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Nova Technology International, LLC NAS Series Owner & User Manual

Dock leveler
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NAS-Series
Dock Leveler
Owner's/User's Manual
NOVA Technology International • N90 W14507 Commerce Dr. • Menomonee Falls, WI 53031
800.236.7325 • fax: 262.502.1511 • www.novalocks.com • sales@novalocks.com
Printed in U.S.A.
Manual No. 4111-0021-N
© 2018 - All Rights Reserved
Sept. 2018

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  • Page 1 NAS-Series Dock Leveler Owner’s/User’s Manual NOVA Technology International • N90 W14507 Commerce Dr. • Menomonee Falls, WI 53031 800.236.7325 • fax: 262.502.1511 • www.novalocks.com • sales@novalocks.com Printed in U.S.A. Manual No. 4111-0021-N © 2018 - All Rights Reserved Sept. 2018...

  • Page 2: Table Of Contents

    Table Of Contents Page Precautions Recognize Precautionary Information ..........1 General Operational Precautions ............1 Operational Precautions ..............2 Safety Decals ..................4 Placard ....................5 Owner’s/User’s Responsibilities............6 Introduction General Information ................8 Component Identification ..............9 Installation Installation Precautions ..............10 Prepare Pit ....................

  • Page 3: Precautions

    PRECAUTIONS Recognize Precautionary Information General Operational Precautions Safety-Alert Symbol The Safety-Alert Symbol is a graphic representation intended to convey a safety message without the Read and understand the Owner’s/User’s Manual and use of words. When you see this symbol, be alert become thoroughly familiar with the equipment and its to the possibility of death or serious injury.

  • Page 4: Operational Precautions

    PRECAUTIONS Operational Precautions Learn the safe way to operate this equipment. Read and understand the manufacturer’s instructions. If you have any questions, ask your supervisor. Stay clear of dock leveling device when transport Chock/restrain all transport vehicles. Never vehicle is entering or leaving area. remove the wheel chocks or release the restraining device until loading or unloading is finished, and transport driver has been given...
  • Page 5 PRECAUTIONS Operational Precautions Do not use dock leveling device if transport vehicle 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.

  • Page 6: Safety Decals

    PRECAUTIONS Safety Decals DO NOT 2.43" PROUDLY MADE FORK THIS SIDE SYSTEMS, INC. GERMANTOWN, WI MALVERN, AR 1751-0329 Rev A 1751-0735 DO NOT Control Box Size: FORK THIS SIDE File Name: 1751-0329 Rev A Decal Size: 2.75 x 1.25 Decal Size: 13 x 2 File Name: 1751-0735 1751-0329 Rev A 1751-0329...

  • Page 7: Placard

    PRECAUTIONS Placard O P E R AT I N G DANGER INSTRUCTIONS POWERED DOCK LEVELERS • Read follow instructions, warnings, and NORMAL OPERATION maintenance schedules in 1. Raise the platform by pressing and holding the manual and on placards. the RAISE button. •...

  • Page 8: Owner's/User's Responsibilities

    OWNER’S/USER’S RESPONSIBILITIES 1) The manufacturer shall provide to the initial the owner’s/user’s company policies, operating purchaser and make the following information conditions and the manufacturer’s specific readily available to the owners/users and their instructions provided with the dock leveling agents, all necessary information regarding device.
  • Page 9 OWNER’S/USER’S RESPONSIBILITIES 7) Loading dock safety equipment should never instructions, labels, decals and placards or be used outside of its vertical working range, or their equivalent. Written documentation of outside the manufacturer’s rated capacity. It shall maintenance, replacement parts or damage also be compatible with the loading equipment should be kept.

  • Page 10: Introduction

    INTRODUCTION General Information Figure 3 This manual provides current information on the Width NAS-series dock leveler. Due to ongoing product 6 ft (1829 mm) improvement, some parts may have changed, along 6-1/2 ft (1981 mm) with operation and troubleshooting methods. This 7 ft (2134 mm) manual describes these changes where applicable.

  • Page 11: Component Identification

    INTRODUCTION Component Identification Inspect package and all components. Report any missing or damaged items immediately and note on the shipping Bill Of Lading (BOL). A — Lip E — Lip Maintenance Prop Pivot H — Air bag support pallet L — Maintenance Prop B —...

  • Page 12: Installation

    INSTALLATION Installation Precautions It is recommended and good safety practice to use DO NOT connect the dock leveler electrical wiring an additional means to support the dock platform and ground connections until all welding has been and lip anytime when physically working in front of completed.
  • Page 13 INSTALLATION This page intentionally left blank. 4111-0021-N — Sept. 2018 © 2018...

