HORMANN HTL2 ISO Dock Leveller Instruction Manual

Instruction Manual for HORMANN models including: HTL2 ISO Dock Leveller, HTL2 ISO, Dock Leveller

Instructions for fitting, operating and maintenance HTL2 ISO

Hörmann Alkmaar / AJO

HTL2 ISO

File Info : application/pdf, 44 Pages, 12.65MB

Instructions HTL2 ISO 1200017139 2023 12 EN

1200017139 / 12.2023

Instructions for fitting, operating and maintenance
HTL2 ISO
ENGLISH

Contents

1 1.1 1.2
2 2.1 2.2 2.3 2.4 2.5 2.6
3
4 4.1 4.2 4.3 4.4 4.5
5 5.1 5.2 5.3 5.4
6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9
7 7.1 7.2 7.3 7.4
8 8.1 8.2 8.3 8.4
9 9.1 9.2
10 10.1 10.2 10.3 10.4
11
12
13 13.1 13.2
14
15
16

About these instructions...................................3 Applicable documents.........................................3 Warnings used.....................................................3
Safety instructions.............................................3 Intended use........................................................3 Non-intended use................................................3 Qualification of personnel....................................3 General safety instructions..................................4 Noise protection ..................................................4 Standards and directives.....................................4
Scope of delivery ...............................................5
Product description...........................................5 Loading capacity .................................................5 Temperature.........................................................6 Seals and insulation ............................................6 Hydraulic system .................................................6 Safety components .............................................6
Fitting requirements ..........................................7 Pit shapes............................................................7 Requirements for the pit ......................................8 Requirements for the base construction ...........11 Requirements for the connection ......................11
Fitting ................................................................ 11 Safety instructions for fitting..............................11 Required tools ...................................................12 Unloading ..........................................................12 Fitting pit model P ............................................13 Fitting frame model FR .....................................16 Fitting frame model F ........................................18 Fitting box model B ...........................................19 Fitting combined fitting models.........................21 Electrical connection .........................................21
Initial start-up...................................................21 Aids....................................................................21 Buffers ...............................................................22 Brief instructions................................................22 Check ................................................................22
Operation..........................................................22 Safety instructions for operation .......................22 Positioning the dock leveller..............................24 Loading and unloading......................................24 Returning to home position ...............................25
Non-operation .................................................25 Home position ...................................................25 Cross traffic .......................................................25
Maintenance ....................................................26 Cleaning and care..............................................26 Inspection and maintenance .............................27 Malfunctions and troubleshooting.....................31 Spare parts ........................................................33
Dismantling and disposal ...............................34
Liability for defects..........................................34
Technical data..................................................34 Data label...........................................................34 Dimensions and effective working range ..........35
Hydraulic system diagram ..............................36
Overview of components................................38
Declaration of conformity ...............................43

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SAFETy INSTRUCTIONS

About these instructions

These instructions are original operating instructions as outlined in EC Directive 2006/42/EC and the Supply of Machinery (Safety) Regulations 2008 No. 1597 (UK).
These instructions apply to dock levellers HTL2 ISO.

1.1

Applicable documents

In addition to these instructions, the following documents must be observed depending on the scope of delivery:

Control operating instructions

1.2

Warnings used

Indicates a danger that can lead to death or injuries.
DANGER
Indicates a danger that immediately leads to death or serious injuries.
WARNING
Indicates a danger that can lead to death or serious injuries.
CAUTION
Indicates a danger that can lead to minor or moderate injuries.
ATTENTION
Indicates a danger that can lead to damage or destruction of the product.

Safety instructions

WARNING
Danger of injury in the event of non-observance of these operating instructions These instructions contain important information on the safe use of the product. Possible dangers are emphasised. Read through all of the instructions carefully. Follow all safety instructions provided in this
document. Keep these instructions accessible.

2.1

Intended use

The product is used in industrial applications and serves the following purposes:
· Attaching to loading sites for lorries · Use for efficient loading · Bridging height differences and distances between the
loading area of the vehicle and the loading ramp
Max. permissible inclination angle in accordance with EN 1398: 12.5%, approx. 7°.
Maximum loading capacity, see Page 5. Maximum levelling with standard sizes, see
Dimensions and effective working range on page 35.

2.2

Non-intended use

The product is not suitable for the following applications: · As a lifting platform · For lifting and lowering goods or persons · As a location for storing goods or loading equipment · For operation with the liftgate of the vehicle.

2.3

Qualification of personnel

Only authorised persons may carry out work on the product. Authorised persons are personnel from the operator or manufacturer who have been instructed and trained in this work.
To perform work on the product, the personnel undertaking these tasks must meet certain requirements. The groups of persons are classified as follows:

2.3.1 Operator
The operator is responsible for the building where the product is used. The operator has the following tasks: · Instructing users · Complying with the legal workplace safety rules and
regulations · Complying with the valid safety, accident prevention
and environmental protection regulations · Providing and observing documentation · Ensuring that the product is always in perfect technical
working order.

1200017139 / 12.2023

SAFETy INSTRUCTIONS

2.3.2 Specialist personnel
Members of specialist personnel are responsible for the following work: · Fitting · Initial start-up · Maintenance · Dismantling and disposal
Please note:
· Work must only be performed by qualified employees who are familiar with the assembly technology as well as the valid safety regulations.
· Fitting includes Mechanical work Welding and casting work, depending on the fitting model Electrotechnical work.
· Special work during fitting must only be performed by suitably qualified employees of specialist companies. This includes work on the building statics or ventilation system.
· Electrical installations must only be performed by qualified electricians.

2.3.3 Users
Users are permitted to perform work for operation and maintenance of the product. Requirements for users: · Instruction on the product by the operator · Knowledge of these instructions · Good sight and hearing, as well as good judgement
and a sense of responsibility

2.4

General safety instructions

The use of the product is prohibited in the following cases: · In non-industrial applications · In case of damage to the product or individual
components.

WARNING
Danger of injury from spacings and openings in the area of the dock leveller
Spacings and openings in the area of the dock leveller can impair workplace safety. Example:
Recesses in the ramp for guiding the hall door Take appropriate measures, e.g. briefing of personnel
or structural protective measures.

ATTENTION
Damage due to mechanical forces The dock leveller can be damaged by mechanical forces, e.g. overloading. Perform a visual inspection for mechanical damage
every day. Commission the repair of all defects immediately. If damage puts the operational safety of the dock leveller at risk, a specialist must inspect the dock leveller and its operational safety. Use of the dock leveller is not permitted until the repair work has been completed.
Cross traffic is possible only in home position. Please observe the notes regarding cross traffic, see
Non-operation on page 25.
WARNING
Danger of injury by changing the construction All the components are precisely matched to one another. Changing components or attaching additional components could affect the construction, disable important safety components and lead to serious injuries. Do not change any parts or the maximum load
without consent of the manufacturer.

2.5

Noise protection

Operation of the dock leveller produces different types of noise:
· Short-term noise when the platform is raised and lowered, when the lip is moved and when the dock leveller is returned to the home position.
· Long-term noise when driving over the dock leveller, depending on the means of transport and cargo. The dock leveller causes a continuous sound level that does not exceed 70 dB(A). The noise can be influenced by the travel speed, type of tyres and type of transport packaging.

WARNING
Health risk due to noise exposure Measure the actual level of noise exposure on site. Take appropriate protective measures, such as
headphones or ear plugs. Observe legal regulations pertaining to noise protection.

ATTENTION
Damage due to liquids Contact with liquids can cause corrosion and short circuits. As a result components may be damaged. Avoid contact with liquids:
Of energized parts Of the hydraulic power unit, e.g. by ingress
through the ventilation filter. Check the dock leveller periodically according to
these instructions. Remove all corrosion and touch up any paint
damage.

2.6

Standards and directives

The product complies with all applicable standards and directives, see Declaration of conformity on page 43. The corresponding marking is attached to the product.
This declaration is not applicable under the following conditions:
· When operating under extreme conditions, e.g. Temperatures outside the range mentioned in section 13 Strong magnetic fields In special situations, e.g. if there is a risk of explosion
· Handling of loads which could lead to dangerous situations (e.g. molten metal, acids, radioactive materials, particularly fragile loads)

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SCOPE OF DELIvERy

· Hazards occurring during transportation, fitting and dismantling
· When fitting into other systems or machines, operation with more than one control box or wirelessly.
· Risks caused when driving loading equipment (forklifts, etc.).
In any of these cases an individual risk assessment and conformity procedure in accordance with the respective European Directives is required.

Scope of delivery

The scope of delivery for the dock leveller comprises:
· Dock leveller · Control · Any individual parts supplied separately, depending on
the version · Transport profile with protective flap (1 × per delivery)

All dock levellers are tested and filled with hydraulic oil on delivery.

