DLM DL Series User manual

DLM • Division of Systems, Inc. • W194 N11481 McCormick Drive • Germantown, WI 53022
800.643.5424 • fax: [phone] • www.docksystemsinc.com • [email protected]
Printed in U.S.A.
Copyright ©2011
Manual No. 4111-0025
March 2011
May 2012
DL-NL-TS SERIES
EOD Dock Leveler
Owner’s/User’s Manual

Page
Safety
Recognize Safety Information.................................................................1
General Operational Safety Precautions ................................................1
Operational Safety Precautions ..............................................................2
Maintenance Safety Precautions ............................................................4
Safety Decals ..........................................................................................5
Owner’s/User’s Responsibilities ..............................................................6
Introduction
General Information ................................................................................8
Dock Leveler Stock Specifications..........................................................8
Installation
Installations Details .................................................................................9
Flush Mount-Weld On ........................................................................... 10
Ramp Mount-Weld/Bolt On ................................................................... 12
Flush Mount-Bolt On ............................................................................. 14
Ramp Mount-Weld On w/Formed Angle............................................... 16
Formed Angle ....................................................................................... 18
Ramp and Face Plate ........................................................................... 20
Installation Check List ........................................................................... 22
Operation
Operating Instructions DL ..................................................................... 23
Operating Instructions NL & TS ............................................................ 24
Maintenance
Periodic Maintenance ........................................................................... 25
Troubleshooting
Troubleshooting .................................................................................... 26
Parts
DL-X Series........................................................................................... 27
NL-X Series........................................................................................... 28
TS Series .............................................................................................. 30
Extension Spring Components ............................................................. 32
Torsion Spring Components.................................................................. 34
Current vs. 2005 and Older................................................................... 35
Handle Options ..................................................................................... 36
Operating Link Options ......................................................................... 37
Bumper Components ............................................................................ 38
Sliding Bumper Components ................................................................ 39
Notes
Customer Information ........................................................................... 41
Warranty................................................................................. Back Cover
Table of Contents

1
Manual No. 4111-0025
March 2011
May 2012
SAFETY
Recognize Safety Information
Read and understand the operating instructions and
become thoroughly familiar with the equipment and its
controls before operating the dock leveler.
Never operate a dock leveler while a safety device or
guard is removed or disconnected.
Never remove DANGER, WARNING, or CAUTION
signs or decals on the equipment unless replacing
them.
General Operational Safety
Precautions
Do not activate the equipment until all unauthorized
personnel in the area have been warned and have
moved outside the operating zone.
Remove any tools or foreign objects from the operating
zone before starting.
Keep the operating zone free of obstacles that could
cause a person to trip or fall.
The use of the word DANGER signifies the presence
of an extreme hazard or unsafe practice which will
most likely result in severe injury or death.
Safety-Alert Symbol
The Safety-Alert Symbol identifies important safety
messages on equipment, safety signs, in manuals,
or elsewhere. When you see this symbol, be alert to
the possibility of personal injury or death. Follow the
instructions in the safety message.
The use of the word WARNING signifies the
presence of a serious hazard or unsafe practice
which may result in serious injury or death.
IMPORTANT
The use of the word IMPORTANT is to draw
attention to a procedure that needs to be followed to
prevent machine damage.
The use of the word CAUTION signifies possible
hazard or unsafe practice which could result in
personal injury.
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2Manual No. 4111-0025
March 2011
May 2012
SAFETY
Operational Safety Precautions
Stay clear of dock leveling device when freight
carrier is entering or leaving area.
Do not move or use the dock leveling device if
anyone is under or in front of it.
Keep hands and feet clear of pinch points. Avoid
putting any part of your body near moving parts.
Chock/restrain all freight carriers. Never remove
the wheel chocks until loading or unloading is
finished and truck driver has been given permission
to drive away.
Do not use a broken or damage dock leveling
device. Make sure proper service and maintenance
procedures have been performed before using.
Make sure lip overlaps onto trailer at least 4 in.
(102 mm).
Keep a safe distance from both side edges.
Learn the safe way to operate this equipment. Read and understand the
manufacturer’s instructions. If you have any questions, ask your supervisor.

