Southworth Dura-Dock DDL5-59M User manual
October 4, 2022
Model:
Serial Number: __________________________
Date placed in service: __________________________
Dura-Dock Dock Lift
(DDL5-59M, DDL6-59M, DL8-59M)
SOUTHWORTH PRODUCTS CORP.
P.O. Box 1380, Portland, ME 04104-1380W
TF +1.800.743.1000 | D +1.207.878.0700 | F +1.207.797.4734
www.SouthworthProducts.com
Owner
Manual
The information in this manual is for our standard machines, if you have any questions
regarding the specifications and dimensions of your actual lift table, contact Southworth
Customer Service or Southworth Sales if your order is being quoted or is in process.
Southworth Products DDL Dock Lift Manual
2Southworth Products DDL Dock Lift Manual
Contents
1 ........................................................................................................ 4
1.1 Specications............................................................................................................................... 4
1.2 Non-Standard Machines .............................................................................................................. 4
1.3 Responsibilities of Owner and Users ........................................................................................... 5
1.4 Responsibilities of Operators ....................................................................................................... 6
2 ................................................................................................................... 8
2.1 Safety Alert Symbols.................................................................................................................... 8
2.2 Signal Words................................................................................................................................ 8
2.3 Safety Devices ............................................................................................................................. 9
3 ............................................................................................................. 10
3.1 Label Placement Diagram.......................................................................................................... 10
4 ....................................................................................................... 12
4.1 External Power Unit ................................................................................................................... 13
4.2 Pit Installation............................................................................................................................. 13
4.3 Typical Pit Plan .......................................................................................................................... 13
4.4 Recommended Pad Plan ........................................................................................................... 15
4.5 Alternative Pad Plan .................................................................................................................. 16
4.6 General Installation .................................................................................................................... 17
5 ........................................................................................................... 21
5.1 Loading ...................................................................................................................................... 22
6 ...................................................................................... 23
6.1 Maintenance Device .................................................................................................................. 24
6.2 Periodic Maintenance ................................................................................................................ 25
6.2.1 Weekly Maintenance ........................................................................................................... 25
6.2.2 Monthly Maintenance .......................................................................................................... 26
6.2.3 Semi-Annual Maintenance .................................................................................................. 26
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3Southworth Products DDL Dock Lift Manual
6.3 Relieving Hydraulic Pressure..................................................................................................... 27
6.4 Replacement Parts .................................................................................................................... 28
7 .............................................................................................. 29
8 .......................................................................................................... 31
8.1 Wiring Schematic ....................................................................................................................... 31
8.2 Typical Control Panel ................................................................................................................. 32
9 ......................................................................................................... 33
9.1 Hydraulic Fluid ........................................................................................................................... 33
9.2 Typical Hydraulic Schematic ...................................................................................................... 33
9.3 Hose Specications ................................................................................................................... 33
9.4 Typical Hydraulic Power Unit ..................................................................................................... 34
9.5 Hydraulic Arrangement .............................................................................................................. 35
9.5.1 Standard Hydraulic Arrangement ........................................................................................ 35
9.5.2 Alternative Hydraulic Arrangement...................................................................................... 36
10 ................................................................. 37
Cancer and Reproductive Harm -
www.P65Warnings.ca.gov
WARNING
This label (part # 10095524)
is required by California Law.
For more information visit:
www.P65Warnings.ca.gov
4Southworth Products DDL Dock Lift Manual
1
1.1
The information in this manual is for our standard machines, if you have any questions
regarding the specications and dimensions of your actual lift table, contact Southworth
Customer Service or Southworth Sales if your order is being quoted or is in process.
DDL5-59M
DDL6-59M 10,000 lb. 59” 8” 18” x 60” 6’ x 8’ 8’ x 10’ 3.2 HP
DL8-59M 10”
DDL5-59M 5,000 lb.
27 seconds
Up to 4,000 lb.DDL6-59M 6,000 lb.
DL8-59M 8,000 lb. 42 seconds
1.2
Non standard machines have features not covered in this manual and can include but are
not limited to such accessories as multiple throw-over plates, powered throw-over plates,
aluminum throw-over plates, hydraulic power unit covers, hydraulic uid immersion heaters,
unique handrail layouts, powered maintenance device, etc. If your dock lift has anything other
than standard specications,
5Southworth Products DDL Dock Lift Manual
1.3
Owners/users shall apply sound principles of safety, training, inspection,
maintenance to the expected operating environment. It shall be the responsibility of the owner/
user to advise the manufacturer where deection may be critical to the application.
