
dock
leveler
or people
are on
rampsmaterial
can lower
unexpectedly.
dock leveler.
Before
allowing
Return
dockvehicle
leveler totoitsleave
stored
position at dock level.
the dock
always:
2
move
the ramp
or lip
the owner’s/user’s
manual.
Call
262.255.1510
for replacement
placards, warning labels, orinowner’s/user’s
manuals.
5. Before activating dock leveler:
2. Maintenance/Service of dock leveler
Ensure trailer is backed in against
restricted to trained personnel.
3. Place barriers on the driveway and on
bumpers.
dock floor to indicate service work is
Remove any end loads if required.
OPERATION
7. Stay clear ofbeing
and front and
performed.
Check trailer alignment to avoidsides
lip of movinghinges
1. Read and follow all instructions and
dock
leveler.
Control Box Size:
4. DO
NOT
ENTER PIT unless dock
interference.
If lip does
not lower
warnings
in owner’s/user’s
manual.
8. Ntoe v e r u s e d a m a g e d o r
leveler
is
securely supported by
Decalthe
Size:
9.12leveler
x 3.25 to its2. Use trailer
of dock
leveler
restricted
to
malfunctioning dock leveler. Report
bed,
reposition
vehicle.
Return
dock
leveler
Unsupported
dock
maintenance
prop.
trained
operators
problems
immediately
to
supervisor.
6. Ensure that truck bed supports
Filecan
Name:
1751-0730
A
ramps
lower
unexpectedly.
stored
position
at dockRev
level.
5.
If
electrically
powered turn off and use
3. Always
chock lip
trailer
wheels
extended
or the
levelerorframe
OSHA lockout/tagout procedures.
engage truck restraint before
MAINTENANCE/SERVICE
dock262.255.1510
leveler or beginning
to 1. Read
and warning
follow labels,
all instructions,
will
resultallowing
in deathvehicle
or serious
injury. operating Call
for replacement
placards,
or owner’s/user’s manuals.
Before
to leave
Failure to follow posted instructions will result in death or serious injury.
Ensure that no equipment,
material or people are on the
dock leveler.
SAFETY INFORMATION
DANGER
3.25"
Failure to follow posted instructions
2
the dock always:
Ensure no equipment,
material or people are on
dock leveler.
Return dock leveler to its
stored position at dock level.
Failure to follow posted instructions will result in death or serious injury.
load or unload.
4. Never use hands or equipment to
move ramp or lip
5. Before activating dock leveler:
Ensure trailer is backed in against
bumpers.
Remove any end loads if required.
Check trailer alignment to avoid lip
interference. If lip does not lower to
trailer bed, reposition vehicle.
6. Ensure truck bed supports extended
lip or leveler frame supports the ramp
before driving on ramp.
2.
warnings and maintenance
schedules in the owner’s/user’s
manual.
Maintenance/Service of dock leveler
restricted to trained personnel.
Place barriers on the driveway and
dock floor to indicate service work is
being performed.
DO NOT ENTER PIT unless dock
leveler is securely supported by
maintenance prop.
If electrically powered turn off and use
OSHA lockout/tagout procedures.
! DANGER
3.
4.
5.
Call 262.255.1510 for replacement placards, warning labels, or owner’s/user’s manuals.
1
Decal 2 will have two positions, one on the outside Control
of theBox
leftSize:
bumper
Size: 9.12and
x 3.25
Decalone
2 willon
have
positions,
oneright
on the
outside of theDecal
left bumper
and
the two
outside
of the
bumper.
File Name: 1751-0730 Rev A
one
on
the
outside
of
the
right
bumper.
Decal 3 represents the placement of the serial tag (left side of gusset)
Decal 3 represents the placement of the serial tag (left side of gusset).
! DANGER
1
2
1
3
2
Ramp swings toward you.
Stand Clear.
Use maintenance strut while servicing.
Failure to do so will result in death or
serious injury.
Ramp swings toward you.
Stand Clear.
Use maintenance strut while servicing.
Failure to do so will result in death or
serious injury.
Refer to owner’s/user’s manual for proper procedure.
Manual No. 4111-0025
March 2011
May 2012
Control Box Size:
Decal Size: 4-5/16 x 4-1/4
File Name: 1751-0763 Rev A
5
OWNER’S/USER’S RESPONSIBILITIES
1. The owner/ user should recognize the inherent dangers of the interface between the loading dock and
the transportation vehicle. The owner/ user should, therefore, train and instruct all operators in the safe
operation and use of the loading dock equipment in accordance with manufacturer’s recommendations
and industry standards. Effective operator training should also focus on the owner’s/user’s company
policies and operating conditions. Maintaining, updating and re training all operators on safe working
habits and operation of the equipment, regardless of previous experience, should be done on a regular
basis and should include an understanding and familiarity with all functions of the equipment. Owner’s/
user’s shall actively maintain, update and retrain all operators on safe working habits and operations of
the equipment.
2. The manufacturer shall provide to the initial purchaser all necessary information regarding Safety
Information, Operation, Installation and Safety Precautions, Recommended Initial and Periodic
Inspections Procedures, Planned Maintenance Schedule, Product Specifications, Troubleshooting
Guide, Parts Break Down, Warranty Information, and Manufacturers Contact Information, as well as
tables to identify the grade(slope) for all variations of length or configuration of the dock leveling device
and information identifying the maximum uncontrolled drop encountered when sudden removal of support
while in the working range of the equipment.
3. It is recommended that when the transportation vehicle is positioned correctly in the dock opening and
in contact with both bumpers, there shall be a minimum of 4.00 inches (100mm) overlap of the leveling
device and the transportation vehicle at all times during the loading and unloading process.
4. The Owner/User must review all name plates, placards, decals, instructions and posted warnings and
place the same in view of the operator or maintenance personnel for whom such warnings are intended
for. Contact manufacturer for any replacements.
5. Manufacturer’s recommended periodic maintenance and inspection procedures in effect at the date of
shipment shall be followed at all times. Written documentation of maintenance, replacement parts or
damage should be retained. In the event of damage notification to the manufacturer is required.
6. Loading dock equipment that has been structurally damaged or has experienced a sudden loss of main
support while under load (such as what might occur when a transport vehicle pulls out from under the
leveling device) shall be removed from service, inspected by a manufacturer’s authorized representative,
and repaired or replaced as needed before being placed back in service.
7. Any modifications or alterations of loading dock equipment shall only be done with prior written approval
from the manufacturer and the same shall be at least as safe as the original equipment was prior to
the modification and shall also satisfy all safety requirements of the manufacturer for the particular
application of the leveling device.