3
Manual No. 4111-0025
March 2011
May 2012
SAFETY
Do not use dock leveling device if freight carrier is
too high or too low.
Do not overload the dock leveling device.
Do not operate any equipment while under the
influence of alcohol or drugs.
Do not leave equipment or material unattended on
dock leveling device.
Operational Safety Precautions

4Manual No. 4111-0025
March 2011
May 2012
4
SAFETY
Maintenance Safety Precautions
ALWAYS stand clear of dock leveler lip when
working in front of the dock leveler. Failure to do this
may result in serious personal injury or death.
To put handle into maintenance prop position,
remove bolt and locknut at base of handle
assembly. Pull handle out of roller arm assembly
and place into maintenance prop receiver, if
equipped.
Post safety warnings and barricade the work area at
dock level and ground level to prevent unauthorized
use of the dock leveler before installation has been
completed.
Failure to follow the installation instructions can
result in damage to dock leveler, the facilities, and/
or serious personal injury or death.

5
Manual No. 4111-0025
March 2011
May 2012
5
SAFETY
1
3
2
2
Unsupported dock leveler
ramps can lower unexpectedly.
Before allowing vehicle to leave
the dock always:


Ensure that no equipment,
material or people are on the
dock leveler.
Return the dock leveler to its
stored position at dock level.
Failure to follow posted instructions will result in death or serious injury.
SAFETY INFORMATION
Call 262.255.1510 for replacement placards, warning labels, or owner’s/user’s manuals.
Operation
1. Read and follow all instructions and
warnings in the owner’s/user’s
manual.
2. Use of dock leveler restricted to
trained operators
3. Always chock trailer wheels or
engage truck restraint before
operating dock leveler or beginning to
load or unload.
4. Never use hands or equipment to
move the ramp or lip
5.
6. Ensure that truck bed supports
extended lip or the leveler frame
Before activating dock leveler:
Ensure trailer is backed in against
bumpers.
Remove any end loads if required.
Check trailer alignment to avoid lip
interference. If lip does not lower to
trailer bed, reposition vehicle.



Supports the ramp before driving on
ramp.
7. Stay clear of hinges and front and
sides of moving dock leveler.
8. Never use damaged or
malfunctioning dock leveler. Report
problems immediately to supervisor.
1. Read and follow all instructions,
warnings and maintenance schedules
in the owner’s/user’s manual.
2. Maintenance/Service of dock leveler
restricted to trained personnel.
3. Place barriers on the driveway and on
dock floor to indicate service work is
being performed.
Maintenance/Service
4. DO NOT ENTER PIT unless dock
leveler is securely supported by
maintenance prop.
5. If electrically powered turn off and use
OSHA lockout/tagout procedures.
DANGER
Unsupported dock leveler
ramps can lower unexpectedly.
Before allowing vehicle to leave
the dock always:


Ensure that no equipment,
material or people are on the
dock leveler.
Return the dock leveler to its
stored position at dock level.
Failure to follow posted instructions will result in death or serious injury.
SAFETY INFORMATION
Call 262.255.1510 for replacement placards, warning labels, or owner’s/user’s manuals.
Operation
1. Read and follow all instructions and
warnings in the owner’s/user’s
manual.
2. Use of dock leveler restricted to
trained operators
3. Always chock trailer wheels or
engage truck restraint before
operating dock leveler or beginning to
load or unload.
4. Never use hands or equipment to
move the ramp or lip
5.
6. Ensure that truck bed supports
extended lip or the leveler frame
Before activating dock leveler:
Ensure trailer is backed in against
bumpers.
Remove any end loads if required.
Check trailer alignment to avoid lip
interference. If lip does not lower to
trailer bed, reposition vehicle.