Product description

The HTL2 ISO is a stationary, hydraulically operated dock leveller. The platform is rotatable. The lip is continuously extendable.
The HTL2 ISO is equipped with insulation panels and seals for thermal insulation.

4.1

Loading capacity

CAUTION
Damage to dock leveller or personal injury caused by overload Excessive load can damage the dock leveller or cause tripping hazards if the platform is deflected. Observe the maximum load. Please observe the conditions regarding cross traffic,
see Non-operation on page 25.
Platform and lip have a sufficient cross torsion flexibility to · Adapt to the tilt of the loading surface during the
loading process · Avoid tripping hazards.
The calculation, dimensioning and design comply with the requirements of EN 1398. The load-bearing capacity stated on the data label applies to the total weight of: · Industrial truck including batteries and any
attachments · Load · Drivers

Maximum load
· Rated load according to data label · In energy saving mode or in case of any other
disruption to the electrical supply: max. 60 kN, including at higher rated loads; see control documentation.

4.1.1 Industrial trucks

Acc. to EN 1398, the rated load refers to
· load on an axle · Two rectangular contact surfaces, aspect ratio 3 : 2
(width : length) with one metre clearance · Pressure load max. 2 N/mm²
These conditions apply to forklift trucks with air-filled tyres or super-elastic tyres.
With PU / Vulkollan tyres, the contact surface is smaller and the pressure load greater. This can cause permanent deformation (lane grooves) on the platform.
The deformation is permissible within the limit values specified in EN 1398. We recommend the following load limitation to prevent lane grooves:

Transport vehicle

Forklift

Electric lift Reach lift

truck

Tyres

Air-filled / Superelastic

Rated load 60 kN

HTL 2 ISO

6 t

Tandem rollers made of PU / Vulkollan®

Rollers made of PU / Vulkollan®

6 t

4 t

4.1.2 Working platforms
If the dock leveller is driven over with mobile working platforms during construction or conversion of the hall:
Make sure you use sufficiently dimensioned driving panels to distribute the point load and prevent deformation.
Do not exceed the maximum loading capacity, see Maximum load on page 5.

4.1.3 Changes to the operating conditions
When changing the operating conditions: Take any potential influences on the loading capacity
of the dock leveller into consideration. Coordinate any necessary adjustments with the
manufacturer or supplier of the dock leveller.
Changes to the operating conditions include: · The use of other, especially heavier, transport
equipment · Docking of other vehicles.

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PRODUCT DESCRIPTION

4.2

Temperature

Temperature range, see Technical data on page 34. The above temperature range applies to the hydraulic unit. Depending on the situation, lower or higher ambient temperatures will not have an adverse impact.

4.3

Seals and insulation

Seals reduce draughts, insulation panels improve thermal insulation.

4.3.1 Moving insulation panel
Link brackets, magnets and a tension spring allow the insulation panel below the bridge plate to extend and retract together with the lip.

4.4

Hydraulic system

An electro-hydraulic system with two lifting cylinders and two lip cylinders operates the dock leveller.

4.5

Safety components

To prevent situations in which personnel can be injured, the dock leveller is equipped with safety devices.

Figure: Frame models and box models
1 Side panel, foot guard, see 4.5.2 2 Maintenance support, see 4.5.4 3 Safety marking, see 4.5.5 4 Pedestrian and driving surface, see 4.5.6

5
6
7
1 Seal made of tarpaulin material 2 Brush seal 3 Seal made of tarpaulin material (only for version with
protruding insulation panel) 4 Gap sealing (plastic profiles) 5 Insulation panel moving under the lip 6 Insulation panel, optionally protruding (as shown) in
combination with correspondingly adapted door version 7 Insulation panels
ATTENTION
Reduced thermal insulation in case of missing or damaged seals and insulation panels Keep the seals and insulation panels complete and
intact at all times.
The dock leveller is optionally equipped with: · Acoustic insulation: acoustic insulation coating on
platform and lip, see Pedestrian and driving surface on page 7.

4.5.1 Emergency stop and restart inhibition
The main switch is equipped with an emergency stop function. The emergency stop function triggers the restart inhibition in the control. All movement is blocked once the electrical supply is interrupted or the emergency stop switch is actuated. This prevents the platform from falling.
WARNING
Danger of injury and damage if the dock leveller is loaded after emergency stop If a vehicle rolls over the dock leveller while the restart inhibition is activated, the platform will drop. The construction and hydraulic system may be damaged. This could result in injuries. Eliminate the cause that triggered the emergency stop. Press the Lift platform button to make the dock
leveller ready for operation again.
WARNING
Danger of injury and damage if the dock leveller is operated using the main switch Operating the dock leveller with the main switch can cause tripping and damage to the construction. Never use the main switch to operate the dock leveller. Only operate the main switch in case of an emergency
and for inspection and maintenance work.
NOTICE: The main switch can be secured with a padlock (not included in delivery) to prevent unauthorised use.

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FITTING REQUIREMENTS

When performing inspection and maintenance work that does not rely on electrical power, set the main switch to 0 and secure it against actuation with a padlock.
4.5.2 Foot guard
The dock leveller is equipped with fixed and, if required, movable side panels. The side panels prevent feet from being trapped between the hall floor and dock leveller.
4.5.3 Automatic safety equipment
Each lifting cylinder is equipped with a hose safety device. The hose safety device prevents unintended, hazardous lowering of the platform carrying a load, e.g. if a lorry drives away unexpectedly.
4.5.4 Maintenance support
The maintenance support prevents the platform from lowering. The sticker below, located on the front beam, contains a clear reference to this safety device.

Avoid increased risk of slipping due to moisture or black ice: Keep the pedestrian and driving surface dry and clean.
Under more severe conditions, e.g. wet surfaces due to frequent cleaning, additional measures, such as anti-slip coating, may be required.
If equipped accordingly, the dock leveller has an anti-slip coating, class R11, according to DIN 51130. The coating also has an optional acoustic insulation effect. The coating on the platform is then approximately twice as thick.

4.5.7

Buffers (not included in the scope of delivery)

Protect ramps and vehicles with suitable buffers. Special measures may be required for impact forces greater than 100 kN. Please contact the supplier or manufacturer.

NOTE
Loading sites with DOBO system (see 5.1) require a movable buffer. After docking, the buffer must be lowered so that the vehicle doors can be opened.

Fitting requirements

Before all work under the platform, such as maintenance and repair work:
Position the maintenance support to securely support the platform, see Position the maintenance support. on page 26.

4.5.5 Safety marking
Yellow-black markings indicate that the platform has left the horizontal position.

Where?

visible when?

Below the running plate

Platform lifted

Side panels (fitting model F, Platform lowered FR, B)

Pit along the sides (fitting Platform lowered model P)

5.1

Pit shapes

Various pit shapes are possible depending on the door guide:

Door guided down onto the dock leveller
The door closes on the dock leveller platform at the front. This door guide does not have any effects on the pit version.

4.5.6 Pedestrian and driving surface
ATTENTION
Damage caused by aggressive agents Aggressive agents on the dock leveller can cause corrosion and damage. Do not use any aggressive cleaning agents or road
salt.
The surfaces of the platform and lip are designed as running plates to prevent slipping.

Door guided in front of the dock leveller
The door guide requires a longer pit with a recess for the door. The dock leveller is fitted further back in the pit.
The lower insulation panel of the dock leveller is extended. The door closes on the insulation panel of the dock leveller.
The design of the recess for the door depends on the door type and the dock leveller fitting model.

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FITTING REQUIREMENTS DIFS: Wide recess for standard door guide in front of dock leveller
DIFT: Narrow recess for special door guide with lowered bottom section in front of dock leveller
Depending on the fitting model, the recess for the door is short (P) or continuous (F, FR).

NOTICE:
The following figures in these instructions do not take into account the extension and adjustment of the pit for: · The door guide in front of the dock leveller · The step with the DOBO system.
(exception: section 5.2.1)
Depending on the fitting model, the dock leveller is suitable for the following fitting methods: · In a prepared pit in the building floor
Pit model P for fitting by welding Frame model FR for fitting by casting Frame model F for fitting by welding to
preassembled frame · Simultaneously with the building floor by using a base
construction and mould Box model B for fitting by casting

5.2

Requirements for the pit

The design of the pit depends on the fitting model, see data label or delivery note.
To ensure long-term proper functioning, the pit must be designed as follows:
· In accordance with the manufacturer's planning drawings for the respective fitting model
· Dimensionally accurate and at right angles on all sides
· Sufficiently stable in order to withstand all common or infrequently occurring forces without damage.

ATTENTION
Danger of breaking out caused by insufficient fixing
With insufficient fixing, the pit cannot withstand the load forces. The dock leveller will break away. When the automatic safety equipment is activated, the forces are particularly high. Example: A lorry drives away while the dock leveller is still in operation. Provide for proper connection to the building
structure, especially in areas where load forces occur.