8. When industrial moving devices are being used in the loading or unloading of product from the
transportation vehicle, this vehicle shall have the brakes and wheel chocks applied appropriately or
all other positive restraining device shall be fully utilized. It is recommended that trailers with air-ride
suspension systems shall have its air exhausted prior to performing loading and unloading operation to
minimize trailer bed drop.
9. Loading dock safety equipment should never be used outside of its intended use, vertical working range,
or capacity. Please consult the manufacturer if you have any questions as to the use, vertical working
range or capacity of the equipment. Only properly trained and authorized personnel should operate the
equipment.
10.When selecting loading dock safety equipment, it is important to consider not only present requirements
but also future plans and any possible adverse conditions, environmental factors or usage.
6
Manual No. 4111-0025
March 2011
May 2012
NOTES
This page intentionally left blank
Manual No. 4111-0025
March 2011
May 2012
7
INTRODUCTION
General Information
DL-NL-TS Series Edge-of-Dock levelers are available
in the following sizes, weight capacities, and options:
Dimensions and Capacities
Model # - Deck - Width
Total Unit
Width
DL-6666” 104”
20,000
DL-7272” 110”
25,000
DL-7878” 116”
Congratulations on your choice of a DLM Edge-ofDock leveler. This manual covers the DL-NL-TS series
mechanical Edge-of-Dock levelers.
Designed by DLM to be a marvel of simplicity and
efficiency, your dock leveler, when properly installed,
will provide many years of trouble-free performance
with an absolute minimum of maintenance. To obtain
maximum performance and longest possible use,
a simple program of preventive maintenance is
recommended.
Once again, thank you and congratulations on your
purchase of a DLM mechanical Edge-of-Dock leveler.
Comparative Industry Rating
30,000
(N/A for DL-78)
Dimensions and Capacities
Model # - Deck - Width
Total Unit
Width
Comparative Industry Rating
NL-6666” 104”
20,000
NL-7272” 110”
25,000
30,000
35,000
NL-7878” 116”
(N/A for NL-84)
NL-8484” 122”
Dimensions and Capacities
Model # - Deck - Width
Total Unit
Width
Comparative Industry Rating
TS-66 66”104”
20,000
TS-72 72”110”
25,000
30,000
35,000
TS-78 78”116”
(N/A for TS-78 & 84)
TS-84 84”122”
8
Manual No. 4111-0025
March 2011
May 2012
INSTALLATION
INSTALLATION DETAILS
50 INCH
PREFERRED
Only trained installation professionals with the
proper equipment should install this product.
IMPORTANT
DO NOT remove the shipping bands around the
dock leveler lip until instructed to do so.
Manual No. 4111-0025
March 2011
May 2012
Post safety warnings and barricade the work area at
dock level and ground level to prevent unauthorized
use of the dock leveler before installation has been
completed.
Failure to follow the installation instructions can
result in damage to dock leveler, the facilities, and/
or serious personal injury or death.
9
INSTALLATION
E.O.D. Installation Instructions - Flush Mount - Weld On
Follow all safety precautions prior to installation.
A flush mount weld on application is used when an 8”
wide (minimum) embed channel is securely anchored
into the concrete at the dock edge, and the dock height
is adequate.
Installation Steps:
1. Remove all existing bumper material and
protruding objects from dock edge. Clean and
sweep dock edge free of debris and flammable
chemicals before installing unit.
2. 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
being flush with the top of the embedded channel.
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 flush with the
top of the embedded channel. Tack right hand
end to dock steel.
8. Installer must remove all welding slag, and repaint
welded areas.
9. Installer must adjust springs on all mechanical
Edge of Dock levelers to provide desired tension
for smooth operation. Stand in front of leveler, with
the unit raised and secured in the maintenance
position, loosen jam nut on the underside of the
linkage pin. To start allow about 3/4” to 1” of
threads between top of jam nut and linkage pin.
Using an open faced wrench, hold locknut on
inside of spring while tightening threaded bolt until
washer on top side of spring closes up tight to jam
nut. Test operation of unit. Further adjust spring
tension if needed by advancing jam nut toward
linkage pin and tightening threaded rod. After
desired unit operation is achieved, tighten jam
nut to outer washer on spring. Springs must be
adjusted alternately to have equal spring tension.
10. Before install is complete, installer must make
a final operational check of dock leveler to
verify all phases of install are correct. Installer
must complete, sign and return the Installation
Checklist upon completion. Reference page 22
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 warpage,
but complete weld across the top must be
completed.
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.
10
Manual No. 4111-0025
March 2011
May 2012
Manual No. 4111-0025
March 2011
May 2012
DESCRIPTION
Top of base plate and bumper
cover plate to be flush with top of
dock floor and embedded channel
Apply continuous bevel weld
across both bumpers and length of
base plate.
NOTE
1
2
Securely block or support ramp and lip when in
vertical positions. Lack of proper bracing can result
in ramp dropping during adjustment or installation
causing personal injury or damage to unit.
INSTALLATION
11
INSTALLATION
E.O.D. Installation Instructions - Ramp­­­­­­Mount - Weld/Bolt On
Follow all safety precautions prior to installation.
A ramp mount weld on application is used when adequate
dock steel is securely anchored in the concrete at the dock
edge, but the existing dock height is too low and the dock
leveler must be installed above this height to correct this
situation.
Installation Steps:
1. Remove all existing bumper material and protruding
objects from dock edge. Clean and sweep dock
edge free of debris and flammable chemicals before
installing unit.
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. At the points marked to each side of center, measure
and mark points 7 - 3/4” below dock level less height
the unit is to be raised to locate bottom of base plate.
This will locate the top of the base plate X” above dock
level.
4. Using a proper lifting device, raise and position the
leveler base plate to marked position. While holding
base plate tight against dock face, tack weld securely
to dock steel on left hand end of leveler. Check right
hand end of base plate, ensure that end is against dock
steel and that the bottom of the base plate is even with
the marks made previously. Tack right hand end to
dock steel. Support unit until final welding is ready to
complete.
5. Position bump blocks out approximately 5/8” out from
the edge of the inside flange of the bump block to the
end of the base plate. Position the top of the tread
cover plate on the bump blocks to be flush with the
top of the base plate. Tack weld bump blocks to dock
steel.
6. 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”.
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,
12
groove concrete approximately 3/4” deep by 2” wide,
and should be the entire length of ramp plate.
9. Break tack welds holding ramp in place, slide ramp
plate back into position with the top of the ramp plate
flush with the top of the base plate. Tack weld each
end and center of ramp plate to base plate.