- Owners/users shall keep and maintain a copy of the operating and maintenance
manual(s) and ensure its availability to operating and maintenance personnel.
- It shall be the responsibility of the users to inspect and
maintain the machine as required to ensure proper operation. The frequency of inspection and
maintenance shall be based upon the manufacturer’s recommendations and be compatible
with operating conditions and the severity of the operating environment. Machinery that is
not in proper operating condition shall be immediately removed from service until repaired.
Maintenance and repairs shall be made by a qualied person and the repairs shall be in
conformance with the manufacturer’s recommendations.
- Before adjustments and repairs are started on the
machine, the following precautions shall be taken as applicable:
1. Remove the load from the platform.
2. Lower platform to the full down position.
3. Relieve system pressure from all circuits before loosening or removing any components.
4. All controls in the “o” position and all operating features secured from inadvertent
motion by brakes, blocks, or other means.
5. Disconnect power and follow established owner/user lockout/tag out policies.
6. Follow precautions and directions as specied by the manufacturer.
When parts or components are replaced, they shall be replaced with
parts or components approved by the original manufacturer.
- The user shall ensure only qualied personnel inspect and maintain
the machine in accordance with the manufacturer’s recommendations.
- An owner/user, who directs or authorizes an individual to operate the
machine shall ensure that the individual has been:
1. Trained in accordance with the manufacturer’s operating manual.
2. Made aware of the responsibilities of operators as outlined. See Section 1.4
Responsibilities of Operators on page 6.
3. Retrained, if necessary, based on the owners/user’s observation and evaluation of the
operator.
and additions shall not be performed without the manufacturer’s prior written
approval. Where such authorization is granted, capacity, operation, and maintenance
instruction plates, tags, or decals shall be changed accordingly.
6Southworth Products DDL Dock Lift Manual
1.4
- Operators shall apply sound principles of safety and good judgment in
the application, and operation of the machine with consideration given to its intended use
and expected operating environment. Since the operator is in direct control of the machine,
conformance with good safety practices is the responsibility of the operator. The operator shall
make decisions on the use and operation with due consideration for the fact that his or her own
safety as well as the safety of other personnel on or near the machine is dependent on those
decisions.
- Only personnel who have received general instructions regarding the
inspection, application, and operation of machine, including recognition and avoidance of
hazards associated with their operation, shall operate the machine. Such topics covered shall
include, but not necessarily be limited to, the following issues and requirements:
1. A pre-start inspection
2. Responsibilities associated with problems or malfunctions aecting the operation of the
machine
3. Factors aecting stability
4. The purpose of placards and decals
5. Workplace inspection
6. Safety rules and regulations
7. Authorization to operate
8. Operator warnings and instructions
9. Actual operation of the machine. Under the direction of a qualied person, the trainee
shall operate the machine for a sucient period of time to demonstrate prociency in
actual operation of the machine.
Before use each day or at the beginning of each shift, the machine shall
be given a visual inspection and functional test including but not limited to the following:
1. Operating and emergency controls
2. Safety devices
3. Hydraulic system leaks
4. Electrical cables and wiring harness
5. Loose or missing parts
6. Nameplates, precautionary and instructional markings and/or labeling
7. Guarding system
8. Items specied by the manufacturer
- Any problems or malfunctions that aect the safety of operations
shall be repaired prior to the use of the machine.
The operator shall:
1. Read and understand the manufacturer’s operating instruction(s) and user’s safety rules
or have them explained.
2. Understand all labels, warnings, and instructions displayed on the machine or have
them explained.
7Southworth Products DDL Dock Lift Manual
- Before the machine is used and during use, the operator shall check
the area in which the machine is to be used for possible hazards such as, but not limited to:
1. Bumps, oor obstructions, and uneven surfaces
2. Overhead obstructions and electrical hazards
3. Presence of unauthorized persons
4. Other possible unsafe conditions as noted in the operating manual.
- The operator shall ensure the operation of the
machine is in compliance with the following:
1. - Guarding shall be installed and positioned, and access gates or
openings shall be secured per the manufacturer’s instructions (If applicable).
