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by
JH
I N D U S T R I E S , I N C .
1981 E. Aurora, Rd.
Twinsburg, Ohio 44087
(330) 963-410 (Phone)
1-800-321-4968 (Toll Free)
www.copperloy.com
Do not install, operate or service this product unless you have read and understand the Safety
Practices, Warnings, Installation and Operating Instructions contained in this manual. Failure to
do so could result in serious injury or death.
Model #__________________________
Serial #__________________________
Date: __________________________
Dock ift
Installation
&
Owner’s Manual
WARNING
!
A WARRANTY C AIMS MUST HAVE PRE-APPROVED RATES, TIMES AND AUTHORIZATION NUMBERS PRIOR TO ANY FIELD WORK,
IN ORDER TO BE ACCEPTED BY JH INDUSTRIES, INC.
J H Industries, Inc. expressly warrants that any PIT MOUNT OCK LIFT sold by it will be free from defects in material and workmanship under
normal use for a period of one (1) year on all structural parts and six (6) months on all electrical and hydraulic parts from the earlier of, 1) sixty (60)
days after the date of shipment, or 2) the date of installation of the PIT MOUNT OCK LIFT by the original purchaser, provided the purchaser main-
tains and operates the PIT MOUNT OCK LIFT in accordance with the Owners Manual.
In the event that the PIT MOUNT OCK LIFT proves to be defective in materials or manufacturing workmanship within the applicable period, J H
Industries, Inc. will, at its option:
1. Replace the PIT MOUNT OCK LIFT or the defective portion thereof without charge to the purchaser, or
2. Alter or repair the PIT MOUNT OCK LIFT, on site or elsewhere, without charge to the purchaser.
This warranty IS EXCLUSIVE AN IS IN LIEU OF ALL GUARANTEES AN WARRANTIES, EXPRESSE OR IMPLIE BY ANYONE OTHER
THAN J H Industries, Inc. sole warranty obligation shall be as set forth above. JH Industries, Inc. reserves the right at any time and only with prior
written notification to change or alter the warranties expressed and provided.
The warranty does not cover any failure caused by improper installation, abuse, misapplication, overloading, negligence, or failure to lubricate and
adjust the E GE-OF- OCK properly. Parts requiring replacement due to damage resulting from vehicle impact, abuse, improper operation or lack of
proper protection are not covered by this warranty. Seller assumes no responsibility or liability for (1) consequential damages of any kind which
result from the use or misuse of the PIT MOUNT OCK LIFT; (2) damage or failure resulting from the use of unauthorized replacement parts or
modification to the PIT MOUNT OCK LIFT; (3) damage resulting from the misuse of the PIT MOUNT OCK LIFT. THERE ARE NO
WARRANTIES, EXPRESSE OR IMPLIE , WHICH EXTEN BEYON THE ESCRIPTION ABOVE. THERE IS NO WARRANTY OF
MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE.
J H Industries, Inc. warranties extend only to the product itself.
J H Industries, Inc. DISC AIMS all liability arising out of the workmanship, methods and materials used by the installer.
J H Industries, Inc. DISC AIMS all liability for premature wear, product failure, property damage or bodily injury arising from improper
installation or maintenance.
WARRANTIES, whether expressed or implied, relating to workmanship and materials used in connection with the installation of
J H Industries, Inc. products are specifically DISC AIMED.
1
Verify that this is the most current Installation, O eration and Service Manuals.
To obtain an u dated version lease contact:
JH Industries Inc.
1981 E. Aurora Rd.
Twinsburg, Ohio 44087
(330) 963-4105 (Phone) or 1-800-321-4968 (toll free)
Or visit our website under EOD SEL to download and rint an u to date
version.
INTRO UCTION
Welcome, and thank you for purchasing your Pit Mount ock Lift from Copperloy by JH Industries, Inc. It is
designed to give you many years of trouble-free operation.
This manual contains information that is needed to operate and maintain the Pit Mount ock Lift safely. Each
dock lift can be modified or designed to fit each customer’s needs, there are many options and accessories that can be
added. JH Industries, Inc. cannot anticipate all possible applications and therefore all warnings, instructions and
information expressed in this manual are not all-inclusive.
This manual also contains a complete parts list and information about ordering replacement parts. JH
Industries, Inc. has selected components for best fit and function for each of our products, therefore replacement parts
should be identical to original equipment or have written approval for non-original equipment. JH Industries, Inc. will
not e responsi le for equipment failures due to incorrect or non-approved replacement parts.