10. Drill 5/8” dia. by 5” deep holes through ramp plate at
back edge. Install anchor bolts per manufacturers
specifications, and tighten securely. Weld anchor bolt
nuts to ramp plate 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.
11. Complete welding of tacked parts as follows:
A. Apply continuous weld across top of each bumper
and base plate to ramp plate. Skip welding is
acceptable to prevent warpage, but complete
weld must be completed.
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.
12. Installer must remove all welding slag, and repaint
welded areas.
13. Installer must adjust main springs on all mechanical
Edge of Dock levelers to provide desired tension for
smooth operation. Stand on ground in front of leveler,
with the unit raised and secured in the maintenance
position, loosen jam nut on the underside of the linkage
pin. To start allow about 3/4” to 1” of threads between
top of jam nut and linkage pin. Using an open faced
wrench, hold locknut on inside of spring while tightening
threaded bolt until washer on top side of spring closes
up tight to jam nut. Test operation of unit. Further
adjust spring tension if needed by advancing jam nut
toward linkage pin and tightening threaded rod. After
desired unit operation is achieved, tighten jam nut to
outer washer on spring. Springs must be adjusted
alternately to have equal spring tension.
14. Before install is complete, installer must make a final
operational check of dock leveler to verify all phases
of install are correct. Installer must complete, sign,
and return the Installation Checklist upon completion.
Reference page 22
Manual No. 4111-0025
March 2011
May 2012
Manual No. 4111-0025
March 2011
May 2012
DESCRIPTION
Top of base plate and bumper
cover plate to be flush with top of
ramp plate.
Apply continuous bevel weld
across both bumpers and length of
base plate.
To figure ramp plate length, need
12” ramp for every 1-1/2” of rise
to ramp.
NOTE
1
2
3
Securely block or support ramp and lip when in
vertical positions. Lack of proper bracing can result
in ramp dropping during adjustment or installation
causing personal injury or damage to unit.
INSTALLATION
13
INSTALLATION
E.O.D. Installation Instructions - Flush Mount - Bolt On
Follow all safety precautions prior to installation.
A flush mount bolt on application is used when there
is no steel on dock edge, and the dock height is
adequate. Additional steel ramp plate and bolting is
required with this type of installation.
Installation Steps:
1. Remove all existing bumper material and
protruding objects from dock edge. Clean and
sweep dock edge free of debris and flammable
chemicals before installing unit.
2. 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. At the points marked to each side of center,
measure and mark points 7-1/2” below dock level
(for 1/4” ramp plate) to locate position for bottom
of base plate. This position will place the top of
the base plate 1/4” above the dock floor. This
position will vary with ramp plate thickness.
4. Mark line connecting these points and position
support angles. Position angles as shown in
installation drawing provided. Mark center of
holes in each of the support angels.
5. At center marks, drill holes 5/8” dial. by 5”
deep in concrete. Install anchor bolts with
washers through support angles into holes in
concrete. Tighten bolts until support angles are
secure. Follow anchor manufacturers installation
instructions for proper installation.
6. Using a proper lifting device, raise and position
the leveler base plate to marked position, while
resting on the support angles. While holding base
plate tight against dock face, tack weld securely
to support angles.
7. Drill 5/8” dia. by 5” deep holes in concrete through
holes in base plate, and install anchor bolts with
washers and tighten securely.
8. Position bump blocks out approximately 5/8” out
from the edge of the inside flange of the bump
block to the end of the base plate. Position the
top of the tread cover plate on the bump blocks to
be 1/4” above dock level. Note that this placement
will vary with ramp plate thickness. Mark centers
of holes in bump block flanges.
14
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.
10. Place steel ramp plate in position, flush with top
backside of base plate. Mark along full length
of base edge of ramp plate. Slide ramp plate
forward over dock leveler the width of brushing
tool, approximately 2”.
11. 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.
12. 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 ramp
plate.
13. Break tack welds holding ramp in place, slide
ramp plate back into position with the top of the
ramp plate flush with the top of the base plate.
Tack weld each end and center of ramp plate to
base plate.
14. Drill 5/8” dia. by 5” deep holes through ramp plate at
back edge. Install anchor bolts per manufacturers
specifications, and tighten securely. Weld anchor
bolt nuts to ramp plate 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.
15. Complete welding of tacked parts as follows:
A.Apply continuous weld across top of each
bumper and base plate to ramp plate. Skip
welding is acceptable to prevent warpage,
but complete weld must be completed.
B.Weld bottom of base plate support angles
using a 1/4” fillet weld.
16. Installer must remove all welding slag, and
repaint welded ares.
17. Installer must adjust main springs on all mechanical
edge of dock levelers to provide desired tension
for smooth operation. Stand on ground in front
Manual No. 4111-0025
March 2011
May 2012
INSTALLATION
of lever, with the unit raised and secured in the
maintenance position, loosen jam nut on the
underside of the linkage pin. To start allow about
3/4” to 1” of threads between top of jam nut
and linkage pin. Using an open faced wrench,
hold locknut on inside of spring while tightening
threaded bolt until washer on top side of spring
closes up tight to ram nut. Test operation of
unit. Further adjust spring tension if needed
by advancing jam nut toward linkage pin and
tightening threaded rod. After desired operation
is achieved, tighten jam nut to outer washer on
spring. Springs must be adjusted alternately to
have equal spring tension.
18. Before install is complete, installer must make
a final operation check of dock leveler to verify
all phases of install are correct. Installer must
complete, sign and return the Installation Checklist
up on completion. reference page 22
Manual No. 4111-0025
March 2011
May 2012
Securely block or support ramp and lip when in
vertical positions. Lack of proper bracing can result
in ramp dropping during adjustment or installation
causing personal injury or damage to unit.
NOTE
DESCRIPTION
1
Top of base plate and bumper
cover plate to be flush with top of
ramp plate.
2
Apply continuous bevel weld
across both bumpers and length of
base plate.
15
INSTALLATION
E.O.D. Installation Instructions - Ramp Mount - Weld On w/Formed Angle
Follow all safety precautions prior to installation.
A ramp mount-weld on used with a formed angle application
is used when dock edge is damaged, there is no dock steel
securely anchored into the concrete, and the dock height is
too low and leveler must be installed above this height to
correct this situation.
Installation Steps:
1. Remove all existing bumper material and protruding
objects from dock edge. Clean and sweep dock
edge free of debris and flammable chemicals before
installing unit.
2. Review and follow formed angle installation instructions
prior to leveler installation. Page 18
3. 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.
4. At the points marked to each side of center, measure
and mark points 7-3/4” below dock level less height the
unit is to be raised to locate bottom of base plate. This
will locate the top of the base plate X” above dock level.