Supports the ramp before driving on
ramp.
7. Stay clear of hinges and front and
sides of moving dock leveler.
8. Never use damaged or
malfunctioning dock leveler. Report
problems immediately to supervisor.
1. Read and follow all instructions,
warnings and maintenance schedules
in the owner’s/user’s manual.
2. Maintenance/Service of dock leveler
restricted to trained personnel.
3. Place barriers on the driveway and on
dock floor to indicate service work is
being performed.
Maintenance/Service
4. DO NOT ENTER PIT unless dock
leveler is securely supported by
maintenance prop.
5. If electrically powered turn off and use
OSHA lockout/tagout procedures.
DANGER
2
2
DANGER
!
Ramp swings toward you.
Stand Clear.
Use maintenance strut while servicing.
Failure to do so will result in death or
serious injury.
1
Decal 2 will have two positions, one on the outside of the left bumper and
one on the outside of the right bumper.
Decal 3 represents the placement of the serial tag (left side of gusset).
3.25"
9.12"
Unsupported dock leveler
ramps can lower unexpectedly.
Before allowing vehicle to leave
the dock always:
Ensure no equipment,
material or people are on
dock leveler.
Return dock leveler to its
stored position at dock level.
Failure to follow posted instructions will result in death or serious injury.
SAFETY INFORMATION
Call 262.255.1510 for replacement placards, warning labels, or owner’s/user’s manuals.
Control Box Size:
Decal Size: 9.12 x 3.25
File Name: 1751-0730 Rev A
DANGER OPERATION 7. Stay clear of hinges and front and
1. Read and follow all instructions and sides of moving dock leveler.
warnings in owner’s/user’s manual. 8. N e v e r u s e d a m a g e d o r
2. Use of dock leveler restricted to malfunctioning dock leveler. Report
trained operators problems immediately to supervisor.
3. Always chock trailer wheels or
engage truck restraint before MAINTENANCE/SERVICE
operating dock leveler or beginning to 1. Read and follow all instructions,
load or unload. warnings and maintenance
4. Never use hands or equipment to schedules in the owner’s/user’s
move ramp or lip manual.
5. Before activating dock leveler: 2. Maintenance/Service of dock leveler
 Ensure trailer is backed in against restricted to trained personnel.
3. Place barriers on the driveway and
bumpers.
dock floor to indicate service work is
 Remove any end loads if required.
being performed.
 Check trailer alignment to avoid lip 4. DO NOT ENTER PIT unless dock
interference. If lip does not lower to leveler is securely supported by
trailer bed, reposition vehicle. maintenance prop.
6. Ensure truck bed supports extended 5. If electrically powered turn off and use
lip or leveler frame supports the ramp OSHA lockout/tagout procedures.
before driving on ramp.
3.25"
9.12"
Unsupported dock leveler
ramps can lower unexpectedly.
Before allowing vehicle to leave
the dock always:
Ensure no equipment,
material or people are on
dock leveler.
Return dock leveler to its
stored position at dock level.
Failure to follow posted instructions will result in death or serious injury.
SAFETY INFORMATION
Call 262.255.1510 for replacement placards, warning labels, or owner’s/user’s manuals.
Control Box Size:
Decal Size: 9.12 x 3.25
File Name: 1751-0730 Rev A
DANGER OPERATION 7. Stay clear of hinges and front and
1. Read and follow all instructions and sides of moving dock leveler.
warnings in owner’s/user’s manual. 8. N e v e r u s e d a m a g e d o r
2. Use of dock leveler restricted to malfunctioning dock leveler. Report
trained operators problems immediately to supervisor.
3. Always chock trailer wheels or
engage truck restraint before MAINTENANCE/SERVICE
operating dock leveler or beginning to 1. Read and follow all instructions,
load or unload. warnings and maintenance
4. Never use hands or equipment to schedules in the owner’s/user’s
move ramp or lip manual.
5. Before activating dock leveler: 2. Maintenance/Service of dock leveler
 Ensure trailer is backed in against restricted to trained personnel.
3. Place barriers on the driveway and
bumpers.
dock floor to indicate service work is
 Remove any end loads if required.
being performed.
 Check trailer alignment to avoid lip 4. DO NOT ENTER PIT unless dock
interference. If lip does not lower to leveler is securely supported by
trailer bed, reposition vehicle. maintenance prop.
6. Ensure truck bed supports extended 5. If electrically powered turn off and use
lip or leveler frame supports the ramp OSHA lockout/tagout procedures.
before driving on ramp.
DANGER
!
Control Box Size:
Decal Size: 4-5/16 x 4-1/4
File Name: 1751-0763 Rev A
Ramp swings toward you.
Stand Clear.
Use maintenance strut while servicing.
Failure to do so will result in death or
serious injury.
Refer to owner’s/user’s manual for proper procedure.
Decal 2 will have two positions, one on the outside of the left bumper
and one on the outside of the right bumper.
Decal 3 represents the placement of the serial tag (left side of gusset)
2
2
1
Safety Decals

