Hinge Dock Leveller NLS - Novoferm

Hinge Dock Leve lle r NLS 

USER’S AND INSTRUCTIONS MANUAL 

January 2006

INDEX 

The user’s and instructions manual is an integral part of the supply of the machinery. The user’s and instructions manual contains: all 

the documents stating the conformity of the machinery with existing regulations, the detailed description, the usage conditions 

foreseen, suggestions, set-up, usage, maintenance and repair. 

All the data that appear in the following manual must be consider approx. 

Safety regulations 

Declaration 2 

Usage of the Dock leveller 

Usage conditions 3 

Maintenance 4 

Fundamental warnings related to safety 5 

Description of the Dock leveller 

Dimensions – capacity - structure 6 

Functioning 7 

Electric diagrams 8-11 

Hydraulic diagram 12 

Hydraulic power pack 13 

Hydraulic oil 14 

Cylinders and Connections 15 

Maintenance 

Troubleshooting 16-17 

Annual checks 18 

Severe dangerous situations 19 

page 

GHL_NLS_E_V02.doc Page 1 of 19

DECLARATION 

Each machine has been manufactured according to the safety regulations presently in force. 

Each machine must carry a permanently fixed identification label as the one shown below. 

Each machine comes with a conformity declaration according to European regulation UNI CEI EN 45014. 

If these machines are used according to all the dispositions contained in this user’s and instruction manual, there will be no harm 

to the health of the user, in conformity to Directives 91/155/CE. 

For each machine an annual check is necessary. 

It is forbidden, in absence of Novoferm authorization to make any modifications 

that could jeopardize safety. 

Improper use , modification of safety devices, lack of maintenance, intervention carried out without 

following the written procedures or by non-competent personnel, “nullifies all responsibility by 

Novoferm” and consequently automatically ceases all forms of insurance or warranty. 


USAGE CONDITIONS 

AIM OF THE 

DOCK LEVELLER 

TRANSPORT 

EQUIPMENT 

GRADIENT 

RESTING POSITION 

The dock leveller is a static or mobile equipment which is used to fill the distance between a loading 

dock or similar loading areas and the loading surface of a vehicle that can be at different levels. 

The dock leveller is not designed to lift or lower goods. 

The operation is therefore not intended to lift the load, but only to modify the position of the dock 

leveller, without any load. 

The dock leveller is not suitable to carry loads if it is not perfectly resting in a balanced position on the 

vehicle surface. 

A safety area of 350 mm. on both sides must be foreseen. 

The transport equipment width will then be equal to the dock leveller plate minus 700 mm. 

Dock leveller width 1750 transport equipment width 1050 mm 



The maximum dock leveller gradient, during loading operations, must not exceed 12.5% of its length. 

The maximum dock leveller gradients are applied only when using forklifts. In the case of transpallet 

usage, both manual or electrical, the gradient is to be reduced to 5 %. 

If the dock leveller features a straight lip, use the dock leveller with negative gradients only; in case of 

positive gradients there is in fact a impact risk. 

The maximum usage gradient is shown by means of orange fluorescent stripes placed on the swinging 

side panels. In case these stripes are visible, the dock leveller must not be used. 

When in the resting position, the dock leveller lip must be in a perfect vertical position, laying on its 

appropriate supports and the dock leveller must form a continuous surface with the floor. 

Only in this position the load can pass over the dock leveller, in whatever direction. 

WORKING 

POSITION 

FREE SWINGING 

CONDITIONS 

ROOM 

TEMPERATURE 

Transit over the dock leveller during loading / unloading operations is allowed only if the lip is perfectly 

extended and laying for its entire length on the vehicle surface. 

The load can pass on the dock leveller only in the longitudinal direction (axis dock leveller-lorry tray). 

While in the working position, the dock leveller must be left free of swinging both vertically and 

crosswise. Vertical swinging is allowed by releasing the working controls. Crosswise swinging, that 

equals to 5% of the total dock leveller length approximately, is obtained as a result of the particular 

structure flexibility. 

Room temperature must be between –10° and + 40° degrees Celsius. 


MAINTENANCE 

All maintenance and/or repair operations must be performed by a ‘competent person’. The European 

regulation EN 1398 defines as a competent person: ‘who that, according to the experience and the 

technical training received has sufficient knowledge in the dock leveller field and has familiarity with 

the dock leveller adjustment to allow its functioning’. 

It is strictly forbidden to carry out maintenance or repairs on a working dock leveller; operations like 

cleaning, adjustment or repairs need to be performed with the dock leveller standing still. 

All maintenance or repairs operations that must be done under the dock leveller must be carried out 

without any load and after inserting the maintenance support device. 

Verify the maintenance setting, because uncorrected works could have broken it. 