5. Using a proper lifting device, raise and position the
leveler base plate to marked position. While holding
base plate tight against dock face, tack weld securely
to dock steel on left hand end of leveler. Check right
hand end of base plate, ensure that end is against dock
steel and that the bottom of the base plate is even with
the marks made previously. Tack right hand end to
dock steel. Support unit until final welding is ready to
complete.
6. Position bump blocks out approximately 5/8” out from
the edge of the inside flange of the bump block to the
end of the base plate. Position the top of the tread
cover plate on the bump blocks to be flush with the
top of the base plate. Tack weld bump blocks to dock
steel.
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.
16
9. 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.
10. Break tack welds holding ramp in place, slide ramp
plate back into position with the top of the ramp plate
flush with the top of the base plate. Tack weld each
end and center of ramp plate to base plate.
11. Drill 5/8” dia. by 5” deep holes through ramp plate at
back edge. Install anchor bolts per manufacturers
specifications, and tighten securely. Weld anchor bolt
nuts to ramp plate 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.
12. Complete welding of tacked parts as follows:
A. Apply continuous weld across top of each bumper
and base plate to ramp plate. Skip welding is
acceptable to prevent warpage, but complete
weld must be completed.
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.
13. Installer must remove all welding slag, and repaint
welded areas.
14. Installer must adjust main springs on all mechanical
Edge of Dock levelers to provide desired tension for
smooth operation. Stand on ground in front of leveler,
with the unit raised and secured in the maintenance
position, loosen jam nut on the underside of the linkage
pin. To start allow about 3/4” to 1” of threads between
top of jam nut and linkage pin. Using an open faced
wrench, hold locknut on inside of spring while tightening
threaded bolt until washer on top side sprint closes
up tight to jam nut. Test operation of unit. Further
adjust spring tension if needed by advancing jam nut
toward linkage pin and tightening threaded rod. After
desired unit operation is achieved, tighten jam nut to
outer washer on spring. Springs must be adjusted
alternately to have equal spring tension.
15. Before install is complete, installer must make a final
operational check of dock leveler to verify all phases
of install are correct. Installer must complete, sign,
and return the Installation Checklist upon completion.
reference page 22.
Manual No. 4111-0025
March 2011
May 2012
Manual No. 4111-0025
March 2011
May 2012
DESCRIPTION
Top of base plate and bumper
cover plate to be flush with top of
ramp plate.
Apply continuous bevel weld
across both bumpers and length of
base plate.
To figure ramp plate length, need
12” ramp for every 1-1/2” of rise
to ramp.
To install formed angle, see formed
angle installation instructions.
NOTE
1
2
3
4
Securely block or support ramp and lip when in
vertical positions. Lack of proper bracing can result
in ramp dropping during adjustment or installation
causing personal injury or damage to unit.
INSTALLATION
17
INSTALLATION
E.O.D. Installation Instructions - Formed Angle
Follow all safety precautions prior to installation.
A formed angle is used when there is no existing
dock steel and concrete at the dock edge has been
damaged. The formed angle is required to rebuild the
damaged concrete edge for a proper installation if the
dock height is adequate.
Installation Steps:
1. Remove all existing bumper material and
protruding objects from dock edge. Clean and
sweep dock edge free of debris and flammable
chemicals before installing unit.
2. 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 bushing 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.
18
Manual No. 4111-0025
March 2011
May 2012
Manual No. 4111-0025
March 2011
May 2012
1
NOTE
Secure formed angle with (18)
anchor bolts, (9) each side
DESCRIPTION
INSTALLATION
19
INSTALLATION
E.O.D. Installation Instructions - Ramp and Face Plate
Follow all safety precautions prior to installation.
A ramp mount requiring a face plate application is
used when there is no existing dock steel and the
concrete at the dock edge has been damaged. The
dock height can be low, high, or adequate for this
application, however, the face plate and ramp plate are
required to rebuild the damaged concrete edge.­­­
Installation Steps:
1. Remove all existing bumper material and
protruding objects from dock edge. Clean and
sweep dock edge free of debris and flammable
chemicals before installing unit.
2. At chosen location for the face plate, locate the
center of space and mark a point half of the face
plate width to the left and right.
5/8” dia. by 5” deep holes through ramp plate at
back edge. Install anchor bolts per manufacturers
specifications, and tighten securely. Weld anchor
bolt nuts to ramp plate using a 1/4” fillet weld all
the way around the nut. Cut off any portion of
the anchor bolt exposed through he 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.
11. Apply a continuous fillet weld at the created joint
between the face plate and ramp. Skip welding
should be the proper method used to avoid
warpage, and a complete weld must be achieved.­­­
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.
10. Break tack welds and slide ramp back until
forward edge is flush with dock face. Tack weld
ramp on each end and center to face plate. Drill
20
Manual No. 4111-0025
March 2011
May 2012
Manual No. 4111-0025
March 2011
May 2012
Secure formed angle with (18)
anchor bolts, (9) each side
Apply continuous fillet weld across
entire length of face plate and ramp
2
DESCRIPTION
1
NOTE
INSTALLATION
21
INSTALLATION - CHECK LIST
E.O.D. Installation Checklist
Date: __________
Order No.: __________
Serial Number:______________
Installer: ____________________________
Customer Name: _____________________
Address: ____________________________
City/State: ___________________________
Zip: __________
Phone: _________________
1. Unit is properly aligned and installed properly.
2. All welding has been fully completed.
3. Welding slag has been removed.



4. Welds and other affected areas have been painted.
5. Springs have been properly adjusted.


6. Unit is functioning properly without fault.

I hereby certify that all installation and/or repair
work has been inspected and approved by:
Company: ________________________
Date Completed: _________________
Name: ___________________________
Signature: ______________________
A copy of this document must be signed and faxed to Systems, Inc
at 262-257-7399 to the attention Customer Service/ Technical Service. To be placed
in job folder.
Copy as needed
22
Manual No. 4111-0025
March 2011
May 2012
OPERATION
OPERATING INSTRUCTIONS FOR DL-SERIES
1. With leveler in stored position, back the truck into
position against the bump blocks.
2. Truck should be chocked before operation of leveler.
3. While standing behind the unit, use lifting hook to
pull back and up on rivet OR engage on the notch
until leveler is cocked.
4. Then actuate the leveler by placing the lifting hook
into lip plate notch and manually lifting the hook
until the lip plate section extends over the truck
bed. Lower lip to bed of the trailer.
5. When truck departs leveler automatically returns
to stored position.