  • Page 14: Prepare Pit

    INSTALLATION Prepare Pit 10” 14” Figure 5 A—Pit Width B— Dock Floor-to-Pit Floor C— Pit Length D— Pit Corner-to-Corner (Front and Rear) (All Four Corners) (Both Sides of Pit) (Top, Bottom, and Both Sides) Before lowering the dock leveler into the pit, the following must be performed: DO NOT remove the shipping bands (B) around 1.

  • Page 15: Prepare Dock Leveler

    INSTALLATION Prepare Dock Leveler Figure 6 A— Lifting Bracket (2 used) B — Shipping Bands NOVA Technology International dock levelers are 5. Attach a temporary switched power supply to the shipped with lifting brackets (A) fastened to the blower before lowering leveler into pit. Keep power platform side joists, and shipping bands (B) around cables clear of frame members, shim locations and the platform lip and leveler frame (see Figure 6).

  • Page 16: Install Dock Leveler

    INSTALLATION Install Dock Leveler Figure 8 Figure 10 Figure 9 A— Distance (Leveler Frame D— Shim Locations (Under J— Shims Location (Under M— Shim Stack Height) Lip Keepers) Lift Arm) N— Dock Leveler Frame B— Shim Locations (Under E— Dock Floor K—...
  • Page 17 INSTALLATION Install Dock Leveler (continued) Shim Stacking Methods Note: NOVA Technology International dock levelers are designed with a nominal 1/2” (12.7 mm) shimming distance to allow for pit inconsistencies. 1. Determine height of shim stack (M) for each shim Pyramid Stepped location (B) by performing the following: (Preferred)
  • Page 18 INSTALLATION Install Dock Leveler (continued) 3/8 in. 6 in. (9.5 mm) (152 mm) Figure 12 A— Front of Dock Pit C— Side Pit Curb Angle E— Pry Locations G— Rear Pit Curb Angle B— Dock Leveler Frame D— Gap [3/4 in. (19 mm) F—...
  • Page 19 INSTALLATION Install Dock Leveler (continued) 12. With the leveler square in the pit and flush with the surrounding dock, remove the banding on the lip of the leveler. Manually raise the platform. DO NOT use the maintenance prop to support the raised platform until the maintenance prop has 13.
  • Page 20 INSTALLATION Install Dock Leveler (continued) 21. Weld front of dock leveler frame (B, page 16) to Shim Stacking Methods shims located under the keepers, then weld the shims to the front pit curb steel. Pyramid Stepped Make sure the platform is properly supported in the (Preferred) (Acceptable) raised position before entering the pit to finish weld...
  • Page 21 INSTALLATION This page intentionally left blank. 4111-0021-N — Sept. 2018 © 2018...

  • Page 22: Install Control Panel And Wiring

    INSTALLATION Install Control Panel and Wiring Where indicated, all components must be connected Make sure that the power source has been locked to a SAFETY EARTH GROUND that conforms to out and tagged according to OSHA regulations and approved local electrical codes. the 1999 National Electrical Code Section 250-50 section (a) or section (c) for a grounding electrode system.
  • Page 23 INSTALLATION Standard Control Panel Wiring 4111-0021-N — Sept. 2018 © 2018...

  • Page 24: Placard Installation Instructions

    INSTALLATION Placard Installation Instructions Placard Installation Instructions • Owner/Users are responsible for the installation and placement of product • Owner/Users are responsible for the installation and placement of product • Owner/Users are responsible for the installation and placement of product placards.

  • Page 25: Put New Dock Leveler Into Service

    INSTALLATION Put New Dock Leveler Into Service Unless the dock leveler is equipped with a tethered A hard hat or other applicable head protection remote, two people are required to engage the should always be worn when working under or maintenance prop: one person to operate the unit, around a dock leveler.

  • Page 26: Operation

    OPERATION Operational Precautions Stay clear of dock leveler and vehicle restraint 12 in. (305 mm) when transport vehicle is entering or leaving dock area. DO NOT move or use the dock leveler or restraint if 12 in. (305 mm) anyone is under or in front of leveler. Keep hands and feet clear of pinch points.
  • Page 27 OPERATION This page intentionally left blank. 4111-0021-N — Sept. 2018 © 2018...

  • Page 28: Ramp Loading/Unloading

    OPERATION Operating Instructions Ramp Loading/Unloading 7. Remove chocks from transport vehicle wheels, or release the vehicle restraint if used. 1. Before activating dock leveler, check to make sure 8. Indicate to driver that the transport vehicle may the transport vehicle is positioned squarely against leave the dock.