2. - The load and its distribution on the platform shall be in
accordance with the manufacturer’s rated capacity for that specic conguration.
3. - The operator shall ensure that adequate clearance
is maintained from overhead obstructions and energized electrical conductors and parts.
4. - The operator shall not place any part of their body under the
platform.
5. - When other moving equipment or vehicles
are present, special precautions shall be taken to comply with the safety standards
established for the workplace.
6. - The operator shall immediately report to a
supervisor any problem(s) or malfunction(s) that become evident during operation. The
operator shall ensure all problems and malfunctions that aect the safety of operations
are repaired prior to continued use.
7. - Rated capacity shall not be exceeded when loads are transferred
to the platform.
8. - The operator shall ensure the area surrounding the machine is clear of
personnel and equipment before lowering the platform.
9. - The operator shall comply with the means and procedures
provided to protect against use by an unauthorized person(s).
10.- Safety devices shall not be altered or disabled.
11. or alterations of the machine or the fabrication and attaching of
frameworks or the mounting of attachments to the machine or the guarding system shall
only be accomplished with prior written permission of the manufacturer.
12. - If an operator encounters any suspected malfunction
or any hazard or potentially unsafe condition relating to capacity, intended use, or
safe operation, the operator shall cease operation of the machine and request further
instruction from the owner/user.
13. - Any problem(s) or malfunction(s) that aect the safety of
operations shall be repaired prior to the use of the machine.
8Southworth Products DDL Dock Lift Manual
2
All personnel installing, operating, and maintaining this machine shall read and understand this
manual. For questions or concerns contact the manufacturer.
This machine shall be installed, operated, and maintained by trained and/or qualied personnel
only.
2.1
A
BCD
A symbol that indicates a hazard. It is composed of an equilateral triangle surrounding an
exclamation mark. The safety alert symbol is only used on hazard alerting signs. It is not used
on safety notice and safety instructions signs.
A – For use with signal word; (safety white triangle, safety red exclamation mark,
safety red background)
B – For use with signal word; (safety black triangle, safety orange exclamation
mark)
For use with signal word; (safety black triangle, safety yellow exclamation mark)
D – For use with signal words; (D is a safety yellow
triangle with a safety black border and safety black exclamation mark;
2.2
10Southworth Products DDL Dock Lift Manual
3
This machine has labeling to indicate potential hazards this machine may pose when operating
and/or maintaining the machine. All labels must be legible. If any label is missing, damaged, or
otherwise illegible contact the manufacturer for replacement labels.
3.1
BK-LD TAG SOUTHWORTH 5900158
BK-LD TAG SOUTHWORTH 5900158
BK-LD TAG SOUTHWORTH 5900158
11Southworth Products DDL Dock Lift Manual
BK-LD TAG SOUTHWORTH 5900158
BK-LD TAG SOUTHWORTH 5900158
12Southworth Products DDL Dock Lift Manual
4
Installation of this machine shall be performed by trained and/or qualied personnel only.
The owner/ installer is responsible for obtaining any necessary permissions and/ or permits.
Follow all applicable codes and ordinances. Read and understand all safety and installation
information in this manual.
, remove all shipping materials and verify all components on the packing
list were received. Inspect the machine, all components, wiring and electrical connections,
hydraulic hoses and ttings for damage. If components are missing or damage is found contact
the manufacturer before continuing installation. If not being installed in a pit see Typical and
Alternative Pad Plan sections.
24.
17.
13Southworth Products DDL Dock Lift Manual
4.1
External power units should be placed within thirty feet (hose length) of the machine to avoid
excess pressure drops. External power units must be protected from moisture and weather.
4.2
1. Verify that the pit dimensions match the pit plan.
2. Verify that pit is clear of tools and other debris before lowering the machine into the pit.
3. Follow General Installation instructions to complete the installation.
4.3
The information in this manual is for our standard machines, if you have any questions
regarding the specications and dimensions of your actual lift table, contact Southworth
Customer Service or Southworth Sales if your order is being quoted or is in process.
FROM ANY DIRECTION
INCLUDING ENTRY FROM
BOTTOM OF PIT SUMP.STEP REQUIRED FOR BRIDGE
PLATE HINGE CLEARANCE
MUST BE SQUARE ( 1/2")
ACROSS CORNERS.
