Alutech SL Series User manual

OPERATIONAL
MANUAL
Electrohydraulic leveller
withswing lip
SL series
English
2020 www.alutech-group.comwww.alutech-group.com

OPERATIONAL MANUAL. ELECTROHYDRAULIC LEVELLER WITH SWING LIP SL SERIES 33
ONTENT
1. General information .............................................................................................5
1.1. Usage of operational manual............................................................................................................................5
1.2. Warranty ...................................................................................................................................................................5
2. Description and work ...........................................................................................6
2.1. Product designation.............................................................................................................................................6
2.2. Тechnical characteristics .....................................................................................................................................6
2.3. Device components..............................................................................................................................................7
2.4. Design and work....................................................................................................................................................8
3. Intended use .........................................................................................................9
3.1. Operating restriction............................................................................................................................................9
3.2. Possible defects...................................................................................................................................................10
3.3. Operation in extreme conditions ................................................................................................................. 10
3.4. Maintenance and cleaning ............................................................................................................................. 10
4. Decommissioning and disposal.........................................................................10

OPERATIONAL MANUAL. ELECTROHYDRAULIC LEVELLER WITH SWING LIP SL SERIES 55
GENERAL INFORMATION
1. GENERAL INFORMATION
1.1 USAGE OF OPERATIONAL MANUAL
This manual describes construction, specications and the principle of electrohydraulic levellers
with hinged lip (ALUTECH SL series), safety technique and operation in extreme conditions.The
information in this manual contains the rules of operation for levellers, which are built in pits, as
well as in combination with transshipment sites (ALUTECH PSL series).
The manual is intended for the operator of the leveller. After completing this tutorial you will be
able to work with the leveller, but you cannot independently x potential problems. For trouble-
shooting you should contact an authorised representative of the ALUTECH Group of Companies.
1.2 WARRANTY
The warranty period of the basic product is 2years. The warranty period of product compo -
nents is: 2 years for the control unit, 1year for the hydraulic unit, hydraulic cylinders and hoses.
A10-year-warranty is given to the Customer against corrosion perforation.
The warranty period is calculated from the supply date of the product to the Customer or the
manufacture date of the product, if the supply date is unknown. The guarantee does not apply
to components, exposed to natural wear (eg, rubber seals).
YATTENTION! During the warranty period, malfunctions caused by Manufacturing faults or by
the Manufacturer authorised Organization that performed installation of the product will be
eliminated by the service sta this Organization.
Warranty obligations are considered invalid in case of:
• operation, maintenance and/or repair contrary to the instructions described in
technical documents;
• in the absence of entries in the maintenance/service passport;
• installation and/or repair by people, which have no authorization from the ALUTECH
Group of Companies;
• use of non-original spare parts of the manufacturer;
• the availability of evidence of illegal, inappropriate or hard usage of the equipment;
• force majeure (fire, lightning, floods, earthquakes and other natural disasters);
• usage of the leveller for other purposes;
• when the item construction has been broken by the Customer or the third parties.

OPERATIONAL MANUAL. ELECTROHYDRAULIC LEVELLER WITH SWING LIP SL SERIES66
DESCRIPTION AND WORK
2. DESCRIPTION AND WORK
2.1 PRODUCT DESIGNATION
Alutech SL series levelling platforms are designed to compensate for the height dierence and
the distance between the ramp or the oor space and the body of the truck that occur during
loading and unloading works.
2.2 ECHNICAL CHARACTERISTICS
The top sheet of the rotating part: steel 6/8 mm with diamond tread pattern
Lip sheet: steel 12/14 mm with diamond tread pattern
Safety devices: full emergency stop of the hydraulics;
lock cylinders in case of premature departure of the truck
Voltage: 230/400 V
Cycles: 50Hz
Power of motor: 0,75kW
Overall diameter of the lift cylinders: 50mm
Overall diameter of the lip cylinder: 50mm
Operating temperature: −25…+50 °C
Tankage of the hydraulic unit 7L
Hydraulic oil: normally—RENOLIN B HVI ISO VG 22 (to −15 °C)
optionally—RENOLIN MR 310 HVLPD 15 (up to −40 °C)
Table1 contains the values of the eective working area, depending on the length of the leveller.
Table 1
The size of the eective working areaThe size of the eective working area
Ordered length, mmOrdered length, mm Operational height H, mmOperational height H, mm , mm, mm , mm, mm
2000 600 265 295
2500 600 325 295
3000 700 390 290
3500 800 450 390
4000 900 510 390
4500 900 570 380