  • Page 29: End Loading/Unloading

    OPERATION Operating Instructions (continued) End Loading/Unloading 1. Before activating dock leveler, check to make sure the transport vehicle is positioned squarely against dock bumpers. Ensure lip will avoid contact with transport vehicle frame, sides and cargo during dock leveler activation. If contact is likely or observed, reposition transport vehicle.

  • Page 30: Maintenance

    MAINTENANCE Maintenance Precautions Figure 24 Figure 22 Figure 23 A - Tag Out Device B - Lock Out Device C - Maintenance Prop D - Header E - Lip Prop When working with electrical or electronic controls, make sure that the power source has been tagged (A) and locked out (B) according to OSHA regulations * Unless the dock leveler is equipped with a tethered and approved local electrical codes (see Figure 22).
  • Page 31 MAINTENANCE This page intentionally left blank. 4111-0021-N — Sept. 2018 © 2018...

  • Page 32: Periodic Maintenance

    MAINTENANCE Periodic Maintenance A— Lip Hinge Area C— Lip Link Pivots E— Lip Linkage Pivot B— Lip Prop Pivot D— Lip Assist Pins F — Safety Leg Linkage Pivots Figure 27 Figure 26 Air Filter, service under rear of platform Under platform service 4111-0021-N —...
  • Page 33 MAINTENANCE Weekly Maintenance Lubricate the following areas with light weight machine oil: • Operate the dock leveler through the complete (A)— Lip hinge area unless equipped with grease operating cycle to maintain lubrication. fittings (apply oil to the top of the entire length of lip hinge when platform is at the full Note: To thoroughly inspect the platform hinge area, below-dock position and lip is folded)

  • Page 34: Adjustments

    ADJUSTMENTS Adjust Lip Latch & Lip Actuator Spring Tension Unless the dock leveler is equipped with a tethered remote, two people are required to engage the maintenance prop: one person to operate the unit, the other person to engage the maintenance prop. In addition, it is recommended and good safety practice to use an additional means to support the dock platform and lip anytime when physically...
  • Page 35 ADJUSTMENTS Adjust Lip Latch & Lip Actuator Spring Tension (continued) The lip latch and lip actuator spring tension Lip Actuator Spring Tension are set at the factory and should not require additional adjustment unless parts have been Note: Use two-turn increments when adjusting replaced.

  • Page 36: Adjust Lip Stop Biolt

    ADJUSTMENTS Adjust Lip Stop Bolt When at rest, lip (E) should be fully resting on the lip keepers (D) and at the lowest part of the lip keepers. If lip is not resting properly in the lip keepers, perform the following adjustment: 1.

  • Page 37: Adjust Lip Assist Chain And Shackle

    ADJUSTMENTS Adjust Lip Assist Chain and Shackle Figure 30 The lip assist chain and shackle are set at the factory and should not require additional adjustment unless parts have been replaced. The above dock service range of the leveler is determined by the overall length of the lip assist chain and shackle assembly.

  • Page 38: Troubleshooting

    TROUBLESHOOTING Unless the dock leveler is equipped with a tethered When service under the dock leveler is required, remote, two people are required to engage the always lock all electrical disconnects in the OFF maintenance prop: one person to operate the unit, position after raising the platform and engaging the the other person to engage the maintenance prop.
  • Page 39 TROUBLESHOOTING Symptom Possible Cause Solution • Check wiring to motor for high resistance. Platform does not rise. • Check for loose or corroded connections. Motor energizes, but does Line voltage too low. • Check if gauge of wires to motor are of correct not run.

  • Page 40: Parts

    PARTS Standard Control Box 1.50" 4-1/2 Arc Flash and Shock Hazard PPE [Personal Protection Equipment] Required De-energize equipment before working on or inside. Do not open cover without appropriate PPE. Refer to NFPA 70E for PPE requirements. This panel may contain more than one power source.

  • Page 41: Optional Electrical Parts (Control Box)

    PARTS Optional Electrical Parts (Control Box) Part Number Description Control Box w/Optional Equipment * Provide dock leveler serial number, voltage, phase, and options when e-mailing, calling or faxing controller orders 4111-0021-N — Sept. 2018 © 2018...