6Manual No. 4111-0025
March 2011
May 2012
OWNER’S/USER’S RESPONSIBILITIES
1. The owner/ user should recognize the inherent dangers of the interface between the loading dock and
the transportation vehicle. The owner/ user should, therefore, train and instruct all operators in the safe
operation and use of the loading dock equipment in accordance with manufacturer’s recommendations
and industry standards. Effective operator training should also focus on the owner’s/user’s company
policies and operating conditions. Maintaining, updating and re training all operators on safe working
habits and operation of the equipment, regardless of previous experience, should be done on a regular
basis and should include an understanding and familiarity with all functions of the equipment. Owner’s/
user’s shall actively maintain, update and retrain all operators on safe working habits and operations of
the equipment.
2. The manufacturer shall provide to the initial purchaser all necessary information regarding Safety
Information, Operation, Installation and Safety Precautions, Recommended Initial and Periodic
Inspections Procedures, Planned Maintenance Schedule, Product Specifications, Troubleshooting
Guide, Parts Break Down, Warranty Information, and Manufacturers Contact Information, as well as
tables to identify the grade(slope) for all variations of length or configuration of the dock leveling device
and information identifying the maximum uncontrolled drop encountered when sudden removal of support
while in the working range of the equipment.
3. It is recommended that when the transportation vehicle is positioned correctly in the dock opening and
in contact with both bumpers, there shall be a minimum of 4.00 inches (100mm) overlap of the leveling
device and the transportation vehicle at all times during the loading and unloading process.
4. The Owner/User must review all name plates, placards, decals, instructions and posted warnings and
place the same in view of the operator or maintenance personnel for whom such warnings are intended
for. Contact manufacturer for any replacements.
5. Manufacturer’s recommended periodic maintenance and inspection procedures in effect at the date of
shipment shall be followed at all times. Written documentation of maintenance, replacement parts or
damage should be retained. In the event of damage notification to the manufacturer is required.
6. Loading dock equipment that has been structurally damaged or has experienced a sudden loss of main
support while under load (such as what might occur when a transport vehicle pulls out from under the
leveling device) shall be removed from service, inspected by a manufacturer’s authorized representative,
and repaired or replaced as needed before being placed back in service.
7. Any modifications or alterations of loading dock equipment shall only be done with prior written approval
from the manufacturer and the same shall be at least as safe as the original equipment was prior to
the modification and shall also satisfy all safety requirements of the manufacturer for the particular
application of the leveling device.
8. When industrial moving devices are being used in the loading or unloading of product from the
transportation vehicle, this vehicle shall have the brakes and wheel chocks applied appropriately or
all other positive restraining device shall be fully utilized. It is recommended that trailers with air-ride
suspension systems shall have its air exhausted prior to performing loading and unloading operation to
minimize trailer bed drop.
9. Loading dock safety equipment should never be used outside of its intended use, vertical working range,
or capacity. Please consult the manufacturer if you have any questions as to the use, vertical working
range or capacity of the equipment. Only properly trained and authorized personnel should operate the
equipment.
10. When selecting loading dock safety equipment, it is important to consider not only present requirements
but also future plans and any possible adverse conditions, environmental factors or usage.

7
Manual No. 4111-0025
March 2011
May 2012
NOTES
This page intentionally left blank

8Manual No. 4111-0025
March 2011
May 2012
INTRODUCTION
General Information
DL-NL-TS Series Edge-of-Dock levelers are available
in the following sizes, weight capacities, and options:
Congratulations on your choice of a DLM Edge-of-
Dock leveler. This manual covers the DL-NL-TS series
mechanical Edge-of-Dock levelers.
Designed by DLM to be a marvel of simplicity and
efficiency, your dock leveler, when properly installed,
will provide many years of trouble-free performance
with an absolute minimum of maintenance. To obtain
maximum performance and longest possible use,
a simple program of preventive maintenance is
recommended.
Once again, thank you and congratulations on your
purchase of a DLM mechanical Edge-of-Dock leveler.
Dimensions and Capacities
Model # - Deck - Total Unit
Width Width Comparative Industry Rating
DL-66 66” 104”
DL-72 72” 110”
DL-78 78” 116”
20,000
25,000
30,000
(N/A for DL-78)
Dimensions and Capacities
Model # - Deck - Total Unit
Width Width Comparative Industry Rating
NL-66 66” 104”
NL-72 72” 110”
NL-78 78” 116”
NL-84 84” 122”
20,000
25,000
30,000
35,000 (N/A for NL-84)
Dimensions and Capacities
Model # - Deck - Total Unit
Width Width Comparative Industry Rating
TS-66 66” 104”
TS-72 72” 110”
TS-78 78” 116”
TS-84 84” 122”
20,000
25,000
30,000
35,000 (N/A for TS-78 & 84)

9
Manual No. 4111-0025
March 2011
May 2012
INSTALLATION
INSTALLATION DETAILS
IMPORTANT
DO NOT remove the shipping bands around the
dock leveler lip until instructed to do so.
Post safety warnings and barricade the work area at
dock level and ground level to prevent unauthorized
use of the dock leveler before installation has been
completed.
Failure to follow the installation instructions can
result in damage to dock leveler, the facilities, and/
or serious personal injury or death.
Only trained installation professionals with the
proper equipment should install this product.
50 INCH
PREFERRED