WARRANTY
JH INDUSTIRES INC.
2
DANGER
WARNING
CAUTION
!
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury. This signal word is to be limited to the most extreme situations.
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe practices.
A product safety sign or label should alert persons to a specific hazard, the degree or level of hazard
seriousness, the probable consequence of involvement with the hazard, and how the hazard can be
avoided. SIGNA WORD is a word or words that designate a degree or level of hazard seriousness. The
signal words for product safety signs are “DANGER, WARNING, CAUTION” and “NOTICE”. Below is
each of these signal words along with their definitions as directly referenced from ANSI Z535.4-1998.
SAFETY
“NOTICE” is the preferred signal word to address practices not related to personal injury. The safety alert
symbol shall not be used with this signal word. As an alternative to “NOTICE”, the word “CAUTION” without
the safety alert symbol may be used to indicate a message not related to personal injury.
NOTICE!
WARRANTY……………………..
INTRO UCTION………………..
TABLE OF CONTENTS………..
SAFETY………………………….
SAFETY PRACTICES………….
GRA E CHART…………………
CAPACITY……………………….
OWNER’S RESPONSIBILITIES…
INSTALLATION………………….
GENERAL INSTALLATION…….
HY RAULIC INSTALLATION…..
OPERATION…………………….
MAINTENANCE………………...
STAN AR PARTS LIST……...
INBOAR HAN LE PARTS LIST…....
STAN AR BUMPER PARTS…
1
1
2
2
3-4
4
5
6
6-10
11-12
13-15
16-19
20-22
23
24
25
!
!
25
26
27
28-31
32
33
34
35
36-37
OPTIONAL BUMPER PARTS…..
LABEL PARTS LIST……………..
HY RAULIC SCHEMATIC……..
SINGLE PHASE ELECTRICAL
SCHEMATIC……………………
PARTS 1-PHASE INSTALLE
ASSEMBLY……………………….
3-PHASE ELECTRICAL
SCHEMATIC……………………..
PARTS 3-PHASE ENCLOSURE
ASSEMBLY……………………….
PARTS 3-PHASE INSTALLE
ASSEMBLY……………………….
NOTES……………………………
TABLE OF CONTENTS
JH INDUSTIRES INC.
SAFETY PRACTICES
3
JH INDUSTIRES INC.
Read and follow all safety practices, manuals,
and instructions before installing, operating or
servicing Pit Mount Dock ifts. Failure to follow
these safety practices and instructions could
result in property damage, equipment damage or
serious injury or death.
READ AND FO OW THE OPERATING
INSTRUCTIONS CONTAINED IN THIS MANUA
BEFORE OPERATING THE IFT TAB E. If you
do not understand the instructions or safety
practices ask your supervisor or consult the
factory for assistance.
This equipment should be used and maintained
only by qualified personnel.
Before doing any maintenance or repair on the
Dock ift SECURE WITH SUPP IED
MAINTENANCE BARS. See Figure on page .
Failure to do any of the above could result in
serious injury or death.
FOR A MODE S
Never exceed the rated capacity of the dock lift.
Never exceed the rated end or side load capacity.
o not operate the dock lift while under the
influence of drugs or alcohol.
o not operate the dock lift with equipment,
material, or people around or under the dock lift.
Always be aware of your surrounding while
operating and keep the dock lift in your sight.
Stay clear of the dock lift when it is moving, keep
hands and feet clear of moving parts at all times.
o not place any body part under the dock lift
without the maintenance bar properly secured.
Consult the factory if there is a need to maintain
the safety of people or debris from entering the
underside of the dock lift. Optional side skirts are
available.
The dock lift is not designed to carry personnel or
other material handling equipment without the
supplied handrail and safety chains installed.
Maintain equipment to safe working condition at all
times during service. See maintenance section for
servicing schedule.
o not use the dock lift it is looks damaged or does
not seem to work properly. Tell your supervisor if it
needs repair right away.
o not use this unit for anything other than it’s
intended design use.
o not attempt to lift the dock lift by any means
other than that described in the operating
procedures contained in this manual. Never use
fork trucks or other material handling equipment to
raise the lift. If the dock lift does not operate
correctly when following the operating procedures
contained in this manual, O NOT USE THE OCK
LIFT.