OPERATIONAL MANUAL. ELECTROHYDRAULIC LEVELLER WITH SWING LIP SL SERIES 77
DESCRIPTION AND WORK
Рic. 1. Eective working area of the leveller
The maximum permissible deviation in the operation of the leveller, in accordance with standard
EN 1398 is 12.5%, i.e. about 7°. For dierent types of loading equipment the maximum slope of
the leveller should be taken in accordance with Table 2.
Table 2
TypeType
of loading equipmentof loading equipment
The maximum slope deviationThe maximum slope deviation
of the rotary part of the lipof the rotary part of the lip
Handtruck 3% (1,7°)
Power truck 5% (3°)
Battery forklift 10% (6°)
Truck with combustion engine 12,5% (7°)
The angle of 7° is marked with a red rectangle on the side walls of the hinged part of the level-
ler. When the mark is visible above the oor, loading and unloading of the vehicle is forbidden.
2.3 DEVICE COMPONENTS
Lip cylinder
Hydraulic unit
Lift part
Back support
Lift cylinder
Support beam
Service support
Reinforcing prole
Reinforcing rod Bracket
Curtains
(frame)
Lip axle
Lip
Рic. 2. General view of the platform

OPERATIONAL MANUAL. ELECTROHYDRAULIC LEVELLER WITH SWING LIP SL SERIES88
DESCRIPTION AND WORK
The main components of the leveller are:
• Back support (frame). Designed for mounting the back part of the leveller to the pit;
• Lift part. Compensate for the difference in height of the truck body and the loading ramp;
• lip. Designed for overlapping and resting on the vehicle body;
• Support beam. Required for mounting the front part of the leveller to the pit. It is a
support element for fastening the hydraulic cylinders;
• Protective shutters. Used for closing of the gap between leveller and pit when the leveller
is in the raised position. Provides protection from crushing or entrapment oflimbs;
• Service support. Used to lock the rotary motion of the leveller during maintenance or
service work;
• Hydraulic unit. It provides hydraulic oil into the cylinders, thereby lifting the rotary part
of the leveller;
• Hydraulic cylinders. They are used for raising and lowering the rotary part of the leveller;
• Lip cylinder. It provides turning and folding of the lip.
2.4 DESIGN AND WORK
YATTENTION! During leveller positioning on to the body of the truck, you should make sure
that people or other objects are not within the working area of leveller. Only qualied workers
can manage the leveller. You should monitor carefully the movement of leveller during the
operation. Everyone who works with the leveller should be acquainted with its functions. The
operator must carefully read the operational manual.
During lifting of the loading/unloading platform by pressing the button for raising of the leveller,
the main power switch button must be turned on the‘1’position. Otherwise, the leveller will not
follow the height dierence of the truck body, and lead to machinery breakdown.
2.4.1 INTERFACING WITH VEHICLE
For safety reasons it is recommended to ensure the following things:
• there are no people or foreign objects at the entrance between the vehicle and the leveller;
• when you are driving up the drop side (tail lift) of the vehicle must be lowered;
• after parking, the vehicle (trailer) is fixed in place and cannot roll back or drive off
(the ignition key switched off, hand brake applied and wheel wedges installed).
2.4.2 LEVELLER POSITIONING IN THE VEHICLE BODY
YATTENTION! If leveller lip is equipped with additional unfolding segmentation, for narrower width
vehicles, the segments will be folded automatically. After the unsetting action of the leveller side
segments, they will return to the operating state. During the next operational cycle the central part
and the side segments will be rotated together, allowing use of the entire width of the lip.
To install the leveller in the vehicle body:
• turn the main switch to position ‘1’. During the leveller operation, loading or unloading
works it is prohibited to change the switch position;
• press the lip lift button. Hold it until the rotating part rises to the highest position and
the lip forms a single plane with the rotating part of the leveller;
• release the lift button. After this the rotating part begins to drop, and the lip lies on the
loading surface of the vehicle body;
• make sure the lip finally lies on the vehicle body surface and comes into it 80–100 mm
across its full-width.