10 Manual No. 4111-0025
March 2011
May 2012
INSTALLATION
E.O.D. Installation Instructions - Flush Mount - Weld On
A flush mount weld on application is used when an 8”
wide (minimum) embed channel is securely anchored
into the concrete at the dock edge, and the dock height
is adequate.
Installation Steps:
1. Remove all existing bumper material and
protruding objects from dock edge. Clean and
sweep dock edge free of debris and flammable
chemicals before installing unit.
2. At chosen location for Edge-of-Dock leveler,
locate the center of space and mark a point half of
the base plate width to the left and right.
3. Using a proper lifting device, raise and position
leveler on dock face with the top of the base plate
being flush with the top of the embedded channel.
Position ends of base plate to match up with
marks made previously.
4. Tack weld base plate to dock steel on left hand
end of the leveler. Check right hand end of base
plate, ensure that end is against dock steel and
that the top of the base plate is still flush with the
top of the embedded channel. Tack right hand
end to dock steel.
5. Position bump blocks out approximately 5/8” from
the edge of the inside flange of the bump block
to the end of the base plate. This will allow for
vertical welding of both the base plate and the
bump block flange back to the dock steel. Top of
the bump block cover plate should be flush with
the top of the embed channel. Tack weld bump
blocks to dock steel.
6. Check the positioning of the base plate and the
bump blocks.
7. Complete welding of tacked parts as follows:
A. Apply a continuous weld across top of each
bumper and base plate to dock steel. Skip
welding is acceptable to prevent warpage,
but complete weld across the top must be
completed.
B. Weld vertically along each end of base plate
and on both inboard and outboard flanges of
bump blocks.
C. Fully plug weld all holes in base plate.
8. Installer must remove all welding slag, and repaint
welded areas.
9. Installer must adjust springs on all mechanical
Edge of Dock levelers to provide desired tension
for smooth operation. Stand in front of leveler, with
the unit raised and secured in the maintenance
position, loosen jam nut on the underside of the
linkage pin. To start allow about 3/4” to 1” of
threads between top of jam nut and linkage pin.
Using an open faced wrench, hold locknut on
inside of spring while tightening threaded bolt until
washer on top side of spring closes up tight to jam
nut. Test operation of unit. Further adjust spring
tension if needed by advancing jam nut toward
linkage pin and tightening threaded rod. After
desired unit operation is achieved, tighten jam
nut to outer washer on spring. Springs must be
adjusted alternately to have equal spring tension.
10. Before install is complete, installer must make
a final operational check of dock leveler to
verify all phases of install are correct. Installer
must complete, sign and return the Installation
Checklist upon completion. Reference page 22
Follow all safety precautions prior to installation.

11
Manual No. 4111-0025
March 2011
May 2012
NOTE DESCRIPTION
1
Top of base plate and bumper cover plate to be flush with top of dock floor and embedded channel
2
Apply continuous bevel weld across both bumpers and length of base plate.
INSTALLATION
Securely block or support ramp and lip when in vertical positions. Lack of proper bracing can result in ramp dropping during adjustment or installation causing personal injury or damage to unit.