For pit model P

DOBO system
For loading sites with DOBO system, the vehicle doors can be opened after docking. The pit has a step that allows the doors to be opened and set down.

NOTE
The cylinder support beam requires additional support for dock leveller lengths over 3000 mm.

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For frame model FR Fitting with prefabricated concrete elements

FITTING REQUIREMENTS
5.2.1 Checking the pit properties 1. Pit without recess for door guide:

C1 = C2 (±10)

NOTICE: At the sides, the reinforcement must go to the edge of the pit. Alternatively, rowlocks must be installed in accordance with the manufacturer's pit drawings.
Fitting with casting groove

2. Pit with step for DOBO system:

PL2

C2 C1

C1 = C2 (±10)

PH 250

For frame model F

3. Pit with narrow recess for special door guide with lowered bottom section in front of dock leveller (door narrower in the ramp area):
PL1

C1 = C2 (±10)

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FITTING REQUIREMENTS 4. Pit with wide recess for standard door guide in front of
dock leveller:
PL1

C1 = C2 (±10)

PH Pit height

PL Pit length

PL1 Pit length from the back to the recess (pit with recess for door guide)

PL2 Pit length from the back to the wall

PW Pit width

C1 / 2 Diagonals

Door space requirement (see planning information

or manufacturer's specifications)

To check the dimensional accuracy, measure
The pit length (PL), only up to the recess (PL1) for pits with recess for door guide, for DOBO pits up to the wall (PL2)
Pit width (PW) Pit height (PH) at front and rear for DOBO pits: height of the level the diagonals (C1 and C2) of the pit
Check the measurement result based on the following tables. The diagonals (C) should not deviate in length by more than 10 mm.

Pits 1, 2 and 3:

Fitting model FR F
P

Pit dimensions (mm)

PL / PL1

(tolerance) (tolerance)

NW + 70 (±10)
NW + 70 (±10)
NW + 25 (+10 / -0)

PL / PL1: NL 5 (+5 / -0)
PL: NL (+10 / -0)
PL1: NL 20 (+ 10 / - 0)

NH + 5

PL2: NL Y (+ 10 / - 0)

Pit 4:

Fitting model FR F P

Pit dimensions (mm)

PL1

(Tolerance) (Tolerance)

NW + 70 (±10)
NW + 25 (+10 / -0)

PL1: NL 75 (+5 / -0)
PL1: NL-70 (+ 5 / - 0)

NH + 5

NW Ordering width NL Ordering length NH Installation height
Ordering sizes, see data label, delivery note or Technical data on page 34.

ATTENTION
Danger of damage due to improper fitting in case of deviating pit dimensions
Fitting in a pit with deviating dimensions may result in damage:
The dock leveller can deform The fixing may be insufficient.
The load on individual connections can considerably exceed the rated load. Contact the manufacturer in case of dimensional
deviations beyond tolerance levels. The manufacturer will advise you on suitable measures for adjusting the pit.

NOTICE:
The dock leveller can be set up with a slope of up to 2% towards the door opening. Widthwise, the dock leveller must be installed precisely horizontally. Otherwise, problems may arise during operation, especially when loading below ramp level.

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FITTING

5.3

Requirements for the base construction

5.3.1 For box model (B)
Provide for an on-site base construction in accordance with the figure and the manufacturer's planning drawing.
Standard:

Fitting

The dock leveller may only be fitted if the requirements for the fitting site are fulfilled.

NOTICE:
Deviations from the pit shape shown are possible. The figures do not consider extension and adaptation of the pit for guiding the door in front of the dock leveller.

DH - NH

With recess for door guide:
NL-20
NW+25 3000

6.1

Safety instructions for fitting

WARNING
Danger of injury in the event of non-observance of these fitting instructions This section contains important information on the safe fitting of the dock leveller. Before starting fitting work, carefully read through
this chapter. Follow all safety instructions. Please observe all applicable local construction and
safety regulations. Perform the fitting as described.
Fitting must only be carried out by qualified specialist personnel, see Specialist personnel on page 4. Electrotechnical work must only be performed by qualified electricians, see Specialist personnel on page 4.
Ensure that the following conditions are met when performing fitting work:
The working area is largely cordoned off. The dock leveller is undamaged and in a proper
state. Cables and hoses are not kinked, squeezed or
damaged.

NL Ordering length NW Ordering width DH Ramp height NH Dock leveller installation height

5.4

Requirements for the connection

Make sure that the following requirements are fulfilled: Mains connection based on the requirements of the dock leveller Suitable cables and fuses UPVC tube for laying the cable

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FITTING

6.2

Required tools

6.3

Unloading

Choose an unloading method according to the weight of the dock leveller. See data label for weight.
Please contact your supplier if there is any deformation or damage.
Touch up minor paint or galvanising damage only after fitting has been completed.

ATTENTION
Damage due to crashes
The base frame structure must not be deformed; otherwise problems may arise during operation. Always keep the dock leveller horizontal. Make sure
that the dock leveller is not involved in crashes and cannot fall. Always unload only one dock leveller at a time.

DANGER
Danger of injury from falling dock leveller Make sure the transport aids are securely fastened to
prevent the dock leveller from falling. Do not stand underneath the dock leveller.
The dock leveller is prepared for two unloading possibilities.
With forklift: Use a forklift with forks at least 1500 mm long. With
shorter forks, transport into the pit (see below) is not possible.

M16
Put together the required tools.

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FITTING

M16
Screw the provided transport profile to the protective flap on the platform.
Never lift more than one dock leveller at a time. With crane:

The box also contains further components in addition to the control box, depending on the equipment.

6.4

Fitting pit model P

6.4.1 Fitting the support angles

90°

Screw four lifting lugs M16 (not supplied) completely into the nuts on the platform.
The crane can pull up the dock leveller by chains (not included) connected to the lifting eyes and transport it.

Provide the rear wall with 2 × 2 drill holes to hold bolt anchors M20.
Distance between top edge of the edge bracket and top edge of the pit: installation height of the dock leveller NH + 5 mm tolerance Fit the two support angles provided.

Remove the box with the control box.

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FITTING 6.4.2 Set-up

10-18 mm

Adjust the position of the transport profile to the required position if necessary.
Use a forklift with forks at least 1500 mm long.
Slide the positioning aids (supplied separately) into the corresponding recesses.

The platform must be on the same level as the ramp. The longitudinal grooves between platform and recess must be the same width on both sides, approx. 10 18 mm.
6.4.3 Welding
WARNING
Health risk from welding galvanized components Zinc fumes are emitted during the welding of galvanized components, which results in health problems when absorbed through breathing. Grind away the zinc layer at the welding points.
The welding symbols correspond to ISO 2553 (E). The dock leveller comes with cut-outs at the rear that show the exact position and length of the welding seams.
30

Move the dock leveller into the pit. 14

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5 n x 100 (200)

a4 90

FITTING
WARNING
Possible crushing and shearing hazard point The working range of the dock leveller must be completely covered. There is a crushing and shearing hazard if the concrete cover on the sides is too thin.

a4 90

Weld the dock leveller on the rear at the indicated points. Make sure the connection is correct and flat. If necessary, push the dock leveller back into the pit using a forklift.
ATTENTION
Damage to protruding insulation panels by forklift If the forklift pushes the loading bridge backwards into the pit, a protruding insulation panel can be damaged. If necessary, place a timber beam on the bottom
insulation panel. The timber beam must be at least as wide as the protrusion of the insulation panel and as long as the platform width.

Make sure this area is sealed off.
Restore the corrosion protection: a. Clean the welds. b. Treat the welds with paint, zinc spray or zinc paint.

Pull the cables through the provided PVC tube.
Weld the front beam. If the pit is too wide for the front beam, fill the spacing with steel plates or strips.
NOTE Welding the underside of the front beam is not necessary.

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FITTING

6.5

Fitting frame model FR

Frame model FR can either be cast with prefabricated

concrete elements (A) or cast in a pit with a sufficiently

wide casting groove (B).

6.5.1 A

Set-up

B B

Align the dock leveller horizontally.

Position the dock leveller. The platform must be on the same level as the ramp.

90°
The dock leveller comes with anchors on the sides and rear. Bend the anchors. in a way that allows you to connect
them with the rowlocks or reinforcement.

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6.5.2 Welding
WARNING
Health risk from welding galvanized components Zinc fumes are emitted during the welding of galvanized components, which results in health problems when absorbed through breathing. Grind away the zinc layer at the welding points.
The welding symbols correspond to ISO 2553 (E).
A

FITTING
At least half of the anchors are welded in total. The remaining anchors are bent. They ensure
sufficient stability after casting. Make sure the spacers between the frame and the
platform have remained in position.
A

B
90°
B

90°
Weld the anchors to the reinforcement or rowlocks.