If you have any problems or questions using or
operating the dock lift, contact your supervisor for
assistance.
o not operate the lift table if operation causes
undue physical strain or if physical impairments
could lead to undue strain in back, muscles, limbs,
or joints.
Loads should be kept uniform as possible to insure
safe operation and maintain even wear on all
moving parts.
Keep area around dock lift free of oil, obstructions,
and debris that could cause slipping or stumbling
into equipment.
Never disconnect any hydraulic or electrical lines, or
remove any part of the dock lift unless the
maintenance bar is engaged and the electrical
power supply is turned off and locked out.
o not modify or change the design of this
equipment without written consent from JH
Industries, Inc.
Never install a dock lift in a pit unless it is supplied
with the toe guard option on the table top. If this is
required and not installed call factory for details.
WARNING
!
4
SAFETY PRACTICES,
continued
JH INDUSTIRES INC.
INSTA ATION, MAINTENANCE AND SERVICE
Place barricades on the floor around and in the
driveway in front of the dock lift’s final location while
installing, maintaining or repairing the dock lift.
PUT THE MAINTENANCE BARS IN PLACE
before doing any maintenance or repair under the
dock lift. (See Maintenance pages 21-23)
When working on any electrical components, after
raising, disconnect the power and properly tag or
lock out before doing any maintenance or repair.
All electrical troubleshooting or repair must be done
by a qualified electrician and must meet applicable
codes.
If it is necessary to make troubleshooting checks
inside the control box with the power on, USE
EXTREME CARE!
Do not place fingers or un-insulated tools inside
the control box. Touching wires or other parts
inside the control box could result in electrical
shock, death or serious injury.
PREPARATION
WARNING
Read and follow this instruction manual. Failure
to do so could result in serious injury or death.
READ AND FO OW THE INSTA ATION
INSTRUCTIONS CONTAINED IN THIS MANUA
BEFORE INSTA ING THE DOCK IFT. If you
have any questions concerning this manual or
it’s contents please contact your dealer or JH
Industries, Inc.
Permanent installation of lift table may be subject to
local code, rules and regulations. Check local
codes and regulations first. It is the owners or
installers responsibility to obtain any necessary
permits and inspections.
During storage and shipping protect the power
unit from weather and moisture. Moisture in or
around the power unit could cause electrical
shock. Prior to installation verify there is no
water or moisture present, failure to do so could
cause personal injury or death.
The electrical motor or power pack can give off
sparks and does not qualify as an explosion
proof unit unless ordered otherwise. Verify the
area where the motor will be installed is free
from flammable gasses. Explosions or fires
could result causing property damage, personal
injury or death.
For all pit installations check the pit for square and
size before installing. Measure the actual length of
width of the dock lift and the length and width of
your pit. Make sure there is 1” min. clearance
between the dock lift and pit on all four sides.
Measure from corner to corner diagonally to verify
the pit is within 1/2” square. With a contractors
square check that the vertical walls of the pit are
within 1/4” square.
Requirements for Installation:
•
Crane or fork truck with capacity to safely lift the
dock lift assembly
•
Masonry drill with bits to install lag bolts
•
Shims, lag bolts and grout
•
isconnect located near the location of the
power unit (See FIGUR # )
•
Check with local codes and regulations for any
permits or other documentation that may be
required
•
Hydraulic oil for refilling or topping off the power
unit (See FIGUR # )
•
2’-0” to 4’-0” long level and contractor’s square
•
3/4”-10 x 6”LG. Forge Eye Bolts & 3/4”-10 Hex
Nuts (Optional)
•
Spreader Bar and Chains for lifting ock Lift
Do not install dock lift if damage has occurred.
The dock lift could malfunction or fail causing
personal injury or death.
!
WARNING
!
WARNING
!
WARNING
!
5
1. Read all installation and maintenance
instructions and manuals. Read and understand
all warnings if there are any questions please
contact the manufacturer.
2. Unskid and remove all shipping material from
the dock lift. Make sure that there was no
damage to the lift during shipping. If damage
has occurred contact the owner and/or
manufacturer. o not install dock lift if damage
has occurred.
4. The dock lift can be either surface mounted or
pit mounted with the use of anchors to secure to
foundation to help maintain stability. (See
FIGUR #1, pg. 5)
FIGURE #1— ock lift possible applications
5. The dock lift can be moved with a lift truck or
slings placed around the base frame. The frame
is also equipped with threaded brackets to allow
for eyebolts to be installed. (See FIGUR #4)
Caution should be used not to deform the frame or
platform. Do not attach slings or use the top of the
table to move the lift, this could damage the dock lift.