12 Manual No. 4111-0025
March 2011
May 2012
INSTALLATION
A ramp mount weld on application is used when adequate
dock steel is securely anchored in the concrete at the dock
edge, but the existing dock height is too low and the dock
leveler must be installed above this height to correct this
situation.
Installation Steps:
1. Remove all existing bumper material and protruding
objects from dock edge. Clean and sweep dock
edge free of debris and flammable chemicals before
installing unit.
2. At chosen location for Edge of Dock leveler, locate the
center of space and mark a point half of the base plate
width to the left and right.
3. At the points marked to each side of center, measure
and mark points 7 - 3/4” below dock level less height
the unit is to be raised to locate bottom of base plate.
This will locate the top of the base plate X” above dock
level.
4. Using a proper lifting device, raise and position the
leveler base plate to marked position. While holding
base plate tight against dock face, tack weld securely
to dock steel on left hand end of leveler. Check right
hand end of base plate, ensure that end is against dock
steel and that the bottom of the base plate is even with
the marks made previously. Tack right hand end to
dock steel. Support unit until final welding is ready to
complete.
5. Position bump blocks out approximately 5/8” out from
the edge of the inside flange of the bump block to the
end of the base plate. Position the top of the tread
cover plate on the bump blocks to be flush with the
top of the base plate. Tack weld bump blocks to dock
steel.
6. Place steel ramp plate in position, flush with top
backside of base plate. Mark along full length of back
edge of ramp plate. Slide ramp plate forward over dock
leveler the width of bushing tool, approximately 2”.
7. Place bushing tool on marked line at each end of ramp
to ensure proper alignment at both ends, and tack weld
ramp plate to dock leveler to hold ramp plate in place
while bushing. A Skil Roto Hammer #736 or similar tool
is recommended.
8. Using the back edge of the ramp plate as a guide,
groove concrete approximately 3/4” deep by 2” wide,
and should be the entire length of ramp plate.
9. Break tack welds holding ramp in place, slide ramp
plate back into position with the top of the ramp plate
flush with the top of the base plate. Tack weld each
end and center of ramp plate to base plate.
10. Drill 5/8” dia. by 5” deep holes through ramp plate at
back edge. Install anchor bolts per manufacturers
specifications, and tighten securely. Weld anchor bolt
nuts to ramp plate using a 1/4” fillet weld all the way
around the nut. Cut off any portion of the anchor bolt
exposed through the nut, and plug weld around the top
of the nut to the anchor bolt. Ensure the top of the nuts
are well rounded for smooth rollover.
11. Complete welding of tacked parts as follows:
A. Apply continuous weld across top of each bumper
and base plate to ramp plate. Skip welding is
acceptable to prevent warpage, but complete
weld must be completed.
B. Weld vertically along each end of base plate and
on both inboard and outboard flanges of bump
blocks.
C Fully plug weld all holes in base plate.
12. Installer must remove all welding slag, and repaint
welded areas.
13. Installer must adjust main springs on all mechanical
Edge of Dock levelers to provide desired tension for
smooth operation. Stand on ground in front of leveler,
with the unit raised and secured in the maintenance
position, loosen jam nut on the underside of the linkage
pin. To start allow about 3/4” to 1” of threads between
top of jam nut and linkage pin. Using an open faced
wrench, hold locknut on inside of spring while tightening
threaded bolt until washer on top side of spring closes
up tight to jam nut. Test operation of unit. Further
adjust spring tension if needed by advancing jam nut
toward linkage pin and tightening threaded rod. After
desired unit operation is achieved, tighten jam nut to
outer washer on spring. Springs must be adjusted
alternately to have equal spring tension.
14. Before install is complete, installer must make a final
operational check of dock leveler to verify all phases
of install are correct. Installer must complete, sign,
and return the Installation Checklist upon completion.
Reference page 22
E.O.D. Installation Instructions - Ramp Mount - Weld/Bolt On
Follow all safety precautions prior to installation.

13
Manual No. 4111-0025
March 2011
May 2012