Pull the cables through the provided UPVC tube.
6.5.3 Casting Concrete quality: at least C20 / 25. We recommend covering the platform with a protective film before casting. Before casting, make sure that the positioning and
fixing of the dock leveller is still intact.
A

All anchors on the rear must be welded.
Under the following conditions, it is sufficient to weld only those anchors on the sides where there are rowlocks:
The pit is equipped with rowlocks on the sides. The pit corresponds to the manufacturer's planning
drawings for fitting model FR. The two outermost anchors are welded.

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FITTING
B

6.6 6.6.1

Fitting frame model F Set-up

Cast the concrete casting compound.
ATTENTION
Damage due to deformation The base frame structure must not be deformed; otherwise problems may arise during operation. Make sure that the side pressure is not too high
during pouring and compacting.
ATTENTION
Danger of breaking out caused by insufficient fixing With insufficient fixing, the pit cannot withstand the load forces. The dock leveller will break away. When the automatic safety equipment is activated, the forces are particularly high. Example: A lorry drives away even though the dock leveller is still in operation. Provide for proper connection to the building
structure, especially in areas where load forces occur.
Make sure the edge bracket is completely backfilled. You can check this through the opening in the edge bracket.

Position the dock leveller.
The platform must be on the same level as the ramp. Spacers ensure that the longitudinal grooves are equally wide on both sides. 6.6.2 Welding
WARNING
Health risk from welding galvanized components Zinc fumes are emitted during the welding of galvanized components, which results in health problems when absorbed through breathing. Grind away the zinc layer at the welding points. The welding symbols correspond to ISO 2553 (E). 1. Make sure the spacers between the frame and the
platform have remained in position.

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A: 17< A20 mm

±210

a4 80

(2x) M16x125

(2x) 250x80x15

A: 20< A 35 mm

FITTING
NOTE Always weld at the hinges and corners. The distance between the welding seams must not exceed 300 mm on the side and 200 mm on the rear.

a4 80

P
Check the gap dimension on the rear. If the gap is wider than 17 mm, the rear must be backfilled near the hinges.
5 n1 x 100 (200)
5 n2 x 100 (300)

Pull the cables through the provided UPVC tube.
Restore the corrosion protection: a. Clean the welds. b. Treat the welds with paint, zinc spray or zinc paint.

6.7

Fitting box model B

6.7.1 Set-up

Weld the edge bracket of the dock leveller to the edge bracket of the recess.

Position and length of the welding seams:

100 100

300

100

200

100 5

Position the dock leveller.

Number of welds: Ordering width NW* Number n1
Ordering length NL* Number n2 * See data label.

2000 8

2100 10

2000 2500 2750 3000

Align the dock leveller horizontally.
Spacers ensure that the longitudinal grooves are equally wide on both sides.

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FITTING
When the mould and reinforcement are in place according to the manufacturer's planning drawing, you can proceed with fitting.

6.7.2 Casting
Concrete quality: at least C20 / 25. Make sure the protective film is still intact over the
entire platform and the adhesive strips are not damaged. If this is not the case, mend the protective film before casting the concrete.

90°
Weld the anchors to the reinforcement.
WARNING
Health risk from welding galvanized components Zinc fumes are emitted during the welding of galvanized components, which results in health problems when absorbed through breathing. Grind away the zinc layer at the welding points.
Make sure the spacers between the frame and the platform have remained in position.

Cast the concrete casting compound slowly and in layers.
ATTENTION
Damage due to deformation The base frame structure must not be deformed; otherwise problems may arise during operation. Make sure that the side pressure is not too high
during pouring and compacting.
ATTENTION
Danger of breaking out caused by insufficient fixing With insufficient fixing, the pit cannot withstand the load forces. The dock leveller will break away. When the automatic safety equipment is activated, the forces are particularly high. Example: A lorry drives away even though the dock leveller is still in operation. Provide for proper connection to the building
structure, especially in areas where load forces occur.

Attach a UPVC tube Ø 50 mm: Maximum angle 45° Positioned at least 150 mm from the door opening
Pull the cables through the UPVC tube.

Make sure the edge bracket is completely backfilled. You can check this through the opening in the edge bracket.
Remove the mould once the concrete has hardened.

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6.8

Fitting combined fitting models

To fit combined fitting models, e.g. side fitting by welding and rear fitting by casting, the following applies:
Follow the fitting instructions for the respective fitting models to make the structural connection on the front or side and rear.

6.9

Electrical connection

The electric motor is pre-wired and connected to the dock leveller.
Please read the separate documentation for connecting the control.

DR sensor (with corresponding equipment)
The DR sensor (door release) is required for the following functions: · "Door release" function: The door only closes when
the dock leveller is in home position. · Functional extensions, depending on the connected
control, e.g. semi-operation, control of warning lights, switching off an inflatable dock seal
The DR sensor is pre-assembled.
Guide the cable alongside the connection cable through the UPVC tube.
Connect the cable. Observe the documentation for the dock leveller and door controls.

INITIAL START-UP

Remove the transport safety devices. 3
3

1 3

Initial start-up

Initial start-up may only be carried out by qualified specialist personnel, see Specialist personnel on page 4.

7.1

Aids

Fitting model P

Remove the positioning aids as follows:
Press the Lift platform button. Move the main switch to 0. Position the maintenance support. Remove the positioning aids. Return the maintenance support to its original
position. Set the main switch to I. To make the dock leveller ready for operation again
after interrupting the electrical supply, press the Lift platform button. Return the dock leveller to the home position, see Returning to home position on page 25.
Fitting model FR, F, B

Remove the transport profile.

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Remove the spacers and the transport profile. 21

OPERATION

7.2

Buffers

ATTENTION
Damage due to impact forces
Impact forces can damage the building structure, the vehicle and the dock leveller. Transfer of impact forces to the dock leveller can affect the stability, functionality and the fixing of the dock leveller. Install sufficiently dimensioned buffers. Observe the transmission of the impact forces to the
building structure. In case of a protruding dock leveller frame, fill in the
connection surface of the buffer.

The depth of the buffers influences the distance between the vehicle and the dock leveller. The depth of the buffers influences the distance between the vehicle and the dock leveller. A greater depth or the use of a mounting bracket can increase the distance if necessary.
Hörmann buffers and fixing materials as well as the planning specifications for the pit version are designed to resist impact forces up to 100 kN.
In case of higher impact forces, please contact the supplier or manufacturer.

7.3

Brief instructions

Attach the illustrated brief instructions in the immediate vicinity of the control.
Affix the supplied label indicating the nominal load to the space provided in the brief instructions.

7.4

Check

Make sure that the platform is level with the ramp.
Conduct a test run. Observe the separate instructions for the control.
Make sure the dock leveller runs evenly and smoothly.
Check the safety equipment. Set the auto-return time of the auto-return function.
Follow the documentation for the control.

Operation

8.1

Safety instructions for operation

WARNING
Danger of injury in the event of non-observance of these operating instructions This section contains important information on the safe operation of the dock leveller. Before operation, carefully read through this section. Follow all safety instructions. Please observe all applicable local safety regulations. Observe the instructions in the documentation for the
control.
Operation must be carried out by qualified specialist personnel, see Specialist personnel on page 4.

WARNING
Danger of injury from tripping or falling Careless behaviour can lead to persons tripping or falling from the dock leveller. Move carefully on the dock leveller. Pay particular
attention to: Backward movements Angled position of the platform In situations where the door is guided in front of
the dock leveller: side clearance in the front area
WARNING
Danger of injury and damage if the dock leveller is operated using the main switch Operating the dock leveller with the main switch can cause tripping and damage to the construction. Never use the main switch to operate the dock
leveller. Use the main switch only in case of an emergency
and for inspection and maintenance work.
WARNING
Danger of injury during incorrect dock leveller operation Persons, body parts or objects may be crushed, trapped or otherwise injured when the dock leveller is operated. Only use the dock leveller if it is in good condition. Always ensure the following before and during
operation: No persons or objects may be on the platform and
in the area of travel of the dock leveller. The dock leveller must not impact any body parts
or other objects. In an emergency, move the main switch to 0, see
Emergency stop and restart inhibition on page 6.
Ensure sufficient lighting and a clear view when operating the dock leveller.
ATTENTION
Danger of damage caused by exceeding the working range Cushioning of the vehicle during loading will also cause the dock leveller to move upwards or downwards. If the dock leveller is already positioned at the highest or lowest level, the maximum working range may be exceeded and the dock leveller damaged. Do not start operating the dock leveller at the highest
or lowest level.
8.1.1 Docking as specified
Vehicles must be docked in such a way that the lip of the dock leveller can be safely positioned:
Evenly over the full width Sufficiently deep.