BEFORE EACH USE 

Verify that the dock leveller has not suffered any external damage after a collision. 

Also verify that both the rear and front hinges are free from debris and/or dirt, that could jeopardize the total and/or partial rotation of 

the lip. 

This is not really a maintenance operation, but only a simple visual check of tidiness of the working area. 

This kind of check must be performed by the operator each time there is the loading/unloading operation of a new lorry, see also on 

page 10. 

MAINTENANCE AND ANNUAL CHECKS 

• At least once every year dock levellers must undergo all checks, as described on page 17 

• The user will then have to keep all the test certificates and show them on request by the Competent Authorities. 

TRIENNIAL MAINTENANCE 

Oil duration depends on different factors like: amount of working hours, presence of debris/impurities, possible humidity; the oil has 

to be replaced when features like limpidity or fluidity are missing. 

In any case it will be necessary to replace the oil every 3 years. 

SIX-YEARLY MAINTENANCE 

Every 6 years it will be necessary to replace all flexible hydraulic pipes 

OUT OF ORDER 

During the maintenance phases, must be exposed on the machine, in a noticeable way, the appropriate advertising poster of “Out of 

order maintenance”. To carry on this operation is necessary to commutate the general switch on OFF position, and lock it on. 


FUNDAMENTAL WARNING RELATED TO SAFETY 

All dock levellers feature all the necessary safeties to avoid, for what it is reasonably possible, every risk. 

This is the case of machines that operate with electrical power tension, and that feature appliances moving and/or rotating, and 

therefore it is required to operate with extreme care. 

DOCK LEVELLER USERS 

All people that use the dock levellers must be 18 years of age or older. These people must be expressly put in charge by the 

Company to operate the dock levellers, not before a proper training period and after having carefully read the user’s and instruction 

manual. 

SCOPE OF THE DOCK LEVELLER 

The dock leveller is a static equipment fit to level all differences in height and gaps between a loading point (or similar loading areas) 

and the surface of a vehicle, and designed solely to allow loading (or unloading) operations. 

Therefore the functioning is not intended to lift the load, but only to modify the position of the dock leveller, without any load. 

The dock leveller is not suitable to carry loads if it is not perfectly laying in a balanced way on the surface of the vehicle. 

USE OF THE DOCK LEVELLER 

Use the dock leveller only according to the directions and only if it is in perfect technical condition. Remove and/or have removed 

whatever matter that could jeopardize safety. 

Before operating the up and/or down controls, check that nobody could be in a situation of danger due to the motion of the dock 

leveller. 


DIMENSIONS - CAPACITY - STRUCTURE 

CAPACITY 

The nominal capacity of our dock levellers is 6.000 Kg., of which 90%, that is to say 5.400 Kg., can sit on a single axis of the forklift if 

it has its front wheels at least 250 mm. wide, and that the single axis weight on a single wheel is therefore equal to 2.700 kg. 

For all loading operations it is possible to use forklifts, electrical or manual transpallets or other similar equipment. 

It is expressly forbidden to use forklifts weighing more than 6.000 Kg. when fully loaded. 

Modell A B C D E F G H I 

weight 

kg 

20/17,5 1750 1930 90 850 

20/20 2000 2000 600 2320 2180 2080 290 290 95 970 

20/22 2200 2380 100 1090 

25/17,5 1750 1930 110 1190 

25/20 2500 2000 600 2820 2180 2580 320 300 120 920 

25/22 2200 2380 125 1040 

30/17,5 1750 1930 120 1170 

30/20 3000 2000 600 3320 2180 3080 340 300 135 1270 

30/22 2200 2380 140 970 

34/17,5 1750 1930 140 1100 

34/20 3400 2000 600 3720 2180 3480 360 300 150 1230 

34/22 2200 2380 155 1330 

N.B. 

G and H values are referring to models featuring bent lip only the value “E” is referring only to the dock leveller with side 

walls (method B, C, D1, D2 and E),for the pit mounted (method A) type E=B 

STRUCTURE – SAFETY VALVE OPERATION 

Inserted at the base of the raising cylinder of the dock leveller there is a balanced valve, that is activated when it is necessary to 

reduce the lowering speed of the dock leveller to 0.05 m/s in case the speed suddenly increases (e.g.: a lorry moves before the end 

of the loading / unloading operation is completed). 

Warning: the operation of the safety valve with a load of more than 2.000 Kg. could damage the dock 

Leveller structure permanently. 


FUNCTIONING SILVER 

All controls must be positioned in a way that the operator can observe all the movements of both the dock leveller and the load. 

Controls are marked and easily understandable. 

1 

1. Main Switch 

2. Operation button 

2 

FUNCTIONING SEQUENCE 

• Let the lorry get close by following the instructions written at the previous page 

• Turn the main switch (1) in the ON position, which signals that the panel is fed: after this operation the dock leveller is ready to 

work. 