NOTE DESCRIPTION
1
Top of base plate and bumper cover plate to be flush with top of ramp plate.
2
Apply continuous bevel weld across both bumpers and length of base plate.
3
To figure ramp plate length, need 12” ramp for every 1-1/2” of rise to ramp.
INSTALLATION
Securely block or support ramp and lip when in vertical positions. Lack of proper bracing can result in ramp dropping during adjustment or installation causing personal injury or damage to unit.

14 Manual No. 4111-0025
March 2011
May 2012
INSTALLATION
A flush mount bolt on application is used when there
is no steel on dock edge, and the dock height is
adequate. Additional steel ramp plate and bolting is
required with this type of installation.
Installation Steps:
1. Remove all existing bumper material and
protruding objects from dock edge. Clean and
sweep dock edge free of debris and flammable
chemicals before installing unit.
2. At chosen location for Edge of Dock leveler,
locate the center of space and mark a point half of
the base plate width to the left and right.
3. At the points marked to each side of center,
measure and mark points 7-1/2” below dock level
(for 1/4” ramp plate) to locate position for bottom
of base plate. This position will place the top of
the base plate 1/4” above the dock floor. This
position will vary with ramp plate thickness.
4. Mark line connecting these points and position
support angles. Position angles as shown in
installation drawing provided. Mark center of
holes in each of the support angels.
5. At center marks, drill holes 5/8” dial. by 5”
deep in concrete. Install anchor bolts with
washers through support angles into holes in
concrete. Tighten bolts until support angles are
secure. Follow anchor manufacturers installation
instructions for proper installation.
6. Using a proper lifting device, raise and position
the leveler base plate to marked position, while
resting on the support angles. While holding base
plate tight against dock face, tack weld securely
to support angles.
7. Drill 5/8” dia. by 5” deep holes in concrete through
holes in base plate, and install anchor bolts with
washers and tighten securely.
8. Position bump blocks out approximately 5/8” out
from the edge of the inside flange of the bump
block to the end of the base plate. Position the
top of the tread cover plate on the bump blocks to
be 1/4” above dock level. Note that this placement
will vary with ramp plate thickness. Mark centers
of holes in bump block flanges.
9. Drill 5/8” dia. by 5” deep holes at center marks.
Reposition bump blocks, insert anchor bolts with
washers and tighten securely to dock face.
10. Place steel ramp plate in position, flush with top
backside of base plate. Mark along full length
of base edge of ramp plate. Slide ramp plate
forward over dock leveler the width of brushing
tool, approximately 2”.
11. Place bushing tool on marked line at each end of
ramp to ensure proper alignment at both ends,
and tack weld ramp plate to dock leveler to hold
ramp plate in place while bushing. A Skil Roto
Hammer #736 or similar tool is recommended.
12. Using the back edge of the ramp plate as a guide,
groove concrete approximately 5/8” deep by 2”
wide, and should be the entire length of ramp
plate.
13. Break tack welds holding ramp in place, slide
ramp plate back into position with the top of the
ramp plate flush with the top of the base plate.
Tack weld each end and center of ramp plate to
base plate.
14. Drill 5/8” dia. by 5” deep holes through ramp plate at
back edge. Install anchor bolts per manufacturers
specifications, and tighten securely. Weld anchor
bolt nuts to ramp plate using a 1/4” fillet weld all
the way around the nut. Cut off any portion of the
anchor bolt exposed through the nut, and plug
weld around the top of the nut to the anchor bolt.
Ensure the top of the nuts are well rounded for
smooth rollover.
15. Complete welding of tacked parts as follows:
A. Apply continuous weld across top of each
bumper and base plate to ramp plate. Skip
welding is acceptable to prevent warpage,
but complete weld must be completed.
B. Weld bottom of base plate support angles
using a 1/4” fillet weld.
16. Installer must remove all welding slag, and
repaint welded ares.
17. Installer must adjust main springs on all mechanical
edge of dock levelers to provide desired tension
for smooth operation. Stand on ground in front
E.O.D. Installation Instructions - Flush Mount - Bolt On
Follow all safety precautions prior to installation.