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OPERATION

Make sure that vehicles dock straight.
A vehicle is properly docked if there is only a small gap left before contacting the buffers. Direct contact between the vehicle and the buffers can cause damage to the buffers and the vehicle. Local conditions may require larger distances. Make sure that the vehicles are always at the right
distance from the dock leveller. Observe the working range and the correct overlap of the lip.
For dock levellers with a width under 1.25 m, the vehicle must not be parked more than 0.20 m away from the dock leveller.
NOTE Loading ramps with DOBO system allow for the lorry to dock with the vehicle doors closed. To accommodate the lorry doors, recesses are provided in the ramp.

Make sure the vehicle is secured against rolling away.
8.1.2 Safe lip positioning
ATTENTION
Danger of injury and damage with too small or too large bearing surfaces Too small bearing surfaces may lead to falls. Loading processes cause movements in which the lip may slip from the loading surface. Too large bearing surfaces may lead to · Tripping hazards if
loading above level · Damage to the lip,
platform and guides

Make sure the full width of the lip is resting on the vehicle loading surface: at least 100 mm, but no more than 150 mm.
Possible adjustments to improve support: vehicle height or distance between the loading surface and the dock leveller
The bridge plate has two recesses on each side. Proper support is ensured when the front-most recess is covered by the loading surface of the vehicle on both sides, but the second recess is not covered.

The dock leveller may only be operated on vehicles with a liftgate if the liftgate can be parked in a recess provided under the dock leveller (tailboard slot).

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OPERATION

For vehicles with an offset loading surface, make sure to position the lip sufficiently far into the cargo area.
The lip has 2 overlap limiters and supports on the underside.

DOBO system First extend the lip to bridge the gap to the lorry. Then lower the movable buffers. Open the vehicle doors. Position the dock leveller as described above.

8.3

Loading and unloading

Make sure that the following prerequisites are fulfilled every time the dock leveller is used:

Compliance with the maximum loading capacity as specified on the data label (rated load)
Only use suitable, safe and permissible transport equipment
Comply with the maximum inclination of 12.5%, taking the limitations depending on the type and the transport equipment into account, see 8.3.1
Max. speed 10 km/h Maximum track width (X) = platform width
(B) 700 mm

Never place the telescopic lip with the overlap limiters or supports on the loading surface or on other vehicle parts.

8.2

Positioning the dock leveller

1. Open the loading ramp door completely, if available. 2. Make sure that no persons or objects are on the platform.

Raise platform

Extend lip

Retract lip

If the loading surface is at the same height or lower than the platform, you can skip step 3 and extend the lip directly (step 4). 3. Press the Lift platform button. Keep the button
pressed until the platform is above the level of the loading surface. 4. Press the Extend lip button within the next second. Press and hold the button until the lip is extended as far as needed and no further. 5. Release the button.
The lip is lowered to the loading surface after approx. one second.
Correct the lip: In order to retract the lip again, use the Retract lip button.
If the lip is already positioned on the loading surface, the platform lifts up briefly and lowers after releasing the button.

X B
X = B 700 mm
No persons or objects in the dock leveller's area of travel
Door fully opened

Goods are protected from slipping and falling, especially large, unsteady or dangerous goods

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NON-OPERATION

8.4

Returning to home position

Drive the transport equipment onto the platform as centrally as possible.
Ensure that the underside of the transport equipment as well as the cargo do not contact the dock leveller.
8.3.1 Inclination The following specifications apply to the highest and lowest operating position. Maximum inclination in accordance with EN 1398: 12.5%. Max. inclination depending on type and transport equipment:
5%
7%
10%
15%

Auto return
After use, return the dock leveller to its home position immediately:
a. Make sure that no persons are in the loading area. b. Briefly press the auto-return button. The dock
leveller will automatically move into the loading position.
ATTENTION
Risk of damage due to incorrect operation The Retract lip button is not suitable for moving the dock leveller directly from the operating position to the home position. If the lip has not been completely retracted by mistake, the platform is not sufficiently supported. Always use the auto-return button. Make sure that the lip is fully retracted.

DOBO system
First retract the lip with the Retract lip button so that the gap to the lorry still is bridged.
Close the vehicle doors. Then release the movable buffers. Briefly press the auto-return button. The dock leveller
will automatically move into the loading position.

Non-operation

When not in use, make sure that the dock leveller is in home position.

9.1

Home position

The lip is fully retracted. The platform and hall floor are at the same height.

9.2

Cross traffic

Cross traffic is possible under the following conditions: · Dock leveller in home position · Maximum load observed. · For the DOBO system, sufficient protection in the area
of the recess

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MAINTENANCE

Maintenance

WARNING
Danger of injury when working below the platform
When working below the platform, persons, body parts or objects may be crushed or jammed. Before carrying out any work, put the maintenance
support into the right position so that the platform is safely supported.

Position the maintenance support. 1. Press the Lift platform button. 2. Move the main switch to 0. 3. Position the maintenance support.
After work is completed 4. Return the maintenance support to its original position. 5. Set the main switch to I. 6. To make the dock leveller ready for operation again
after interrupting the electrical supply, press the Lift platform button. 7. Return the dock leveller to the home position, see Returning to home position on page 25.

10.1

Cleaning and care

Remove the two screws from the lower insulation panel.

ATTENTION
Damage caused by aggressive agents Use of aggressive cleaning agents or road salt on the pedestrian and driving surface may lead to corrosion and damage. Do not use any aggressive cleaning agents or road
salt.
Waste and dirt can impair the function of the dock leveller: Keep the platform hinges and area below the platform
clean.
Water and ice can cause an increased risk of slipping. Keep all pedestrian and driving surfaces dry and clean. Dirt can damage the gap sealing, impair the thermal insulation and cause the insulation panels to jam. Keep the following components clean at all times:
Gap sealing between the platform and frame / edge of the pit
Front insulation panels
Cleaning the front insulation panels Perform cleaning work at least once a year (after
twelve months).

Extend the bridge plate at least 650 mm.
Slide the lower insulation panel about 300 mm outwards.

Clean the insulation panels.
After cleaning Bring the insulation panel into its original position. Secure it with the screws you just removed. Conduct a function test.

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10.2

Inspection and maintenance

WARNING
Danger of injury in the event of non-observance of these inspection and maintenance instructions
This section contains important information on the correct inspection and maintenance of the dock leveller.
In case of insufficient inspection and maintenance important safety components may fail or be defective.
Before starting maintenance work, carefully read through this section.
Follow all safety instructions.
Carry out inspection and maintenance at the specified intervals.
Commission the repair of all defects immediately.
If damage puts the operational safety of the dock leveller at risk, a specialist must inspect the dock leveller and its operational safety. Use of the dock leveller is not permitted until the repair work has been completed.

MAINTENANCE
ATTENTION
Risk of damage to insulation panels during maintenance work The insulation panels can easily be damaged during or after dismantling. Wind can blow away dismantled insulation panels. Sparks can occur during maintenance work and damage insulation panels. Handle the insulation panels with care. Dismantle the insulation panels in the order specified. Store the insulation panels in a safe place.
1
2

Inspection and maintenance work must only be performed by qualified specialist personnel, see Specialist personnel on page 4.
WARNING
Danger of injury during inspection and maintenance Persons, body parts or objects may be crushed or jammed by the dock leveller during inspection and maintenance work. Before carrying out maintenance work, put the
maintenance support into the right position so that the platform is safely supported. When performing inspection and maintenance work that does not rely on electrical power, set the main switch to 0 and secure it from actuation with a padlock. No strain can be placed on the dock leveller in this state. Secure the maintenance area. Use barrier tape, traffic cones or similar aids.
ATTENTION
Danger of short circuits due to liquids If liquids reach parts of the dock leveller that are under electrical voltage, this can result in a short circuit. Avoid contact between energized parts and liquids.
Inspect the dock leveller at least once a year for damage and test it for proper operation. The maintenance intervals are shortened under the following conditions: No protection by a dock seal or canopy High exposure to weathering Multi-shift operation
Dismantling the insulation panels
Some maintenance work requires the insulation panels to be removed. This is indicated in the corresponding maintenance steps.

1. On the underside of the platform, remove the securing split pins with the small plates.

2. Remove the insulation panels in the order specified. 3. After completing the inspection and maintenance
work, reattach the insulation panels in reverse order.