  • Page 42: Lip Activation

    PARTS Lip Activation (pre-2012) Item Quantity Part Number Description 9514-0107 Lip Latch Assy.( bolts on to DPLA-2130) DPLA-2130 Lip Assist Rod Complete 34” Lg (Includes Items A-D) DOTH-2449 Bearing DOTH-2076 Bolt, 5/8-11 unc x 3-1/2” DOTH-2160 Nut,Nylon DOTH-2546 Spring, Lip assist DOTH-2225 Washer DPLA-2126...
  • Page 43 PARTS Lip Activation (2012-present) Located on Deck DPLA-0338 Complete Located on Lip Item Quantity Part Number Description DLIP-0305 Lip Assist Rod Complete 34” Lg (Includes Nuts) 2101-0221 Washer 1-3/4 9511-0156 Spring, Lip STD 9514-0114 Spring, Lip HD 2101-0222 Bolt, Shoulder x ½ x 1¾ 2101-0223 Nut, Nylon lock 9513-0091...
  • Page 44 PARTS Item Quantity Part Number Description 0941-0013 Spring, Lip Latch Extension 2101-0230 Ring, Split 1-3/4” OD 2101-0239 Link, Chain snap 1/4” 4111-0021-N — Sept. 2018 © 2018...

  • Page 45: Airbag And Support Pallet

    PARTS Airbag and Support Pallet Air Bag serial number on left hand corner next to blower motor. Item Quantity Part Number Description 5812-0045 Hold Down Rod, 45” long x 7/16” diameter 5811-0009 Air Bag Bladder 5811-0012 Skid, Air Bag Leveler 5813-0001 Skid BRKT, Air Bag Leveler, 2101-0098...

  • Page 46: Frame And Platform

    PARTS Frame and Platform Lip latch Release Arm Up Grade. Maybe required on some levelers (manufactured before 4/2014) if below dock is required Item Quantity Part Number Description 8435-____ 1 Frame, Welded Assembly 0941-0013 Spring Lip Latch Ext. 2101-0230 Ring, Split 1-3/4” OD 8432-1129 Keeper Lip 16 inch 20”...
  • Page 47 PARTS Frame and Platform PLATFORMS 6 FOOT 8 FOOT 10 FOOT ITEM QTY 6.0 FOOT 6.5 FOOT 7.0 FOOT 6.0 FOOT 6.5 FOOT 7.0 FOOT 6.0 FOOT 6.5 FOOT 7.0 FOOT 25K 9515-5300 9515-5304 9515-5308 25K 9515-5312 9515-5316 9515-5320 25K 9515-5324 9515-5328 9515-5332 30K 9515-5301 9515-5305 9515-5309 30K 9515-5313 9515-5317 9515-5321 30K 9515-5325 9515-5329 9515-5333 35K 9515-5302 9515-5306 9515-5310 35K 9515-5314 9515-5318...

  • Page 48: Below Dock Control

    PARTS DPLA-0338 LIP BANGER ASSY. DPLA-0341 5775-0004 LIP LATCH ASSEMBLY (includes spring and cable, 16“ long) 5775-0005 LIP LATCH ASSEMBLY (includes spring and cable, 21“ long) DOTH-2374 COTTER PIN DOTH-2210 WASHER DOTH-2351 BOLT/PIN DOTH-2163 NUT, LOCK DPLA-0343 BELOW DOCK CONTROL ASSY. DOTH-2382 PIN, COTTER DOTH-2074...

  • Page 49: Blower Motor Assembly

    PARTS Blower Motor Assembly 11.8 FLA Amp Draw Item Quantity Part Number Description 9395-0359 PPAC,Blower Assy 9391-0021 Filter Element (Included With 9395-0359) 9391-0022 Tube, 2” (50.8mm) OD, 36” (914.4mm) Length 6’ and 8’ Levelers 9391-0041 Tube, 2” (50.8mm) OD, 46” (914.4mm) Length 10’ levelers 9392-0047 Pipe, PVC, 1-1/2”...

  • Page 50: Weather Seals

    PARTS Weather Seals Weather Seal Kits Item Quantity Part Number Description 0195-0021 Brush Kit (Includes Seal and Track), 1-1/2 in. 82" Lg. (Both Sides) 0195-0033 Rubber Kit (Includes Seal and Track), 1-1/2 in. 82" Lg. (Both Sides) Individual Replacement Seals Item Quantity Part Number...

  • Page 51: Miscellaneous

    MISCELLANEOUS Customer Information Figure 34 Figure 33 NOTE: Refer to Figure 33 for left/right orientation of dock Dock Leveler Information leveler and Figure 34 for example of decal. The LEVELER model/serial number decal is Model ___________________________________ located on the left platform joist near the front (lip) of dock leveler (A).

  • Page 52: Warranty

    Owner/User. In the event of a defect, as determined by NOVA Technology International, LLC, covered by this warranty, NOVA Technology International, LLC shall remedy such defect by repairing or replacing any defective equipment or parts, bearing the cost for the parts, labor and transportation.

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