OPERATIONAL MANUAL. ELECTROHYDRAULIC LEVELLER WITH SWING LIP SL SERIES 99
INTENDED USE
YATTENTION! During the loading/unloading process it is essential to control the lip position
within the vehicle body. If the lip has moved, it is necessary to stop work immediately. Lift
truck maximum travel speed should not exceed 5km/h.
2.4.3 LEVELLER UNSET
Оperational sequence after cargo handling works:
• press lip lift button. Immediately, the rotating part of the lip begins to rise, and at the
same time the lip folds. Hold the button until the lip folds fully;
• release the lift lip button. After this the rotating part begins to drop, and the platform
will unset;
• make sure the ramp is on the supports.
YATTENTION! If you hold the lip lift button for a long time, the rotating part reaches the top
position, and the lip starts to fold-out, i.e., platform switches into positioning mode.
3. INTENDED USE
3.1 OPERATING RESTRICTION
YATTENTION! Failure to comply with the rules of operation can lead to breakage of equipment
and injury of people!
• The leveller is not a lifting platform! Do not use it for lifting and lowering objects
or people. In the case of misuse or non-observance of current operating manual
instructions the product manufacturer is not responsible for damage to Customer’s
equipment and property and injury to the people;
• do not use the leveller combined with a vehicle lift tailgate;
• lift truck maximum travel speed should not exceed 5km/h.
• during operation of the leveller or the loading/unloading process, do not set the switch
to ‘0’ position;
• do not exceed the maximum angle of leveller lifting during the loading/unloading
process (7°);
• do not exceed the maximum load on the leveller (6 tons). It permits the use of loading
equipment (truck,electric pallet trucks, hydraulic hand truck, etc.), when the maximum
width of the wheels (seedimension X) isless than the width of the platform byat least
700mm (pic.3).
B
X
Pic.3

OPERATIONAL MANUAL. ELECTROHYDRAULIC LEVELLER WITH SWING LIP SL SERIES1010
DECOMMISSIONING AND DISPOSAL
3.2 POSSIBLE DEFECTS
If failures occur, the risk of unsafe operation of the leveller increases. Operation of the defec-
tive leveller may cause injury to people and damage to objects. For troubleshooting refer to
organisations accredited by the ALUTECH group of companies.
3.3 OPERATION IN EXTREME CONDITIONS
In case you need to immediately halt the dock leveller, turn the red-yellow power switch into
the ‘0’ position. This will result in leveller movement blocking. Leveller movement blocking
happens in the following cases:
• when the switch is moved into ‘0’ position;
• when the mains power supply is cut.
After the mains power supply is restored it is necessary to press the platform lift button. The
dock leveller will return into freewheel mode.
3.4 MAINTENANCE AND CLEANING
Maintenance procedure is described in detail in the relevant section of the service book, which
you can download from the website alutech-group.com.
Dicult equipment handling operations call for professional knowledge. For your safety we
strongly recommend that you take out a contract for aftersales service with an organisation
accredited by ALUTECH GC.
The place under the platform needs to be kept clean. Debris accumulation prevents dock leveller
from functioning normally. Leveller pivot joints should be clean and free from dirt, stones and
other rubbish. Platform surface should be clean and dry. Don’t use aggressive substances or salt
to clean the platform. This may lead to corrosion.
4. DECOMMISSIONING AND DISPOSAL
If dock leveller is out of order it should be carefully disassembled and recycled. The disassembly
procedure is given below:
• before disassembly make sure the platform is in the inoperative position;
• deactivate supply voltage;
• drain any hydraulic oil, disassemble all hydraulic units and recycle them according to
current requirements and directions;
• after that fully disassemble the platform and take away all its parts. Appropriate
organisations may recommission dock leveller parts. If the platform is to be installed in
another place it is necessary to check operation safety according to new conditions of use;
• pass this manual and documentation on the control unit together with the platform to
the company dealing in disposal.