RIVET
NOTCH
Only trained personnel should operate the dock
leveler.
DO NOT use a broken or damaged dock leveler.
Make sure proper service and maintenance
procedures have been performed on leveler before
using.
Truck/trailer wheels must be chocked unless the
truck restraint is used. Never remove the wheel
chocks until loading/unloading is finished and truck
driver has been given permission to leave.
Stay clear of dock leveler when freight carrier is
entering or leaving dock area.
Make sure platform lip rests on the truck/trailer bed
with at least 4 in. (102 mm) of overlap.
DO NOT move or use the dock leveler if anyone is
under or in front of leveler.
Maintain a safe distance from side edges of leveler
during the loading/unloading process.
Keep hands and feet clear of pinch points. Avoid
putting any part of your body near moving parts.
Failure to follow these instructions may result in
serious personal injury or death.
Failure to follow these instructions may result in
severe personal injury or death.
Manual No. 4111-0025
March 2011
May 2012
23
OPERATION
OPERATING INSTRUCTIONS FOR NL & TS SERIES
1. Grasp the captured operating handle and raise to
its full extended length.
3. Push forward on operating handle against the rivet,
rotating leveler out onto truck.
2. Move handle toward you, rotating center plate
back past vertical. Lip plate extend link arm will
engage at this time.
4. Return handle to stored position.
5. To remove leveler from truck repeat step number one
until the lip clears the bed of the trailer. Return leveler and
handle to the stored position. OR When the truck departs,
the unit will automatically return to the stored position.
RIVET
24
Manual No. 4111-0025
March 2011
May 2012
MAINTENANCE
PERIODIC MAINTENANCE
When maintenance is to be performed in front of the
dock leveler, support the lip with the handle in the
maintenance prop position OR by other means.
Always post safety warnings and barricade the
work area at dock level and ground level to prevent
unauthorized use of the dock leveler before
maintenance is complete. Failure to do this may
result in serious personal injury or death.
Put handle into maintenance prop position by removing
bolt and locknut at base of handle assembly. Pull
handle out of roller arm assembly and place into
maintenance prop receiver.
If maintenance requires that the lip be in the extended
position, raise the lip by hand and support the lip with
the lip maintenance prop.
Always stand clear of the dock leveler lip when
working in front of the dock leveler. Failure to do
this may result in serious personal injury or death.
Securely block or support ramp and lip when
in vertical position. Lack of proper bracing can
result in ramp dropping during maintenance causing
personal injury or damage to unit.
Quarterly Maintenance
Regular maintenance must be performed on a weekly
and quarterly schedule.
•
Follow weekly maintenance schedule in addition
to the following:
Weekly Maintenance
•
Lubricate the following areas with light-weight
machine oil:
•
Operate the dock leveler through the complete
operating cycle to maintain lubrication.
•
Look for cracks or damage. Repair or replace
damaged or cracked parts as needed.
•
Inspect the platform hinge and the lip hinge
areas. The hinge areas must be kept free of
dirt and debris. Build-up of foreign material in
the hinge areas will increase wear and cause
abnormal operation. reference page 9.
Extend link arm pivots
Lip linkage pivot
Operating link pivots
Torsion arm pivots
•
Lubricate the following areas with white lithium
grease:
Lip plate grease fittings
Base plate grease fittings
Note: Failure to lubricate the dock leveler will
cause abnormal operation of the leveler.
Manual No. 4111-0025
March 2011
May 2012
25
TROUBLESHOOTING
Symptom
Unit does not operate
properly
Extended link arm does
not latch out lip or
unlatch
Possible Cause
Debris impacted on or
around the leveler
Clean out debris on or around leveler
Insufficient lubrication
Lubricate leveler
Excessive weight on top of
deck
Remove weight from deck.
Main springs need more
tension or less tension
Adjust main spring tension as needed
Damaged or missing parts
Repair of replace as needed
Debris impacted in extended Clean out debris from extended link arm
link arm
Extended link arm needs
lubrication
26
Solution
Lubricated extended link arm
Manual No. 4111-0025
March 2011
May 2012
PARTS
5
DL-X Series
6
1
5
2
9
6
10
4
11
7
3
S
4
Y
S
T
E
M
S,
P O W E R A
D
I
N
C.
L o a d i n g D o c k E q u i p m e n
DL-X MODEL - BILL OF MATERIAL
DRAWN BY
9
SR
TOLERANCES
(UNLESS OTHERWISE NOTED)
FRACTIONAL: `1/32"
DECIMAL:
8
CHECKED BY
1
SIZE/CAPACITY
DESCRIPTION
PART NUMBER (15”) LIP
PART NUMBER (17”LIP)
1
6620/25
Lip Plate & Hinge Assembly
DOTH-3112
DOTH-3142
1
6630
Lip Plate & Hinge Assembly
DOTH-3114
DOTH-3116
1
7220/25
Lip Plate & Hinge Assembly
DOTH-3130
DOTH-3154
1
7230
Lip Plate & Hinge Assembly
DOTH-3126
DOTH-3128
1
7820/25
Lip Plate & Hinge Assembly
DOTH-3939
DOTH-3971
1
6620/25
Center Plate & Hinge Assembly
DOTH-3200
6630
Center Plate & Hinge Assembly
DOTH-3243
1
7220/25
Center Plate & Hinge Assembly
DOTH-3210
1
7230
Center Plate & Hinge Assembly
DOTH-3245
1
7820/25
Center Plate & Hinge Assembly
DOTH-3942
1
ALL
Base Plate & Hinge Assembly
Consult Factory
2
All 66
Hinge Pin
DOTH-3104
2
All 72
Hinge Pin
DOTH-3122
2
All78
Hinge Pin
DOTH-3946
5
2
All
Rivet - Button
DOTH-2400
6
2
All
Rivet - Flat
DOTH-2398
1
6620/25/30, 7220/25
Spring Linkage Assy - X-Regular
DOTH-3618
1
7230, 7820/25
Spring Linkage Assy - X-Hvy Duty
DOTH-3630
DOTH-3342
2
3
4
7
This print is the property of Systems, Inc. and represents a proprietary article in which Systems, Inc. re
patent and other rights, including exclusive rights of use and/or manufacture and/or sale. Possession o
not convey any permission to reproduce, print or manufacture the article or articles shown therein, suc
granted only by written authorization signed by an officer or other authorized agent of Systems,Inc. the
QTY
1
8
1
All
Lifting Hook
9
2
All
Extra Hvy Duty Bumper Blocks
DBBS-3500
10
2
All
X-Gusset
DOTH-3589
11
-
All
Secondary Gussets
DOTH-3319
Manual No. 4111-0025
March 2011
May 2012
5/9/2
DL-X-1
.00 = `.01"
.000 = `.005"
ANGULAR: `1~
ITEM
DATE
DRAWING NO.