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MAINTENANCE

Inspection and maintenance schedule

Actions T = Test function V = Visual inspection C = Change

Intervals
D = Daily
W = Weekly
M = Monthly
A = Annually or after twelve months, or more frequently if used in multi-shift operation or used intensively

Area
User information, see 10.2.1
Completeness Legibility
General condition of the dock leveller, see 10.2.2
Visual assessment Damage,
deformation Corrosion Dirt · Buffers Existence Condition, wear
Emergency stop switch, see 10.2.3
Status Function Ease of movement Option to secure
system against unintentional actuation
General operating functions, see 10.2.4
Function Operational safety
Construction, see 10.2.5 · Welding seams,
connections, guides, hinges, safety components Status Ease of movement Deformation Corrosion · Seals and insulation panels Completeness Condition, wear Deposits, see
Cleaning and care on page 26

Actions V V
D
D V, T

Intervals A D
W
M A

· Safety components Completeness Status Function

Area
· Lip guide slider profiles Condition, wear

Actions

If equipped accordingly: · Anti-slip or acoustic
insulation coating Status

Electrical system, see

V, T

10.2.6

· Control system and

control elements

Status

Function

· Cables

Status

Fixing

Connections

Hydraulic unit, see 10.2.7

V, T

Status

Tightness

Corrosion

Function

Safety equipment

· Hose lines

Status

Fixing

Service life

Connections

· Cylinder

V, T

Status

Connections

· Oil

Quantity

Status

Bleeding

Intervals
A
A
A 5 A A A 5 A

10.2.1 User information
Check that the user information is complete and in good, legible condition.

What?

Where?

Data label with the following information: Manufacturer, type, rated load, serial number, year of manufacture, power supply

On the front beam

Motor label

On the hydraulic unit

Hydraulic unit data label on the tank

Oil type sticker

on the tank

Operating instruction for maintenance support

On the front beam

Safety marking

On the side edges below the running plate, for frame and box models on the side panels of the frame construction. For pit models on the side in the pit

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MAINTENANCE

What?

Where?

Brief instructions: · Control operating
symbols · Label specifying rated
load · Illustrated brief
instructions

On or in direct vicinity of the control housing

Instructions for fitting,

Readily accessible

operating and maintenance

Documentation for control and, if needed, functional extensions

Readily accessible

Log book

Readily accessible

Specification of next inspection and maintenance date

On or in direct vicinity of the control housing

A
B C
A

10.2.2 General condition

Perform a visual inspection for mechanical damage, deformation and corrosion. Pay attention to the connection to the building structure and the condition of the weld seams.
Remove any dirt, see Cleaning and care on page 26.
Check that the buffers are present on the ramp and in good condition.
Commission the repair of all defects immediately.

10.2.3 Main switch and emergency stop

Inspect the condition and functioning of the emergency

stop function of the main switch and the restart

inhibition. Follow the documentation for the control.

10.2.4 General operating functions
Conduct a test run during which all operating functions are inspected: Lifting Extending and retracting the lip Lowering Returning to home position Door release (with corresponding equipment) Floating position Follow the documentation for the control.

10.2.5 Design
Make sure that the insulation panels have been dismantled, see Dismantling the insulation panels on page 27.
Perform a visual inspection for mechanical damage, deformation or corrosion. Pay attention to weld seams, screw connections and corrosions.
Check the connection to the building structure. Check to see that movable parts move freely. Pay particular attention to the completeness, condition
and functioning of the following safety devices: Anti-slip platform Foot guard plates Maintenance supports Securing split pins, see figures

C
Check the completeness and condition of the insulating components:

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MAINTENANCE
Insulation panels Gap sealing Brush seals Seals made of tarpaulin material Replace insulating components immediately in case of wear. With corresponding equipment: Check whether the following equipment is intact: Anti-slip and acoustic-rated coating of the platform
and lip. Check that the slider profiles for the lip guide are
intact. Replace the slider profiles in case of wear.
NOTE Do not grease the slider profiles.
Commission the repair of all defects immediately.
10.2.6 Electrical system Perform a visual inspection for mechanical damage to
the electric cables and control elements. Follow the separate documentation for the control and, if appropriate, for the functional extensions of the dock leveller. Commission the repair of all defects immediately.
10.2.7 Hydraulic system
Deviations from the version shown may occur. Hydraulic diagrams, see Hydraulic system diagram on page 36.

Do not disconnect the power, as the solenoid valve will cease to function.
If there is no tailboard slot, make sure that the hydraulic components can be reached safely.
Perform a visual inspection for mechanical damage to the following components: Hose lines including connections. Check for porosity. Check the position of the hose clamps. Movements caused by differences in pressure during operation may not lead to friction damage. Cylinders, including fastenings and connections. Check for the following: leaks, cracks, grooves, dirt and corrosion Hydraulic unit, including connections. Check for the following: leaks, cracks, grooves, dirt and corrosion
Remove any dirt and rust.
Replace defective components immediately.
Check that the automatic safety device (hose safety device) is in place and functioning.
Remove the valve and make sure it is easy to move and free of dirt.
Re-install the valve. Exchange the valve if necessary.
Test the oil level and oil quality. The dock leveller should be in the home position for this. The tank should be half to three quarters full. If the oil level is insufficient, top up the oil. Change the oil in case of: dark colouration, cloudiness, soiling, burned odour Standard value for oil change:
With normal use after five years after 2.5 years with frequent use Do not substitute an oil change by purifying the oil. Purifying does not sufficiently prevent the oil quality from deteriorating.
NOTE
We recommend changing oil and hose lines every five years. The reference date is the year of manufacture as per the data label. If any evidence of wear or damage is visible, replace hose lines earlier, e.g. in case of small cracks or leaks.

Pressure relief valve Throttle valve

Testing and setting the lowering speed
Basic setting: The lowering speed is set correctly when the platform lowers as quickly as it raises. The lowering speed must be fast enough to ensure that the lip is supported directly on the loading surface at all times during loading. The lowering speed must not exceed a max. of 200 mm/s on average measured at the front of the dock leveller. Test the lowering speed at least 1 × a year If necessary, adjust the lowering speed with the
throttle valve.
Adjusting the pressure
The hydraulics pressure was set during production; it can, however, be affected by local conditions (temperature). If faults are due to incorrect pressure, readjust the pressure: 1. With the lip extended, move the dock leveller to its
lowest position 2. Remove the cover cap of the pressure relief valve.

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3. Turn the main pressure relief valve to the left so that the main pressure is reduced. The platform should not rise anymore.
4. Turn the pressure relief valve to the right to increase the main pressure.
5. Once the platform begins to rise, turn the pressure relief valve another half rotation to the right.
6. Seal the valve with a new cover cap.
Changing the oil
WARNING
Danger of burns from hot oil The oil may heat up excessively during operation of the dock leveller. Wear gloves. Carefully feel the tank to see if the oil is sufficiently
cool.
1. Remove the insulation panels, see Dismantling the insulation panels on page 27.
2. Raise the dock leveller. 3. Secure the dock leveller using the maintenance
support. 4. Remove the lifting cylinder from the platform and the
base frame. 5. Unlock throttle valve 8 and open the valve completely.
Note the number of rotations. 6. Press the lifting cylinder in by hand, thus causing the
oil to flow back into the tank. 7. Remove the hose line from the lifting cylinder. Put the
lifting cylinder into a receptacle. 8. Press the Lift platform button so that the oil can run
out of the tank and into the receptacle. Stop as soon as the oil begins to squirt. 9. Fill the tank with new oil. If you use a different type of oil, rinse the tank with the new oil first. 10. Attach the hose line to the cylinder again. 11. Bleed the hydraulic system and check the lowering speed. 12. Document the type and viscosity of the oil used. 13. Properly dispose of the waste oil.
Changing the hose line
1. Remove the insulation panels, see Dismantling the insulation panels on page 27.
2. Raise the dock leveller. 3. Secure the dock leveller using the maintenance
support. 4. Remove the damaged hose line from the cylinder. Put
the hose line in a receptacle. 5. Install a new hose line.
Changing a cylinder
1. Remove the insulation panels, see Dismantling the insulation panels on page 27.
2. Raise the dock leveller. 3. Secure the dock leveller using the maintenance
support. 4. Loosen the cylinder on both cylinder axles. 5. Press the damaged cylinder in by hand, thus causing
the oil to flow back into the tank.

MAINTENANCE

6. Remove the hose lines from the cylinder. Put the cylinder into a receptacle.
7. Attach the hose lines to a new cylinder. 8. Attach the new cylinder. 9. Make sure that the lowering speed is set correctly.

Changing a valve
1. Raise the dock leveller. 2. Secure the dock leveller using the maintenance
support. 3. Release the hydraulic unit from the holder. 4. Place the hydraulic unit vertically so that the oil is
primarily in the tank. 5. Replace the damaged valve. 6. Make sure that the lowering speed is set correctly. 7. Refasten the hydraulic unit to the holder.

10.3

Malfunctions and troubleshooting

WARNING
Danger of injury when remedying malfunctions In the case of a malfunction, the dock leveller may no longer function reliably. Persons, body parts or objects may be crushed or jammed if a faulty dock leveller is operated. Before performing any work on the dock leveller,
always unfold the maintenance support and secure it in a vertical position. Set the main switch to 0 and secure it with a padlock to prevent unauthorized operation.
Troubleshooting must only be carried out by qualified specialist personnel, see Specialist personnel on page 4. In the case of a malfunction, always first check if there
is any mechanical damage or if any components are jammed. Only after that has been ruled out, start looking for other causes as described in the following overview.