3" X 3" X 1/4" ANGLE BY
PIT CONTRACTOR. ALL
CORNERS TO BE
SECURELY WELDED. PIT
CONDUIT ENTRY CAN BE
COUPLINGS FOR
HYDRAULIC
CONNECTIONS
1 1/2"
BRIDGE
+1-1/2"
PLATFORM LENGTH + 1-1/2"
WIDTH
LENGTH + 1/2"
BRIDGE PLATE
PLATFORM
PLATE
WIDTH
+1/2"
2" CONDUIT
VOIDS
COMPACTED WITH NO
ANGLES MUST BE WELL
CONCRETE BEHIND CURB
FRONT OF PIT
ALIGNED WITH
CONCRETE ANCHORS TO
BOLLARDS TO BE
CENTER LINE OF
FROM EACH END.
12" O.C. WITH ONE 3"
1/2" X 6" LOCATED
PREVENT STANDING WATER
PIT DRAIN AS REQUIRED TO
BE
IN PIT. (BY CONTRACTOR)
CROSS HATCHING INDICATES AREAS OF•
BASE FROM THE MUST BE SHIMMED AND
OR GROUTED AFTER LEVELING OF THE
BASE FRAME TO ENSURE PROPER BASE
FRAME SUPPORT.
CONDUIT RUN IS REQUIRED FOR ROUTING
•
OF HYDRAULIC HOSES AND ELECTRICAL
WIRING UNLESS ALTERNATIVE
ARRANGEMENTS ARE REQUESTED.
2" ELECTRICAL CONDUIT USED WHEN 1/2"
•
HYDRAULIC HOSE, VENT LINE, AND
ELECTRICAL LEADS ARE TO BE INSTALLED
FROM POWER UNIT TO LIFT (BY PIT
CONTRACTOR).
8" BOLLARDS
36"
STEEL PIPE FILLED
48"
1/2"
3"
6" +1/2"
HEIGHT
LOW
(BY CONTRACTOR)
WITH CONCRETE
1/2" SHIM
UNDER EACH
LAG PLATE FOR
PROPER DRAINAGE
Ø3/4” LAG HOLES FOR
Ø5/8” ANCHORS WITH
MIN. 2000 LB PULL
OUT. (BY INSTALLER)
14Southworth Products DDL Dock Lift Manual
FROM ANY DIRECTION
INCLUDING ENTRY FROM
BOTTOM OF PIT SUMP.STEP REQUIRED FOR BRIDGE
PLATE HINGE CLEARANCE
MUST BE SQUARE ( 1/2")
ACROSS CORNERS.
3" X 3" X 1/4" ANGLE BY
PIT CONTRACTOR. ALL
CORNERS TO BE
SECURELY WELDED. PIT
CONDUIT ENTRY CAN BE
COUPLINGS FOR
HYDRAULIC
CONNECTIONS
1 1/2"
BRIDGE
+1-1/2"
PLATFORM LENGTH + 1-1/2"
WIDTH
LENGTH + 1/2"
BRIDGE PLATE
PLATFORM
PLATE
WIDTH
+1/2"
2" CONDUIT
VOIDS
COMPACTED WITH NO
ANGLES MUST BE WELL
CONCRETE BEHIND CURB
FRONT OF PIT
ALIGNED WITH
CONCRETE ANCHORS TO
BOLLARDS TO BE
CENTER LINE OF
FROM EACH END.
12" O.C. WITH ONE 3"
1/2" X 6" LOCATED
PREVENT STANDING WATER
PIT DRAIN AS REQUIRED TO
BE
IN PIT. (BY CONTRACTOR)
CROSS HATCHING INDICATES AREAS OF
•
BASE FROM THE MUST BE SHIMMED AND
OR GROUTED AFTER LEVELING OF THE
BASE FRAME TO ENSURE PROPER BASE
FRAME SUPPORT.
CONDUIT RUN IS REQUIRED FOR ROUTING
•
OF HYDRAULIC HOSES AND ELECTRICAL
WIRING UNLESS ALTERNATIVE
ARRANGEMENTS ARE REQUESTED.
2" ELECTRICAL CONDUIT USED WHEN 1/2"
•
HYDRAULIC HOSE, VENT LINE, AND
ELECTRICAL LEADS ARE TO BE INSTALLED
FROM POWER UNIT TO LIFT (BY PIT
CONTRACTOR).