6. When positioning the dock lift in a pit, position
the lift and align the frame carefully so a 1”
clearance is maintained around the deck or
platform. Level the unit and place solid shims
and grout under the base frame as required.
(See FIGUR #2)
FIGURE #2—Eyebolts for lifting
Mount the dock lift on a stable flat surface, grout
and add shims as needed. If not mounted
properly the dock lift could be unstable and tip
over during use which could cause serious
injury or death.
FIGURE #3—Pit Mount ock Lift Installation
Note: Above diagram is to be used as a general guide
line. Consult anchor manufacturer for specific
installation instructions.
INSTALLATION
JH INDUSTIRES INC.
ON TOP OF GRA E IN FRONT OF HIGH OCK
FLUSH WITH GRA E IN FRONT OF LOW OCK
CAUTION
!
Optional
Ramp
ock
ock
MOVE OFF AN ON
ROLLER EN
SHIM AN GROUT UN ER
ENTIRE BASE FRAME
FIXE
EN
1”
WARNING
!
ock Lift Base
3/4”-10 Captive
Hex Nut
3/4”-10 x 6”LG
Eye Bolt
Use chain spreader
bar between eye
bolts to lift dock lift
into place
Note: All lifting chains should pull vertically, do not use chains if lifting on an
angle. It is the responsibility of the operator, owner or contractor to make
sure the lifting procedure is done safely.
INSTALLATION,
continued
6
WARNING
!
WARNING
!
WARNING
JH INDUSTIRES INC.
FIGURE #4—Lag and Anchor Bolts
All anchor bolts must be installed in accordance
with the manufacturer’s instructions and local
codes and regulations. Improper installation
may result in serious injury or death.
Do not install anchor bolts in cracks or
expansion joints in concrete. Anchors may
come loose or pull out and the dock lift would
become unstable and may result in serious
injury or death.
7. rill anchor hole to diameter and depth per the
manufacturers specifications. Use a min. of 3/4”
diameter anchor bolts. All anchor bolt lengths
must suit local codes and conditions. Type and
depth of concrete will determine type and length
of anchor bolts required. (See FIGUR #3)
8. With the nut and washer in place, insert the
anchor bolt and tap into position. Tighten to
manufacturers specifications.
Keep all hydraulic oil and lines free of dirt, moisture
and any type of contamination. Be sure to flush all
hydraulic lines before connecting xternal Power
lines as they could have become contaminated
during shipping or installation. Dirt or moisture can
damage the pump or valves in the hydraulic system
or cause other problems in the hydraulic system.
9. Install the power unit in its desired location.
External power units are shipped standard with
mounting brackets to install to the floor. The
brackets can either be bolted through, welded to
a steel floor or anchor bolted into a concrete
floor. Optional wall mount brackets are
available.
10. Connect all hydraulic lines as required. Make
sure to blow out all lines prior to connection with
compressed air or flush with hydraulic fluid.
Use correct hydraulic fluid as stated in this manual.
(See FIGUR # ) If incompatible hydraulic oil is
used damage to the hydraulic system could occur.
Make sure that all hydraulic lines are free of the
dock lift during operation. A pinched or cut
hydraulic line could cause the lift table to lower
suddenly causing serious injury or death.
Never place any body part near the hydraulic
system to test or look for damaged or leaking
hydraulic lines or equipment. Exposure to high
pressure hydraulic fluid will pierce through skin
and enter the blood stream causing death.
Only qualified electricians are to work with any
electrical parts. The dock lift power supplies
can be up to 460 Volts AC, this voltage will
cause death.
Fusing requirements are shown in FIGURE #5,
all fuse sizes are calculated to work safely per
NEC specifications. Failure to fuse properly
could result in fire or electrical shock. Serious
injury or death could occur.
11. See fusing table (FIGUR #5) for correct fuse
sizing. Always use the correct fuse and wire
size for connections.
12. Follow all wiring diagrams located in this manual
to make permanent electrical connections.
13. Always verify that in 3-phase motors the motor is
turning in the correct direction as shown on the
motor housing or pump. If the motor is not
turning in the correct direction STOP, do not
operate. Change any two of the three-phase
leads to change motor direction. If this does not
!
CAUTION
!
CAUTION
!