• Press the operation button (2), wait until the dock leveller reaches its maximum inclination and the lip is completely open, being a 

continuous line with the dock leveller plate. 

• Release the operation button and it will start to lower by gravity until reaching the lorry’s box; it is now free to float and ready for 

the loading/unloading operations. 

• When all loading/unloading operations are finished, press the operation button and wait for the lip to get completely folded. 

• Release the operation button and wait until the dock leveller gets to its resting position, with the lip perfectly resting on its lateral 

seats. 

• Rotate the main switch (1) in the OFF position, which signals that the panel is no longer fed; after this operation the dock leveller 

can no longer work. 

If the main switch is rotated in the OFF position, the dock leveller will stay still in whichever 

position. To restore the functioning it is necessary to rotate it in an anticlockwise way in ON 

position and press the operation button. 

If the voltage fails, the dock leveller will stay still in whichever position. To restore the cycle 

it is necessary (when the voltage resets) to press the operation button that, when released, 

will get the floating dock leveller. 


ELECTRIC DIAGRAMS NLS 

CONTROL BOX 



CONTROLDIAGRAM 



INSTALLATIONDIAGRAM 



For spare parts please refer to the names on each separate component. 

For teleruptors and thermal relays it is possible to use without problems Telemecanique, ABB, Siemens etc. 

Cable length to the hydraulic power pack: 8 m 

The electric panel is always supplied to work with a feeding voltage of 400. However, it’s possible to make it working with a feeding 

voltage of 240V changing two wires on the electric …. 

For more details, see the following diagram: 


HYDRAULIC DIAGRAM S-05 

POS CODE NAME CHARACTERISTICS 

1 - 2 V3.889.04.A32 Max pressure valve VM15 Adjustment field 30 - 120 bar 

3 V3.892.25.000 Valve VU3/8”-MD Unidirectional Valve 

4 V3.888.25.00G Valve VMS12-L 

5 V3.888.24.001 Valve VSS-FR Adjustment field 30 - 120 bar 

6 V3.892.90.000 Valve VUPC14 Piloted valve to close 

7 V3.896.69.A20 Valve VE1-NC cav. V096004 Electric valve 

C1.664.32.OC2 Solenoid S2-CE 24Vdc H Class 

8 V3.895.57.000 Valve STM10 Limiting device 

9 V2.371.35.011 Diaphragm ¼” Hole Ø1,1 

ME ref. Power pack Electric engine See plate 

PO ref. Power pack Hydraulic pump Gear type 

FA ref. Power pack Suction filter filtering max 90 micron 


HYDRAULIC PLUNGED MOTOR POWER PACK 

+ THERMIC 

1. Motor 

2. Oil plug 

3. Clump box 

4. Valve group 

5. Pump 

6. Filter 

MOTOR: • Power: 0,75 Kw 

• Nr. Poles: 2 (2780 turns/min.) 

• Nominal tension 230 - 400 V, 50 Hz with tolerance on tension and frequency data ± 5%. 

• Absorption: 3.6A to 230V; 2.1A to 400V 

• ca/cn ratio: 2.8 - cos = 0.78 

• Intermittent service S2 = 5 minutes 

PUMP: • Type CV6400800C (cubic capacity 1,6 cc) 

• Gear type, with fixed capacity 4.5 lt./min. 

• It is forbidden to invert the sense of rotation of the pump, even if it is for brief periods of time. 

Warning: If the pump works without intaking oil, it will be damaged in an irreparable way 

FILTER: • Made of metallic nets, filtering capacity: 90 microns 

OIL • Agip ARNICA 22 - Quantity: 4.5 litres 

OIL PLUG • The power pack oil plug features an internal air filter, it has a diameter of ½ inch. 

POWERPACK CHECK 

• Dismount the power pack and position it on the floor or an appropriate working bench; open then the power pack cover. 

• Put a container under the plug to replace the oil (placed on the rear power pack side), unscrew the plug and wait until the power 

pack is empty. 

• Remove possible sediments from the bottom of the tank. 

• Dismount the pump filter and clean it with fuel oil; if the filter happens to be jammed, then it is necessary to replace it. 

• Add oil equal or with similar features to the one used and filtered with a filtration value equal or less than 90 microns. 

• Warning; if sediment or impurities are found in the tank, it is also necessary to dismount all cylinders and pipes and to clean and 

wash them with fuel oil. 

• Do not dispose the oil in sewers or rivers. It is necessary to collect and bring it to the Competent Authorities for its disposal (DPR 

691/82). 

• After finish up re-assembling the power pack it is necessary to perform the operation of air clearing; to do so it is sufficient to 

make the dock leveler go up and down 3-4 times. 