15
Manual No. 4111-0025
March 2011
May 2012
of lever, with the unit raised and secured in the
maintenance position, loosen jam nut on the
underside of the linkage pin. To start allow about
3/4” to 1” of threads between top of jam nut
and linkage pin. Using an open faced wrench,
hold locknut on inside of spring while tightening
threaded bolt until washer on top side of spring
closes up tight to ram nut. Test operation of
unit. Further adjust spring tension if needed
by advancing jam nut toward linkage pin and
tightening threaded rod. After desired operation
is achieved, tighten jam nut to outer washer on
spring. Springs must be adjusted alternately to
have equal spring tension.
18. Before install is complete, installer must make
a final operation check of dock leveler to verify
all phases of install are correct. Installer must
complete, sign and return the Installation Checklist
up on completion. reference page 22
INSTALLATION
NOTE DESCRIPTION
1
Top of base plate and bumper
cover plate to be flush with top of
ramp plate.
2
Apply continuous bevel weld
across both bumpers and length of
base plate.
Securely block or support ramp and lip when in
vertical positions. Lack of proper bracing can result
in ramp dropping during adjustment or installation
causing personal injury or damage to unit.

16 Manual No. 4111-0025
March 2011
May 2012
INSTALLATION
A ramp mount-weld on used with a formed angle application
is used when dock edge is damaged, there is no dock steel
securely anchored into the concrete, and the dock height is
too low and leveler must be installed above this height to
correct this situation.
Installation Steps:
1. Remove all existing bumper material and protruding
objects from dock edge. Clean and sweep dock
edge free of debris and flammable chemicals before
installing unit.
2. Review and follow formed angle installation instructions
prior to leveler installation. Page 18
3. At chosen location for Edge of Dock leveler, locate the
center of space and mark a point half of the base plate
width to the left and right.
4. At the points marked to each side of center, measure
and mark points 7-3/4” below dock level less height the
unit is to be raised to locate bottom of base plate. This
will locate the top of the base plate X” above dock level.
5. Using a proper lifting device, raise and position the
leveler base plate to marked position. While holding
base plate tight against dock face, tack weld securely
to dock steel on left hand end of leveler. Check right
hand end of base plate, ensure that end is against dock
steel and that the bottom of the base plate is even with
the marks made previously. Tack right hand end to
dock steel. Support unit until final welding is ready to
complete.
6. Position bump blocks out approximately 5/8” out from
the edge of the inside flange of the bump block to the
end of the base plate. Position the top of the tread
cover plate on the bump blocks to be flush with the
top of the base plate. Tack weld bump blocks to dock
steel.
7. Place steel ramp plate in position, flush with top
backside of base plate. Mark along full length of back
edge of ramp plate. Slide ramp plate forward over dock
leveler the width of bushing tool, approximately, 2”.
8. Place bushing tool on marked line at each end of ramp
to ensure proper alignment at both ends, and tack weld
ramp plate to dock leveler to hold ramp plate in place
while bushing. A Skil Roto Hammer #736 or similar tool
is recommended.
9. Using the back edge of the ramp plate as a guide,
groove concrete approximately 3/4” deep by 2” wide,
and should be the entire length of ramp plate.
10. Break tack welds holding ramp in place, slide ramp
plate back into position with the top of the ramp plate
flush with the top of the base plate. Tack weld each
end and center of ramp plate to base plate.
11. Drill 5/8” dia. by 5” deep holes through ramp plate at
back edge. Install anchor bolts per manufacturers
specifications, and tighten securely. Weld anchor bolt
nuts to ramp plate using a 1/4” fillet weld all the way
around the nut. Cut off any portion of the anchor bolt
exposed through the nut, and plug weld around the top
of the nut to the anchor bolt. Ensure the top of the nuts
are well rounded for smooth rollover.
12. Complete welding of tacked parts as follows:
A. Apply continuous weld across top of each bumper
and base plate to ramp plate. Skip welding is
acceptable to prevent warpage, but complete
weld must be completed.
B Weld vertically along each end of base plate and
on both inboard and outboard flanges of bump
blocks.
C Fully plug weld all holes in base plate.
13. Installer must remove all welding slag, and repaint
welded areas.
14. Installer must adjust main springs on all mechanical
Edge of Dock levelers to provide desired tension for
smooth operation. Stand on ground in front of leveler,
with the unit raised and secured in the maintenance
position, loosen jam nut on the underside of the linkage
pin. To start allow about 3/4” to 1” of threads between
top of jam nut and linkage pin. Using an open faced
wrench, hold locknut on inside of spring while tightening
threaded bolt until washer on top side sprint closes
up tight to jam nut. Test operation of unit. Further
adjust spring tension if needed by advancing jam nut
toward linkage pin and tightening threaded rod. After
desired unit operation is achieved, tighten jam nut to
outer washer on spring. Springs must be adjusted
alternately to have equal spring tension.
15. Before install is complete, installer must make a final
operational check of dock leveler to verify all phases
of install are correct. Installer must complete, sign,
and return the Installation Checklist upon completion.
reference page 22.
E.O.D. Installation Instructions - Ramp Mount - Weld On w/Formed Angle
Follow all safety precautions prior to installation.

17
Manual No. 4111-0025
March 2011
May 2012
INSTALLATION
NOTE DESCRIPTION
1
Top of base plate and bumper cover plate to be flush with top of ramp plate.
2
Apply continuous bevel weld across both bumpers and length of base plate.
3
To figure ramp plate length, need 12” ramp for every 1-1/2” of rise to ramp.
4To install formed angle, see formed
angle installation instructions.
Securely block or support ramp and lip when in vertical positions. Lack of proper bracing can result in ramp dropping during adjustment or installation causing personal injury or damage to unit.

18 Manual No. 4111-0025
March 2011
May 2012
INSTALLATION
A formed angle is used when there is no existing
dock steel and concrete at the dock edge has been
damaged. The formed angle is required to rebuild the
damaged concrete edge for a proper installation if the
dock height is adequate.
Installation Steps:
1. Remove all existing bumper material and
protruding objects from dock edge. Clean and
sweep dock edge free of debris and flammable
chemicals before installing unit.
2. At chosen location for the formed angle, locate
the center of space and mark a point half of the
angle width to the left and right.
3. Using a proper lifting device, raise and position
the formed angle to marked position, slide formed
angle against dock face.
4. Mark along full length of back edge of formed
angle. Slide angle forward the width of brushing
tool, approximately 2”.
5. Place bushing tool on marked line at each end of
formed angle to ensure proper alignment at both
ends. A Skil Roto Hammer #736 or similar tool is
recommended.
6. Using the back edge of the formed angle as a
guide, groove concrete approximately 5/8” deep
by 2” wide, and should be the entire length of the
formed angle.
7. Slide formed angle back until tight against dock
face. drill 5/8” dia. by 5” deep holes through
formed angle at back edge. Install anchor bolts
per manufacturers specifications, and tighten
securely. Weld anchor bolt nuts to formed angle
using a 1/4” fillet weld all the way around the nut.
Cut off any portion of the anchor bolt exposed
through the nut, and plug weld around the top of
the nut to the anchor bolt. Ensure the top of the
nuts are well rounded for smooth rollover.
8. Drill 5/8” dia. by 5” deep holes in dock face
through holes in formed angle. Install anchor
bolts with washers and tighten securely per
manufacturers specifications.
E.O.D. Installation Instructions - Formed Angle
Follow all safety precautions prior to installation.