8" BOLLARDS
36"
STEEL PIPE FILLED
48"
1/2"
3"
6" +1/2"
HEIGHT
LOW
(BY CONTRACTOR)
WITH CONCRETE
1/2" SHIM
UNDER EACH
LAG PLATE FOR
PROPER DRAINAGE
Ø3/4” LAG HOLES FOR
Ø5/8” ANCHORS WITH
MIN. 2000 LB PULL
OUT. (BY INSTALLER)
15Southworth Products DDL Dock Lift Manual
4.4
Use of a sump/drain for proper drainage and a conduit run for hydraulic/electrical routing in
pad is recommended.
BASE FRAME
2° SLOPE GRADE
AWAY FROM PAD
THROW OVER
PLATE AREA
CONDUIT ROUTE CAN BE
FROM ANY DIRECTION
INCLUDING FROM BOTTOM
OF PIT SUMP
2" CONDUIT
FRAME
BASE
12"
8" STEEL
PIPE
FILLED WITH
CONCRETE TYP.
(BY CONTRACTOR)
PLATFORM
WIDTH
LAGS
LAGS
6"
12"
6"
2X
PLATFORM LENGTH
NOTES:
CROSS HATCHING INDICATES AREAS OF•
BASE FRAME THAT MUST BE SHIMMED
AND/OR GROUTED AFTER LEVELING OF THE
BASE FRAME TO ENSURE PROPER BASE
FRAME SUPPORT.
CONDUIT RUN IS RECOMMENDED FOR•
ROUTING OF HYDRAULIC HOSES AND
ELECTRICAL WIRING.
2" ELECTRICAL CONDUIT USED WHEN 1/2"•
HYDRAULIC HOSE, VENT LINE, AND
ELECTRICAL LEADS ARE TO BE INSTALLED
FROM POWER UNIT TO LIFT (BY
CONTRACTOR).
COUPLINGS FOR
HYDRAULIC
CONNECTIONS
HINGE END OF BASE
NO VOIDS
WELL COMPACTED WITH
SMOOTH AND LEVEL
SURFACE MUST BE
POSTS TO BE ALIGNED WITH
EDGE OF PAD
CENTER LINE OF BUMPER
CONCRETE PAD MUST BE
PAD DRAIN AS REQUIRED TO
PREVENT STANDING WATER
ON PAD (BY CONTRACTOR)
8"
36"
48"
36"
3"
6"
ROLLER END
CONCRETE PAD
Ø3/4” LAG HOLES FOR
Ø5/8” ANCHORS WITH MIN.
2000 LB PULL OUT.
(BY INSTALLER)
16Southworth Products DDL Dock Lift Manual
4.5
If sump/drain is not used lift will require 1/2” shims under the lag plates to allow proper water
drainage. The base frame must be shimmed and/or grouted according to the pad plan to
ensure the base frame is properly supported. Hydraulic connections are to be made at the
couplings on the roller end of the base frame.
BASE FRAME
2° SLOPE GRADE
AWAY FROM PAD
PLATE AREA
THROW OVER
COUPLINGS FOR
HYDRAULIC
CONNECTIONS. FOR
MACHINES MOUNTED
ON
PADS WITH NO CONDUIT
ROUTING PROVIDED.
6"
LAGS
FILLED WITH
CONCRETE TYP.
(BY CONTRACTOR)
8" STEEL PIPE
PLATFORM LENGTH
PLATFORM
WIDTH
FRAME
LAGS
2X
BASE
6"
NOTES:
IF SUMP IS NOT USED, THE BASE FRAME•
MUST BE RAISED 1/2" TO ALLOW FOR
PROPER WATER DRAINAGE.
CROSS HATCHING INDICATES AREAS OF•
BASE FRAME THAT MUST BE SHIMMED
AND/OR GROUTED AFTER LEVELING OF THE
BASE FRAME TO ENSURE PROPER BASE
FRAME SUPPORT.
IF CONDUIT RUN IN PAD IS NOT USED FOR•
HYDRAULIC ROUTING CONNECTIONS ARE
TO BE MADE AT COUPLINGS ON ROLLER
END OF BASE FRAME.