Possible malfunctions are described in the following:
Malfunction
Possible cause Remedy
Adjustment work necessary to remedy faults is described in the "Inspection and maintenance" section.
The dock leveller does not respond. The motor does not run. The emergency stop switch / main switch is set to "O" or the restart inhibition is activated. Check whether (and why) the emergency stop switch
has been actuated (e.g. for maintenance work). After eliminating the cause, press the Lift platform
button to deactivate the restart inhibition. Then the dock leveller is ready for operation again.

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MAINTENANCE
The dock leveller does not respond. The motor does not run.
Fault in the power supply Check the connecting voltage and the wiring. Check the control box to see if a fuse or the wiring
has loosened. Follow the documentation for the control.
Dock leveller release function blocks the dock leveller. If equipped accordingly, the dock leveller cannot be operated if the door is not completely open. Open the door completely. Check the "OPEN" signal. Follow the documentation
for the control.
Wheel chock with sensor blocks the dock leveller. If equipped accordingly, the dock leveller cannot be operated if the wheel chock with sensor is not positioned correctly. Make sure that the wheel chock is positioned
correctly. Check for damage to the sensor or wiring. Check whether the wheel chock switches properly.
Follow the documentation for the wheel chock. If the wheel chock functions properly, test the
function of the dock leveller Disconnect the wheel chock. Test whether the dock
leveller is functioning. Follow the documentation for the control.
Fault in the hydraulics If none of the above possibilities solve the problem,
contact the supplier's or manufacturer's customer service department.
Platform does not rise, even with a functioning motor
The motor is running in the wrong direction. It is possible that the motor was connected with inverted phases during initial operation of the dock leveller or after the replacement of the hydraulic unit. In this case, the motor rotates, but the platform does not respond. Correct the polarity of the motor connections in the
control or, if necessary, on the motor.
Platform has jammed. Check to see if the movement of the platform is
blocked.
Inadequate pressure in the hydraulic system The hydraulics pressure was set during production; it can, however, be affected by local conditions (temperature). Readjust the pressure.
Oil level is too low In the home position, the tank should be half to three quarters full. Inspect the system for leaks on the cylinders, hose
lines and connections. Replace defective parts. Top up the oil tank with a suitable oil.

Platform does not rise, even with a functioning motor Fault in the hydraulics If none of the above possibilities solve the problem,
contact the supplier's or manufacturer's customer service department.
Platform rises very slowly or incompletely Soiled hinge Check for contamination on the hinges on the rear
side. Clean if required.
Oil level is too low In the home position, the tank should be half to three quarters full. Inspect the system for leaks on the cylinders, hose
lines and connections. Replace defective parts. Top up the oil tank with a suitable oil.
Contaminated oil Remove and dispose of the contaminated oil. Clean the valves. Top up the oil tank with a suitable oil.
Inadequate pressure in the hydraulic system The hydraulics pressure was set during production; it can, however, be affected by local conditions (temperature). Readjust the pressure.
Fault in the hydraulics If none of the above possibilities solve the problem,
contact the supplier's or manufacturer's customer service department
Platform does not go down, is blocked at the highest position or during lowering The emergency stop switch / main switch is set to "O" or the restart inhibition is activated. Check whether (and why) the emergency stop switch
has been actuated (e.g. for maintenance work). After eliminating the cause, press the Lift platform
button to deactivate the restart inhibition. Then the dock leveller is ready for operation again.
Fault in the power supply Check the connecting voltage and the wiring. Check the control box to see if a fuse or the wiring
has loosened. Follow the documentation for the control.
Platform has jammed. Check to see if the movement of the platform is
blocked.

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Platform does not go down, is blocked at the highest position or during lowering
Automatic safety device (hose safety device) has been activated.
Attention Do not use the dock leveller any longer if the hose safety device has tripped. Find the cause:
The hydraulic system is contaminated or damaged.
There is air in the cylinder. There is a load on the platform while the lip is not
resting on the loading surface of the lorry. Eliminate the cause. Briefly press the Lift platform
button to unblock the platform.
The lowering speed is set too high The hydraulics pressure was set during production; it can, however, be affected by local conditions (temperature). Readjust the pressure.
Soiling or damage to the hydraulics Inspect the system for soiling and leaks on the
cylinders, hose lines, and connections. Clean the system and replace defective parts.
Incorrect oil The specified viscosity was not observed when changing or topping up the oil. Exchange the oil.
2 / 2-way valve blocks the oil flow. Press the Lift platform button. Check the function of
the solenoid coil: With a magnetic field tester or by loosening the nut and pulling the coil. Perceptible resistance indicates that the solenoid is functioning properly. Remove the valve and clean the inlet.
Platform lowers too quickly or too slowly
Extremely high or low temperatures Consult the manufacturer or supplier if the dock
leveller is operated in a cooled or heated room. It may be necessary to use a different type of oil or adjust the settings.
Do not change the settings if the malfunction is the result of a temporary temperature fluctuation.
Pressure in the hydraulic system is too low or too high The hydraulics pressure was set during production; it can, however, be affected by local conditions (temperature). Readjust the pressure.
Incorrect oil The specified viscosity was not observed when changing or topping up the oil. Exchange the oil.

MAINTENANCE
Telescopic lip does not extend Defective hose line Check the hose line for breaks or leaks. Replace defective parts.
Dirt has accumulated on the telescopic lip Increase the pressure on the valves until the
telescopic lip extends. Thoroughly clean the telescopic lip and the
underside of the platform. Bring the valve pressure back to the original level. Lip valve does not close properly. Contact the supplier's or manufacturer's customer
service department.
Telescopic lip does not retract Dirt has accumulated on the telescopic lip Completely extend the telescopic lip. Thoroughly clean the telescopic lip and the
underside of the platform. Defective hose line Check the hose line for breaks or leaks. Replace defective parts.
Lip valve does not open. Contact the supplier's or manufacturer's customer
service department.
Auto-return button does not work One of the sensors on the front of the platform or on the support yoke of the front beam does not function correctly. Check that the sensors are clean and the wiring is in
order. Replace defective sensors, if necessary.
The emergency stop switch / main switch is set to "O" or the restart inhibition is activated. Check whether (and why) the main switch has been
actuated (e.g. for maintenance work). After eliminating the cause, press the Lift platform
button to deactivate the restart inhibition. Then the dock leveller is ready for operation again.

10.4

Spare parts

Only use original spare parts from the manufacturer. The warranty claims for all defects attributable to the use of non-original spare parts will be invalidated.
When ordering spare parts, always provide the following data: All data label information, see section 13.1. Component designation, see section 15. Quantity and, if known, article number of the spare part Shipping method and personal data

It is sometimes a good idea to keep some spare parts in stock. Ask your loading technology consultant for more information.

1200017139 / 12.2023

DISMANTLING AND DISPOSAL

10.4.1 Returning parts
If the defective parts are still under warranty: Ask the supplier's or manufacturer's customer service
whether the parts have to be returned. Do not return any parts that have been damaged due
to wear, your own fault or by accident. Always provide the following data with your returns:
Type and serial number according to the data label, see section 13.1.
Serial number of the hydraulic unit, see motor data label
Delivery date, see invoice documents Reference number, e.g. order number, service report
number or ticket number, see correspondence Personal data
Assemblies must not contain hydraulic oil for customs and environmental reasons. Remove the oil from the hydraulic unit before shipping. Properly dispose of the oil.

Technical data

The specified dimensions and values apply for the standard versions.

Type
Weight
Rated load
Temperature range in the surrounding area of the hydraulic unit Energy supply
Technical data for the control Insulation panels fire behaviour

See data label
See data label
See data label
10°C to +50°C When using a suitable oil: 25°C to +50°C See data label
See the control documentation Class B s2 d0 according to EN 13501-1:2018.

13.1

Data label

Dismantling and disposal

During dismantling, make sure that the dock leveller is in home position.
Disconnect the mains voltage.
Drain the hydraulic oil and remove all hydraulic components.
Properly dispose of the components.
Completely disassemble and remove the dock leveller. Provide the components of the dock leveller to
sufficiently qualified companies for recycling.

If you intend to install the dock leveller at another location, check for operational safety in accordance with the new operating conditions.
To do this, pass these instructions, as well as documentation for the control, on to the responsible party.

Liability for defects

For the liability for defects (warranty), the generally recognised terms and conditions or those agreed in the delivery contract apply.
The liability for defects lapses for defects that can be traced back to the following causes: · Non-observance of these instructions · Improper use of the product · Improper fitting and handling of the product · Insufficient inspection and maintenance · Use of the product by unqualified personnel · Modifications to the design of the product without the
manufacturer's prior permission · Use of spare parts that were not manufactured or
approved by the manufacturer.