27
PARTS
NL-X Series
28
Manual No. 4111-0025
March 2011
May 2012
PARTS
ITEM
1
2
3
4
QTY
SIZE/CAPACITY
DESCRIPTION
PART NUMBER (15”) LIP
PART NUMBER (17”LIP)
1
6620/25
Lip Plate & Hinge Assembly
DOTH-4047
DOTH-4048
1
6630
Lip Plate & Hinge Assembly
DOTH-4049
DOTH-4050
1
6635
Lip Plate & Hinge Assembly
DOTH-4051
DOTH-4052
1
7220/25
Lip Plate & Hinge Assembly
DOTH-4053
DOTH-4054
1
7230
Lip Plate & Hinge Assembly
DOTH-4055
DOTH-4056
1
7235
Lip Plate & Hinge Assembly
DOTH-4057
DOTH-3167
1
7820/25
Lip Plate & Hinge Assembly
DOTH-4058
DOTH-4059
1
7830
Lip Plate & Hinge Assembly
DOTH-3924
DOTH-4060
1
8420/25
Lip Plate & Hinge Assembly
DOTH-3156
DOTH-3155
DOTH-4061
1
8430
Lip Plate & Hinge Assembly
DOTH-3159
1
6620/25
Center Plate & Hinge Assembly
DOTH-4062
1
6630
Center Plate & Hinge Assembly
DOTH-4063
1
6635
Center Plate & Hinge Assembly
DOTH-4064
1
7220/25
Center Plate & Hinge Assembly
DOTH-4065
1
7230
Center Plate & Hinge Assembly
DOTH-4066
1
7235
Center Plate & Hinge Assembly
DOTH-3258
1
7820/25
Center Plate & Hinge Assembly
DOTH-4067
1
7830
Center Plate & Hinge Assembly
DOTH-3923
1
8420/25
Center Plate & Hinge Assembly
DOTH-3242
1
8430
Center Plate & Hinge Assembly
DOTH-3241
1
ALL
Base Plate & Hinge Assembly
Consult Factory
2
6620/25/30
Hinge Pin
DOTH-3104
2
6635
Hinge Pin
DOTH-4312
2
7220/25/30
Hinge Pin
DOTH-3122
2
7235
Hinge Pin
DOTH-4313
2
7820/25/30
Hinge Pin
DOTH-3946
2
8420/25/30
Hinge Pin
DOTH-3920
5
2
All
Rivet - Button
DOTH-2400
6
2
All
Rivet - Flat
DOTH-2398
7
2
All
Extra Hvy Duty Bumper Blocks
DBBS-3500
1
6620/25/30, 7220/25
Spring Linkage Assy - X-Regular
DOTH-3618
8
1
6635,7230,7820/25,
8420/25
Spring Linkage Assy - X-Hvy Duty
DOTH-3630
1
7235, 7830/35, 8430
Spring Linkage Assy - 3 Spring
DOTH-3626
9
2
All
X-Gusset
DOTH-3589
10
11
-
All
Secondary Gussets
DOTH-3319
1
66/7220-30
NL Roller Arm Assembly - Open
DOTH-3834
1
78/84
NLIII Operating Link Assembly
DOTH-3696
1
35K Only
NLIII Operating Link Assembly
DOTH-3697
1
66/7220-30
NL Pipe Handle Assembly
DOTH-3833
1
66/7235 - 78/84
NLIII Hanlde Assembly
DOTH-3694
13
1
All
Extend Link Arm
DOTH-3585
14
1
All
Extend Link Arm Stop
DOTH-3586
15
2
All
Pivot Block
DOTH-3316
16
1
All
Shoulder Bolt
DOTH-2061
17
1
All
Locknut
DOTH-2136
12
18
1
All
Lip Stop
DOTH-3734
19
1
All
NLIII Handle Holder
DOTH-3695
Manual No. 4111-0025
March 2011
May 2012
29
PARTS
TS Series
6
16
15
14
12
2
11
4
1
5
9
13
8
3
4
18
19
20
S
Y
S
L o a d i n
17
NL-RR MO
DRAWN BY
21
SR
TOLERANCES
10
(UNLESS OTHERWISE NOTED)
FRACTIONAL: `1/32"
DECIMAL:
.00 = `.01"
.000 = `.005"
7
30
ANGULAR: `1~
This print is the property of Systems, I
patent and other rights, including exclu
not convey any permission to reprodu
granted only by written authorization s
Manual No. 4111-0025
March 2011
May 2012
PARTS
ITEM
QTY
SIZE/CAPACITY
DESCRIPTION
PART NUMBER (15”) LIP
PART NUMBER (17”LIP)
1
6620/25
Lip Plate & Hinge Assembly
DOTH-4068
DOTH-4069
1
6630
Lip Plate & Hinge Assembly
DOTH-4070
DOTH-4071
1
6635
Lip Plate & Hinge Assembly
DOTH-4072
DOTH-4073
1
7220/25
Lip Plate & Hinge Assembly
DOTH-4074
DOTH-4075
1
7230
Lip Plate & Hinge Assembly
DOTH-4076
DOTH-4077
1
7235
Lip Plate & Hinge Assembly
DOTH-4078
DOTH-4079
1
7820/25
Lip Plate & Hinge Assembly
DOTH-4080
DOTH-4081
1
7830
Lip Plate & Hinge Assembly
DOTH-4082
DOTH-4083
1
8420/25
Lip Plate & Hinge Assembly
DOTH-4084
DOTH-4085
1
8430
Lip Plate & Hinge Assembly
DOTH-4086
DOTH-4087
1
6620/25
Center Plate & Hinge Assembly
DOTH-4088
1
6630
Center Plate & Hinge Assembly
DOTH-4089
1
6635
Center Plate & Hinge Assembly
DOTH-4090
1
7220/25
Center Plate & Hinge Assembly
DOTH-4091
1
7230
Center Plate & Hinge Assembly
DOTH-4092
1
7235
Center Plate & Hinge Assembly
DOTH-4093
1
7820/25
Center Plate & Hinge Assembly
DOTH-4094
1
7830
Center Plate & Hinge Assembly
DOTH-4095
1
8420/25
Center Plate & Hinge Assembly
DOTH-4096
1
8430
Center Plate & Hinge Assembly
DOTH-4097
1
ALL
Base Plate & Hinge Assembly
Consult Factory
2
6620/25/30
Hinge Pin
DOTH-3104
2
6635
Hinge Pin
DOTH-4312
2
7220/25/30
Hinge Pin
DOTH-3122
2
7235
Hinge Pin
DOTH-4313
2
7820/25/30
Hinge Pin
DOTH-3946
2
8420/25/30
Hinge Pin
DOTH-3920
5
2
All
Rivet - Button
DOTH-2400
6
2
All
Rivet - Flat
DOTH-2398
1
2
3
4
7
All
Extra Hvy Duty Bumper Blocks
DBBS-3500
8
2
All
HL LInkage Adder Assembly
DOTH-3675
9
2
All
X-Gusset
DOTH-3589
1
66/7220-30