HINGE END OF BASE
SURFACE MUST BE
SMOOTH AND LEVEL WELL COMPACTED WITH
NO VOIDS
CONCRETE PAD MUST BE
CENTER LINE OF BUMPER
POSTS TO BE ALIGNED WITH
EDGE OF PAD
36"
48"
8"
ROLLER END
Ø3/4” LAG HOLES FOR Ø5/8”
ANCHORS WITH MIN. 2000 LB
PULL OUT. (BY INSTALLER)
17Southworth Products DDL Dock Lift Manual
4.6
1. Attach a chain or lifting strap with an appropriate load spreader to the main lifting eyes.
The chain or strap must pull on the lifting eyes vertically.
2. Using an appropriate lifting device, carefully move the machine into position. Lifting
device must be capable of supporting up to 4000 lb.
INSTALL LIFTING EYES INTO SECOND SET OF
HOLES TO MANUALLY RAISE THE PLATFORM
(OFF PLATFORM CENTERLINE)
LIFTING EYE POSITION FOR
MOVING ENTIRE MACHINE
(ALONG PLATFORM CENTERLINE)
USE LOAD SPREADER SO THAT CHAIN/
STRAPS PULLS VERTICALLY ON LIFTING
EYES
3. If manually raising the platform of the lift, remove the lifting eyes and install them into
the second set of holes. The second set of holes (o platform centerline) have a nut
welded to the bottom of the platform and are used to manually raise the platform for
access during installation. Reattach the chain or strap.
4. Using the lifting eyes, raise the platform and engage the maintenance device and then
lower the platform onto the maintenance device. See Section 6.1 Maintenance Device
on page 24. Ensure the roller end of the platform is not lifted o of the upper rollers.
18Southworth Products DDL Dock Lift Manual
5. Remove the lifting eyes and save them for future use, if needed.
6. Once the platform has been raised and the maintenance device has been engaged,
verify the pins at the base of the hydraulic cylinders are properly seated.
VERIFY CYLINDERS ARE
PROPERLY SEATED AFTER
MANUALLY RAISING THE
PLATFORM
7. Ensure the machine is level. If necessary, use shims beneath the lag plates. All load
bearing points of the base frame must be fully supported by using grout beneath the
base frame.
CROSS HATCHING INDICATES AREAS THAT
HINGE END
ROLLER TRACKS (BOTH SIDES)
NEED TO BE SHIMMED AND/OR GROUTED,
ONCE LEVELED.
FRONT ROLL-OVER SUPPORT
SIDE ROLL-OVER
SUPPORT (BOTH SIDES)
LAG PLATES (ALL
FOUR CORNERS)
8. Anchor the machine using appropriate anchors.
19Southworth Products DDL Dock Lift Manual
9. Clear the hydraulic lines by ushing with compressed air.
10.Make all hydraulic connections according to the specications and hydraulic schematic.
See Section 9 Hydraulics on page 33.
11. Make all electrical connections according to the specications and wiring schematic.
See Section 8 Electrical on page 31.
24/1/60 CONTROL SIGNAL &
G
ROUND FROM CONTROL PANEL
T
ERMINALS TO JUNCTION BOX IN
BASE FRAME FOR LIMIT SWITCHES
AND
/OR OTHER DEVICES MOUNTED
O
N LIFT (IF APPLICABLE).
208/230/460 & GROUND
FROM SUPPLY TO
CONTROL PANEL
24/1/60 CONTROL
SIGNAL
& GROUND
FROM CONTROL
PA
NEL TERMINALS TO
CONTROLS
12.If applicable, install and anchor ramp.
20Southworth Products DDL Dock Lift Manual
13.Install handrails, exible restraints and throw-over plate pull cable.
BEFORE PERSONNEL MAY
RIDE ON LIFT
MUST BE SECURED
ALL FLEXIBLE RESTRAINTS
THROW OVER PLATE
MUST BE IN RAISED
POSITION BEFORE
RAISING OR LOWERING
THE PLATFORM
ALL HANDRAILS MUST BE
INSTALLED AND SECURED
BEFORE PERSONNEL MAY
RIDE ON LIFT
14.Check all hydraulic hoses and connections, wiring and electrical connections, and other
components for proper installation and damage.
15.Cycle the lift to test function. If platform does not begin to raise after a few seconds, See
Section 7 Troubleshooting on page 29.
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2
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