APS Resource HTC Kit Installation And Owner's Manual

Hydraulic conversion kit with auto-return to dock for mechanically operated dock levelers

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APS Resource

Your Aftermarket Solution

6219 West Eastwood Court • Mequon, Wisconsin 53092 • TEL: (262) 518-1000 • FAX: 1-800-827-7491

HTC

Kit

™

Hydraulic Conversion™ Kit

With Auto-Return to Dock

For Mechanically Operated Dock Levelers

Installation and Owner's Manual

Do not install, operate or service this product unless

you have read and understand the Safety Practices,

Warnings, and Installation and Operating Instructions

contained in this manual. Failure to do so could result

in death or serious injury.

AP4047 RA 11/10

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Summary of Contents for APS Resource HTC Kit

Page 1 Safety Practices, Warnings, and Installation and Operating Instructions contained in this manual. Failure to do so could result in death or serious injury. AP4047 RA 11/10 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 2: Limited Warranty
HYDRAULIC CONVERSION KIT that proves to be defective in material or workmanship shall be as set forth in its standard warranty above (i.e., APS Resource will, at its option, repair or replace the HYDRAULIC CONVERSION KIT or portion thereof, without charge to the purchaser).
Page 3: Table Of Contents
Indicates a potentially hazardous situation which, if Notice is used to address practices not related to not avoided, could result in death or serious injury. personal injury. AP4047 RA 11/10 PAGE 2 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 4: Safety Practices
PRACTICEs/TOOLs TOOL LIsT sAFETY PRACTICEs List of tools and equipment needed to field install the HTC Kit. This job would typically require two service Read these safety practices before installing, technicians. operating or servicing the dock leveler. Failure to...
Page 5: Installation
5. Verify that all welds are intact and that all structural members are in good working condition. 6. Thoroughly inspect the structural integrity of the dock leveler to be sure it is suitable for conversion. AP4047 RA 11/10 PAGE 4 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 6: Site Preparation
3. If conduit must be installed do so at this time. Refer to the conduit requirements on the pit detail (See Figure 2). Follow all applicable electrical codes and standards. PAGE 5 AP4047 RA 11/10 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 7: Secondary Maintenance Strut
Make sure the decal on the lower tube, and the tab Figure 6 on the upper tube, both face outward toward the driveway as shown. See Figure 6. Figure 3 AP4047 RA 11/10 PAGE 6 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 8: Leveler Preparation
3. Install full range sliding toe guards if applicable. In some applications, it may be necessary to create holes in the stationary toe guards for clearance of the pivot and slider bolts. See Figure 9. PAGE 7 AP4047 RA 11/10 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 9: Ramp Platform Bracket Installation
LIP CYLINDER 17" RAMP LUG 4-3/4" 8-3/8" LIP CYLINDER LIP LUG RAMP BRACKET PIT FLOOR BRACKET LEVELER LENGTH APPROX. PIT DEPTH DIMENSION "A" 8 FT. 20 IN. 36-1/8" AP4047 RA 11/10 PAGE 8 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 10: Pit Floor Bracket
PIT CLEVIS TO PIT continuous and surround the entire perimeter of the FLOOR PLATE BASE clevis bracket. See Figure 13. ANCHOR HOLES FOR 3/4" X 6" ANCHORS PAGE 9 AP4047 RA 11/10 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 11: Lip Cylinder Installation
9. After making sure that the lip cylinder has the proper range, weld the rear cylinder lug permanently in position. AP4047 RA 11/10 PAGE 10 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 12: Lip Support Installation
BOTH LIP KEEPERS. SHIM AS REQUIRED. leveler to be converted does not have lip supports, install the lip supports included with the HTC Kit. 1. Install lip supports if applicable. 2. Carefully lower the lip to the closed position. Check to be sure that the lip cylinder does not bottom out.
Page 13: Power System Installation