NLI Operating Link Assembly
DOTH-3726
1
78/84
NLIII Operating Link Assembly
DOTH-3696
1
35K Only
NLIII Operating Link Assembly
DOTH-3697
10
1
66/7220-30
NLI Handle Assembly (Tube)
DOTH-3752
11
1
Optional
NLI Handle Assembly (Solid)
DOTH-3769
1
78/84
NLIII Handle Assembly
DOTH-3694
12
1
All
Extend Link Arm
DOTH-3585
13
1
All
Extend Link Arm Stop
DOTH-3586
14
2
All
Pivot Block
DOTH-3316
15
1
All
Shoulder Bolt
DOTH-2061
16
1
All
Locknut
DOTH-2136
DOTH-3734
17
1
All
Lip Stop
18
1
All
Pivot Block
DOTH-3597
19
2
All
Cotter Pin
DOTH_2375
20
1
All
Spring
DOTH-2559
21
1
All
NLIII Handle Holder
DOTH-3695
Manual No. 4111-0025
March 2011
May 2012
31
PARTS
DOTH-3618 Replacement Extension Spring Kits (Includes all parts listed below)
Item Quantity Part Number
1
2
3
4
5
6
7
8
9
10
1
2
4
2
1
2
2
4
2
2
Description
DOTH-3620
Bar - Lip linkage
DOTH-2061
1-1/2” Shoulder Bolt
DOTH-2131
Nylon Lock Nut
DOTH-3621
Bar - Base Linkage
DOTH-2347
Pin - Linkage
DOTH-2390
Roll Pin
DOTH-2520 Spring, Extension, Reg., Painted
DOTH-2209 Washer - Fender - Zinc Plated
DOTH-2045 HHCS - Grade 5 - Zinc Plated
DOTH-2130 Hex Nut - Zinc Plated - Grade 5
Extension Spring Adjustment Instructions
1. Lift and secure leveler in full upright maintenance
position to start.
2. Loosen jam nut A by turning the nut clockwise. Once
jam nut is loosened, use an open faced wrench to
hold the locknut B inside the spring body. Tighten the
hex bolt C by turning clockwise.
3. To start, the top fender washer should be tightened
until the washer is about one and a half inches from
the underside of the linkage pin.
4. Tighten the jam but A by turning the nut clockwise
until the jam nut is tight against the top fender
washer.
5. Test leveler operation. If spring tension is not
sufficient, repeat the previous steps until desired
tension is achieved.
6. Return leveler to stored position.
32
Manual No. 4111-0025
March 2011
May 2012
PARTS
DOTH-3630 Replacement Extension Spring Kits (Includes all parts listed below)
Item Quantity Part Number
1
2
3
4
5
6
7
8
9
10
1
2
4
2
1
2
2
4
2
2
Description
DOTH-3620
Bar - Lip linkage
DOTH-2061
1-1/2” Shoulder Bolt
DOTH-2131
Nylon Lock Nut
DOTH-3621
Bar - Base Linkage
DOTH-2347
Pin - Linkage
DOTH-2390
Roll Pin
DOTH-2521 Spring, Extension, Reg., Painted
DOTH-2209 Washer - Fender - Zinc Plated
DOTH-2045 HHCS - Grade 5 - Zinc Plated
DOTH-2130 Hex Nut - Zinc Plated - Grade 5
Extension Spring Adjustment Instructions
1. Lift and secure leveler in full upright maintenance
position to start.
2. Loosen jam nut A by turning the nut clockwise. Once
jam nut is loosened, use an open faced wrench to
hold the locknut B inside the spring body. Tighten the
hex bolt C by turning clockwise.
3. To start, the top fender washer should be tightened
until the washer is about one and a half inches from
the underside of the linkage pin.
4. Tighten the jam but A by turning the nut clockwise
until the jam nut is tight against the top fender
washer.
5. Test leveler operation. If spring tension is not
sufficient, repeat the previous steps until desired
tension is achieved.
6. Return leveler to stored position.
Manual No. 4111-0025
March 2011
May 2012
33
PARTS
DOTH-3675 Torsion Spring Kit (Includes all parts listed below)
Item Quantity Part Number
1
2
3
4
5
6
7
8
9
10
11
12
1
1
1
1
1
1
3
1
1
2
2
2
Description
DOTH-3305 L&R Gusset Assembly w/Bearing
DOTH-3327
HL Model Gusset w/Guide
DOTH-3679
HL Torsion Tube Assembly
DOTH-3676
HL Torsion Bar Assembly
DOTH-2509
Spring Torsion
DOTH-3316
Bar-Pivot
DOTH-2033 HHCS - Grade 2 - Zinc Plated
DOTH-2121
Nylon Lock Nut
DOTH-3682
HL Plate Locking Torsion
DOTH-3617
Bar - 6630 L-Linkage
DOTH-2061
1-1/2” Shoulder Bolt
DOTH-2136
Center Locknut
Torsion Spring Adjustment Instructions
1. Lift and secure leveler in full upright maintenance
position to start.
2. Remove nut (A) from hex bolt (B)
3. Place crescent wrench on torsion tube assembly,
apply enough downward force to tube assembly until
hex bolt can be removed.
4. Continue to apply downward force until flange on
tube assembly has the next hole in series come into
alignment with hex bolt hole.
5. Insert hex bolt (B) through the flange on the tube
assembly, and tighten nut until secure.
6. Test leveler operation. If spring tension is not
sufficient, repeat the previous steps until desired
tension is achieved.