DANGER
!
DANGER
!
7
INSTALLATION,
CONTINUE
JH INDUSTIRES INC.
Voltage Phase HP GPM Full oad
Amps
Overload
Setting
Fused
Disconnect
ifting
Time
owering
Time
120/208/230 1 1 1/2 16/8.8/8 16/9/8 25/15/15 159 sec. 20 sec.
208/230/460 3 2 2 7.5/6.8/3.4 8/7/4 15/15/15 40 sec. 20 sec.
208-230/460 3 5 3.1 11.3/5.65 12/6 25/15 26 sec. 20 sec.
PSI
3000
3000
3000
OCK LIFT EXTERNAL POWER PACK INFORMATION
NOTE: All lift times are calculated for a dock lift that requires (2) total cylinders. Lifting and lowering times will increase with the number
of cylinders required. Please consult factory for actual lift times for specific applications.
FIGURE #5
solve the issue see the trouble shooting section or
contact the factory.
If the motor is rotating in the incorrect directions this
could cause damage to the pump. Never let the
motor run longer than 3 seconds in the incorrect
direction. Always verify that the motor is turning in
the correct direction after installation.
14. Raise the dock lift to it’s full raised height.
15. Insert both maintenance bars as directed in the
maintenance section of this manual.
16. Lower the dock lift onto the maintenance bars.
(For single-acting cylinders only) continue to
depress the down button for 10 seconds to
relieve all pressure in the hydraulic system.
17. Clean up and clear the entire area around the
dock lift. Remove any material that is not
necessary for the use or function of the dock lift.
Make sure to remove all hydraulic oil from the
area. Hydraulic oil can cause unsafe work areas
and can be a fire hazard.
Any material or foreign objects in the area of the
dock lift could interfere with the movement of
the lift and cause damage. Because of pinch
points and geometry foreign objects that get
caught in the table could become projectiles and
cause personal injury or death.
Clean all hydraulic oil that is not contained in
the system. Failure to do so could result in fire
or unsafe working conditions which could cause
personal injury or death.
18. Raise the lift table to it’s full raised position.
19. Warn all personnel the lift table will be in use.
Raise the dock lift to it’s full raised height.
20. Remove both maintenance bars and place in a
safe place where it will not interfere with the use
of the dock lift.
21. Lower the dock lift to the fully lowered height.
Check the hydraulic oil level on the sight on the
side of the power unit. Fill as needed see the
maintenance section of this manual for
instructions.
22. Raise and lower the lift a few times making sure
to go from the fully raised height to the fully
lowered height. At the lowered height depress
the down button for 5-10 extra seconds to
relieve the system of it’s pressure. Verify that all
air is purged from the system. Make sure the
motor is running smoothly and quietly. The lift
should raise and lower smoothly.
23. Once the lift table has been tested fill in the se-
rial number, model number and date on the front
cover of this manual. On the back cover fill in
your company information, date installed and
contact number. By doing this you are agreeing
that the lift was installed as per the instructions
manual’s directions and per local codes and
regulations.
CAUTION
!
WARNING
!
INSTALLATION,
continued
6
JH INDUSTIRES INC.
(WI TH) + 2”
(LENGTH) + 2”
PIT RAIN
3”X3”X1/4’ MIN. CURB
ANGLE WITH ANCHOR
STRAPS (BY OTHERS)
ELECTRICAL POWER
SUPPLY LOCATION TO BE
ETERMINE BY CUSTOMER
POWER PACK
20”
2-1/2” MIN. CON UIT
WITH 14” MIN. RA IUS
20”
EPTH = LOWERE HEIGHT + 1/2”
PIT FLOOR MUST BE LEVEL
SUPPLIE BY OTHERS
FIGURE #6—Three Sided Pit Diagram
FIGURE #7—Standard Pit Diagram
(BRI GE WI TH) + 2”
(PLATFORM LENGTH) + 6-1/2”
7” 8” IA. BUMPER POST
(2) REQUIRE (BY
OTHERS)
3”X3”X1/4’ MIN. CURB
ANGLE WITH ANCHOR
STRAPS (BY OTHERS)
60”
60”
20”
20”
2-1/2” MIN. CON UIT
WITH 14” MIN. RA IUS
EPTH = LOWERE HEIGHT + 1/2”
POWER PACK
1/2” EEP
BRI GE RECESS
(BRI GE
LENGTH) - 3-1/2”