Explanation of the specifications

TYPE

Type and fitting model of the dock leveller

SERIAL NO.

Serial number

DIMENSIONS (NW NL NH)

Ordering width NW Ordering length NL Installation height NH

LIP SPECIFICATIONS

Lip length and shape (R = straight, S = chamfered)

SUPPLY: VOLTAGE,

Electrical data

FREQUENCY, CURRENT

PRODUCTION DATE

Production date

RATED LOAD

Rated load according to EN 1398

WEIGHT

Weight of the dock leveller

COLOUR

Colour of the dock leveller

SPECIAL PROPERTIES

Special versions and other optional extras

1200017139 / 12.2023

13.2

Dimensions and effective working range

The specified dimensions and values apply for the standard versions. The working range will deviate from the information in the tables if the installation height, length or rated load is different. If necessary, please ask the supplier or manufacturer for this information.
The dock leveller can be raised above and lowered below the ramp level.

AE BE

Levelling / effective working range:

HTL2 ISO with fully extended bridge plate

Bridge plate Bridge plate 650 mm 1150 mm

Ordering Installation AE BE AE BE

length

height

3000

645

405 395 460 420

2750

645

370 400 430 430

2500

595

340 345 395 395

2000

595

270 350 3251) 4101)

Ordering width 2000, 2100, 2250

1) Due to the design, the bridge plate is 950 mm long instead of 1150 mm.

TECHNICAL DATA

1200017139 / 12.2023

HyDRAULIC SySTEM DIAGRAM

Hydraulic system diagram

3x230V 3x400V

A Hose line, extend telescopic lip cylinder
B Hose line, retract telescopic lip cylinder
C1 Hose line for lifting cylinder C2 Hose line for lifting cylinder D Telescopic lip cylinder E Lifting cylinder 3 Main pressure relief valve 4 Free-flow valve 8 Throttle valve (lowering) 10 Hose safety device 11 Throttling, integrated in lifting
cylinder outlet y1 2 / 2-way valve, lowering
(emergency off) y2 2 / 2-way valve, extend bridge plate y3 2 / 2-way valve, retract bridge plate

1200017139 / 12.2023

OvERvIEW OF COMPONENTS

1200017139 / 12.2023

OvERvIEW OF COMPONENTS

Overview of components

Pit model (may deviate from the illustration)

3.4

2.6

2.5

3.5

5 4
2.5

2.8 3.7

3.3

3.4

3.6

3.2 3.1
3.3

2.9 2.2
7

2.4 2.7

1.3 2.1
1 38

2.3
1.2 6
1.4
1.1

1200017139 / 12.2023

OvERvIEW OF COMPONENTS

10 9

7.2

7.3 7.1

7.1 7.4

1 Base frame 1.1 Front beam 1.2 Folding supports 1.3 Sealing tarpaulin 1.4 Filler plate (deviating quantity possible) 2 Platform 2.1 Rear hinge axle 2.2 Insulation panel (aluminium) 2.3 Insulation panel holder 2.4 Insulation panel (steel) 2.5 Gap sealing 2.6 Slide plug 2.7 Bracket with brush seal 2.8 Spacer profile 2.9 Tension spring 3 Telescopic lip 3.1 Moving insulation panel 3.2 Guide profile 3.3 Gap sealing 3.4 Slider profile 3.5 Magnet 3.6 Pressure spring unit 3.7 Slide rollers 4 Foot guard plate 5 Marker stripes 6 Maintenance support 7 Hydraulic unit 7.1 Lifting cylinder 7.2 Telescopic lip cylinder 7.3 Cylinder axle 7.4 Securing split pin 8 Hose line 9 Coupling 10 Elbow screw fitting 11 Coupling with hose safety device*

* If the product deviates from the illustration (coupling as in item 9), the hose safety device is integrated in the lifting cylinder.

1200017139 / 12.2023

OvERvIEW OF COMPONENTS Frame model and box model (may deviate from the illustration)
3.4
2.6 2
2.5

3 3.5

5 4
2.5

2.8 3.7

3.3

3.4

3.6

3.2 3.1
3.3

2.9 2.2
7

2.4 2.7

2.3 1.2

6 1.4 1.3

2.1

1.1

1200017139 / 12.2023

OvERvIEW OF COMPONENTS

10 9

7.2

7.3 7.1

7.1 7.4

1 Base frame 1.1 Front beam 1.2 Folding supports 1.3 Sealing tarpaulin 1.4 Filler plate (deviating quantity possible) 2 Platform 2.1 Rear hinge axle 2.2 Insulation panel (aluminium) 2.3 Insulation panel holder 2.4 Insulation panel (steel) 2.5 Gap sealing 2.6 Slide plug 2.7 Bracket with brush seal 2.8 Spacer profile 2.9 Tension spring 3 Telescopic lip 3.1 Moving insulation panel (steel) 3.2 Guide profile 3.3 Gap sealing 3.4 Slider profile 3.5 Magnet 3.6 Pressure spring unit 3.7 Slide rollers 4 Foot guard plate 5 Marker stripes 6 Maintenance support 7 Hydraulic unit 7.1 Lifting cylinder 7.2 Telescopic lip cylinder 7.3 Cylinder axle 7.4 Securing split pin 8 Hose line 9 Coupling 10 Elbow screw fitting 11 Coupling with hose safety device*

* If the product deviates from the illustration (coupling as in item 9), the hose safety device is integrated in the lifting cylinder.

1200017139 / 12.2023

OvERvIEW OF COMPONENTS

1200017139 / 12.2023

DECLARATION OF CONFORMITy

Declaration of conformity

EC declaration of conformity (EU)
as defined in EC Machinery Directive 2006/42/EC, Annex II, Part 1 A.
Manufacturer: Hörmann KG Verkaufsgesellschaft Upheider Weg 94 - 98 33803 Steinhagen, Germany Management: Axel Becker

The manufacturer above herewith declares under his sole responsibility that the product:

Hörmann dock leveller HTL2 ISO with control 420 T, 420 Ti, 560 T
conforms to the respective essential requirements of the directives listed below with intended use, on the basis of its design and style in the version marketed by us:

2006/42/EC 2014/35/EU 2014/30/EU
2011/65/EU (RoHS)

EC Machinery Directive EU Low-Voltage Directive EU Electromagnetic Compatibility Directive EU Directive on the restriction of the use of certain hazardous substances

Applied and consulted standards and specifications (if undated, the latest edition of the publication applies, including any amendments):

· EN 1398

Dock levellers

· EN ISO 13849-1, Safety of machinery Safety-related

PL ,,c"

parts of control systems

· EN 60204-1

Safety of machinery Electrical equipment of machines

· EN 61000-6-2

Electromagnetic compatibility Immunity standard for industrial environments

· EN 61000-6-3 Electromagnetic compatibility

Emission standard for equipment in residential environments

If any of the combinations described above is fitted and commissioned according to our requirements, the construction complies with these standards. Any modifications made to the product without our approval will invalidate this declaration.
The management of the above-mentioned manufacturer is the person authorised to compile the required technical documentation.

Steinhagen, 01.07.2023

Declaration of conformity - UK
as defined in Supply of Machinery (Safety) Regulations 2008, Part 2, Annex II A.
Manufacturer: Hörmann UK Ltd. Gee Road Coalville LE67 4JW GB-Leicestershire Management: Wolfgang Gorner

The manufacturer above herewith declares under his sole responsibility that the product

2008 No. 1597 2016 No. 1101 2016 No. 1091 2012 No. 3032

Supply of Machinery (Safety) Regulations 2008
Electrical Equipment (Safety) Regulations 2016
Electromagnetic Compatibility Regulations 2016
Restriction of the use of certain Hazardous Substances (only regarding the control)

Applied and consulted standards and specifications (if undated, the latest edition of the publication applies, including any amendments):

· EN 1398

Dock levellers

· EN ISO 13849-1, Safety of machinery Safety-related

PL "c"

parts of control systems

· EN 60204-1

Safety of machinery Electrical equipment of machines

· EN 61000-6-2 Electromagnetic compatibility Immunity for industrial environments

· EN 61000-6-3 Electromagnetic compatibility Interference emission

Any modification made to this product without our express permission and approval shall render this declaration null and void.
The management of the above-mentioned manufacturer is authorised to compile the required technical documentation.

Coalville, 01.07.2023

ppa. Axel Becker Management
1200017139 / 12.2023

Wolfgang Gorner Management
43

Dissemination as well as duplication of this document and the use and communication of its content are prohibited unless explicitly permitted. Noncompliance will result in damage compensation obligations. All rights reserved in the event of patent, utility model or design model registration. Subject to changes.
HÖRMANN KG Verkaufsgesellschaft Upheider Weg 94 98 33803 Steinhagen, Germany www.hoermann.com

References

Gates, doors, frames and drives | Hoermann

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