7. Return leveler to stored position.
34
Manual No. 4111-0025
March 2011
May 2012
PARTS
CURRENT VS 2005 and Older
Item Quantity Part Number
1
1
DOTH-3730
2
1
DOTH-3744
3
1
DOTH-3585
4
1
DOTH-3586
Manual No. 4111-0025
March 2011
May 2012
Description
Bar - NL Extended Link Arm
(pre 09/2005)
NL SB Catch Assembly
(pre 09/2005)
Bar - NL Extend Link Arm
(09/2005 - present)
NL SB Catch Assembly
(09/2005 - present)
35
PARTS
HANDLE OPTIONS
Item Quantity Part Number
1
2
3
4
36
1
1
1
1
Description
DOTH-3752
NL Handle Assembly (Tube)
DOTH-3769
NL Handle Assembly (Solid)
DOTH-3691 NLII Handle Assembly (Formed)
DOTH-3694
NLIII Handle Assembly
Manual No. 4111-0025
March 2011
May 2012
PARTS
OPERATING LINK OPTIONS
Item Quantity Part Number
1
2
1
1
DOTH-3726
DOTH-3696
3
1
DOTH-3697
4
1
DOTH-2449
Description
NL Operating Link Assembly
NLIII Operating Link Assembly
Operating Link Assembly for all 35K
units (not shown)
Roller Bearing
ITEM QTY PART NO.
1
1 DOTH-3726 NL OPERA
2
1 DOTH-3696 NLIII OPER
3
1 DOTH-3834 NLIII ROLL
PIPE
4
2
1
Manual No. 4111-0025
March 2011
May 2012
37
Item Quantity Part Number
1
1
4
4
4
4
2
DOTH-3537
12” BB Weldment
DOTH-3505
Rubber - Tuf-Cord
DOTH-2056
Hex Head Cap Screw
DOTH-2210
Wahser - Flat - Zinc Plated
DOTH-2208
Washer - Flat
DOTH-2129
Nylon Lock Nut
DBBS-3506 15” Projection x 18” high (option)
1
4
6
5
4
3
2
1
IT
EM
1
Q
TY
1
2
3
4
5
6
Description
P
D AR
O
D
T T
4
D OT H-3 NO
4
O
H
D
T -3 53 .
4
D OT H-2 50 7 1
O
H
0 5
2
D
O TH -22 56 RU " B
TH -2 10 H B B
-2 208 W EX BE WE
B
12
D IL
R
9 W AS HE - LDM ES L O
H
A
T
A
N
YL SH ER D C UF EN CR F M
O ER - F A -C T IPT AT
N
P O
IO E
LO - F LAT SC RD
N RI
AL
C LAT R
K
E
ZI
W
N
N
U
C
T
PL
AT
ED
DBBS-3500 Complete 15” Projection Bumper Assembly
DKIT-3540 Bumper & All Hardware (weldment not included)
4
7/ X 1
1
1/ 6- 2 X
SI
1/ 2" D 14 13
ZE
2
7/ " D IA UN
16
C
I
A
-1
X
4
3U
1/
N
4
C
PARTS
3
4
3
2
4
1
2
5
1
5
6
6
38
Manual No. 4111-0025
March 2011
May 2012
QT
Y
PA
1
DO RT N
2
O
T
DO H-35 .
2
37
TH
-35
DO
12"
1
BIL
1
T
LO
DO H-35 4 AN BB W
15
TH
EL DESC F M
GL
D
-35
E
BA
RIP ATE
ME
-1
17
R
RIA
TIO
12" - BB 2" BB NT
L
N
SL
SL
S
L
I
IDI
NG DING IDE
S
BB
PL TOP
AT
EW
/RU
BB
ER
PARTS
DBBS-3512 Complete 15” Projection Sliding Bumper Assembly
Item Quantity Part Number
1
2
2
1
DOTH-3537
DOTH-3514
DOTH-3515
DOTH-3517
12” BB Weldment
Angle - 12” BB Slide
Bar - BB Sliding Stop
12” Sliding BB Plate w/Rubber
4
3
2
1
IT E
M
1
2
3
4
Description
2
4
4
2
1
1
3
3
Manual No. 4111-0025
March 2011
May 2012
39
MISCELLANEOUS
This page intentionally left blank
40
Manual No. 4111-0025
March 2011
May 2012
MISCELLANEOUS
Customer Information
A
NOTE: The model/serial number decal (A) is located
on the outboard side of the outer most (LH)
gusset or base plate.
When you receive your DL, NL or TS series Edgeof-Dock leveler, write down the dock leveler model
and serial number in the form provided. This will help
ensure safe keeping of the numbers in the event
the model/serial number decal (A) becomes lost or
damaged.
Also, write down DLM’s job number, the company that
installed the dock leveler, and the original owner’s
name. This will all help to identify the specific dock
leveler if more information is required.
When ordering, use part numbers and description
to help identify the item ordered. Do not use “item”
numbers. These are only for locating the position of
the parts. Always give dock leveler MODEL NUMBER
and/or SERIAL NUMBER.
For service, call or contact:
Systems, Inc.
P.O. Box 309
Germantown, WI 53022
Dock Leveler Information
Model
Serial No.
DLM, Job No.
Original Owner Information
Name
Address
Installer Information
Name
Address
Date of
Installation
Phone:(800) 643-5424
Fax: (262) 255-5917
Manual No. 4111-0025
March 2011
May 2012
41
STANDARD PRODUCT WARRANTY
SYSTEMS, INC. warrants that its products will be free from defects in design, materials and workmanship
for a period of one (1) year from the date of shipment. All claims for breach of this warranty must be
made within 30 days after the defect is or can with reasonable care, be detected. In no event shall any
claim be made more than 30 days after this warranty has expired. In order to be entitled to the benefits
of this warranty, the product must have been properly installed, maintained and operated in accordance
with all manufacturer’s recommendations and/or specified design parameters and not otherwise
have been subject to abuse, misuse, misapplication, acts of nature, overloading, unauthorized repair
or modification, application in a corrosive environment or lack of maintenance. Periodic lubrication,
adjustment and inspection in accordance with all manufacturers’ recommendations are the sole
responsibility of the Owner/User.
In the event of a defect, as determined by SYSTEMS INC., covered by this warranty, SYSTEMS INC.
shall remedy such defect by repairing or replacing any defective equipment or parts, bearing the cost
for the parts, labor and transportation. This shall be exclusive remedy for all claims whether based on
contract, negligence or strict liability.
WARRANTY LIMITATIONS
THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES, WHETHER EXPRESSED
OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE. SYSTEMS INC. AND ITS SUBSIDIARIES SHALL
NOT IN ANY EVENT BE LIABLE TO ANYONE, INCLUDING THIRD PARTIES, FOR INCIDENTAL,
CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND INCLUDING BUT NOT LIMITED TO,
BREACH OF WARRANTY, LOSS OF USE, LOSS OF PROFIT, INTERRUPTION OF BUSINESS OR
LOSS OF GOODWILL.