8. Install the breather to the cylinder. 9. With the ramp resting on the maintenance strut, and the lip pendant, fill the oil reservoir near the top with MIL 5606 oil. AP4047 RA 11/10 PAGE 12 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 14: Wiring Diagrams
NOTE: VISUALLY CONFIRM MOTOR TAG (BY OTHERS) 10 AMP MAX 208-230V MOTOR 1 PHASE BLACK 50/60HZ GREEN WHITE 3/4 HP MOTOR HAS AUTOMATIC THERMAL PAGE 13 AP4047 RA 11/10 PIT WALL ©2010 4Front Engineered Solutions, Inc. - APS Resource OVERLOAD JUNCTION BOX (BY OTHERS)
Page 15: Artd System Installation
Route the power cord towards the rear of the pit. Figure 21 Figure 18 Subframe 3" 9" ARTD LIP BRACKET ARTD RAMP BRACKET (ORIENT SLOT TOWARD FRONT OF DOCK LEVELER) AP4047 RA 11/10 PAGE 14 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 16 DECK sensor cable through this loop. Leave a small amount of slack in the DECK sensor cable and tighten cable tie. See Figures 22 and 24. Figure 23 Figure 24 PAGE 15 AP4047 RA 11/10 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 17 (Below Dock) (Pendant) PRS1 PRS2 PRS1: Closes 4° Below Dock, Opens 4° Above Dock PRS2: Closes When Lip is Pendant J BOX NEMA 5 15P Power Cord AP4047 RA 11/10 PAGE 16 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 18: Conversion System Test
Failure to follow these instructions could result in Hydraulic Oil. death or serious injury to operators and/or bystanders. 3"- 4" Check Oil Level With Ramp Resting on the Matienance Strut And Lip Pendant. PAGE 17 AP4047 RA 11/10 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 19 5.3 Release the "RAISE" button once the lip is fully extended. 5.4 Ramp and lip will lower until the lip rests on the vehicle bed. See Figure 31. 6. Proceed with loading or unloading. AP4047 RA 11/10 PAGE 18 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 20 7. Turn the “ON/OFF” switch to the “OFF” position. 8. Unchock or release vehicle. 9. Tell vehicle driver “Your vehicle may now leave the dock”. PAGE 19 AP4047 RA 11/10 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 21: Maintenance
Reference Figure 28. *Acceptable Hydraulic Oils: 1. Mobil Aero HFA (49011) 2. Exxon univis Grade JI3 3. Texaco Aircraft Oil #1554 4. u.s. Oil Co.,Inc. #ZFI-5606 (Low Temp.) AP4047 RA 11/10 PAGE 20 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 22: Troubleshooting Guide
3. Check for binding in lip hinge. 4. Check hydraulic oil level in reservoir. Add if required. 5. Check hydraulic bypass pressure and adjust as required. 6. Check lip sequence valve pressure setting. PAGE 21 AP4047 RA 11/10 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 23: Parts List
131-507 Flat Washer, 3/8 000-214 Lower Strut w/ Decal 713-268 Upper Strut 713-267 Safety Decal (Not Shown) 138846 Complete Secondary Maintenance Post AP0353 Kit (includes Items 1-8) AP4047 RA 11/10 PAGE 22 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 24 SE328859 5/8" x 4" Subframe Anchor Bolt (Not Shown) 131-526 Motor Mounting Plate (Not Shown) C68058 3/4" x 6" Pit Floor Bracket Anchor Bolt (Not Shown) AP2815 PAGE 23 AP4047 RA 11/10 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 25 Cotter Pin, 1/8 x 2 ZP 035-020 035-020 Reservoir AP5227 AP5227 Breather Cap 031477 031477 Shuttle Valve AP4056 AP4056 Sequence Valve (Not Shown) C102664 C102664 Reservoir O-Ring (Not Shown) 031478 031478 AP4047 RA 11/10 PAGE 24 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 26 Fuse, 250V, 1/2 AMP 061-152 Channel, Mounting 148-023 Terminal Block, 3 Pole 148-022 Wire, 16 GA. black x 3" lg. 151-042 Connector, Solderless Lug 061-674 DANGER Placard AP4049 PAGE 25 AP4047 RA 11/10 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 27 Cable Tie Anchor 131476 Power Cord, NEMA 5-15 Plug 712027 Wire Nut (Not Shown) 161011 Lock Washer, 1/4" 000505 Lip Bracket, ARTD AP4043 Deck Bracket, ARTD 152839 AP4047 RA 11/10 PAGE 26 ©2010 4Front Engineered Solutions, Inc. - APS Resource...
Page 28 Please direct questions about your HTC Kit to your local distributor or to 4Front Engineered Solutions, Inc. - APS Resource Your local APS Resource distributor is: AP4047 RA 11/10 ©2010 4Front Engineered Solutions, Inc. - APS Resource...