HYDRAULIC OIL AGIP ARNICA 22 

FEATURES 

EQUIVALENT HYDRAULIC OILS 

Viscosity at 40° C 22 SHELL – TELLUS T 22 

Viscosity at 100° C 5,2 ESSO - INVAROL EP 22 

Viscosity index 175 MOBIL - DTE 11 

Inflammability edge (°C) 192 CASTROL – HYSPIN AWH 22 

Flowing edge (°C) -39 

Density at 15° C 0,857 

IDENTIFICATION OF DANGERS 

This product, when used in the foreseen proper usage conditions, does not present any risk to the user. However, repeated and 

extended contact, together with scarce personal hygiene, can cause skin irritation and contact dermatitis. 

FIRST AID PROCEDURES 

Skin contact 

Eye contact 

Swallowing 

Inhalation of the 

product 

Wash thoroughly with soap and water 

Irrigate the area with abundant water, if the irritation persists contact a specialist 

Do not provoke vomiting, in order to avoid inhalation of the product to the lungs, immediately call for a 

doctor 

If, in the case of spontaneous vomiting there is the reasonable suspicion of inhalation of the product to 

the lungs, transport the patient with extreme urgency to the nearest hospital. 

In case of exposure to an elevated concentration of oil steams, transport the patient to a steam free area 

and call for a doctor 

FIRE PREVENTION PROCEDURES 

• To extinguish fire use: CO2 foam, chemical dust: avoid using water extinguishers. 

• Cover all machinery not touched by fire with foam or soil. 

• Cool down all surfaces not touched by fire with water. 

ACCIDENTAL LEAKING PROCEDURES 

Floor shadings 

Water shadings 

Contain the leakage of the product with sand or soil, then collect it and send it to be reduced to 

ash 

Remove the shed product using mechanical means, then inform the Authorities about the 

accident 

PRODUCT DISPOSAL 

Do not dispose of the oil in sewers or rivers. It is necessary to collect and bring it to the Competent Authorities for its disposal. 

OIL CHANGE 

Oil duration depends on different factors like: amount of working hours, presence of debris/impurities, possible humidity; it has to be 

replaced when features like limpidity or fluidity are missing. 

In any case it is necessary to replace the oil at least every 3 years. Quantity 4.5 litres 


CYLINDERS AND FLEXIBLE PIPES 

460 

RAISING CYLINDER GASKETS 

POS. MOD. POLYPAC GASKET 

1 WNE BUSAK 000500 

2 BALSELA 236196 

3 OR 142 

4 SEEGER Ø 46X54 

LIP CYLINDER GASKETS 

1 WNE BUSAK 000250 

2 BALSELA 129098/1 

3 DU BUSH Ø 25X20 

230 

All mounting, dismounting or adjustment operations that must be done under the dock leveller must be carried 

out after inserting the maintenance support device. 

Beware that all max. pressure valves must be regulated only by authorized personnel, which have to seal all 

valves after regulation according to the existing Safety Rules. 


MAINTENANCE 

TROUBLESHOOTING 

In case of improper functioning of the dock leveller it is suggested firstly to carry out the following checks : 

• Carry out a careful visual check of the dock leveller in its entirety, making sure that the main structure does not have 

deformations, damages and / or bumps that could jeopardize the proper functioning. 

• Check that the flexible pipes are not bent excessively, are not squeezed or damaged. 

• Check that all bolts, nuts and joints to the flexible pipes are not loose and that there is not any oil leakage. 

• Make sure that all electric wires are not disconnected or cut. 

• Also check that there are not any mechanical obstacles that can block the correct total and/or partial sequence of the dock 

leveller movements . In fact, sometimes the dock leveller can be obstructed in its movements by impurities or foreign bodies. 

TROUBLE SHOOTING 

DEFECT CAUSE SOLUTION 

The dock leveller does not 

raise 

1: the electric motor does not start 

Check the power feeding, all contactors and the 

motor safety device 

2: the electric motor is burnt Replace the electric motor 

3: the sense of rotation of the motor is not correct Invert the feeding phases 

1: the side protections are jammed Clean the slidings and set up them manually 

The dock leveller moves in 

spurts 

2: foreign bodies in the rear and front hinges Remove dirt or foreign bodies 

3: the oil level is insufficient Add hydraulic oil 

4: the dock leveller is blocked by a mechanical 

resistance 

Remove the obstacle 

1: the motor is working with two phases or is 

underfed 

2: oil leakages from a pipeline Fasten the joints 

Check the electric connection and the line tension 

The dock leveller raises 

slowly 

3: the dock leveller is overloaded, the max 

pressure valve has intervened 

Remove the load 

4: the pump filter is jammed Dismount and clean the filter (replace it if needed) 

5: air intaking in the intaking pipe Check the fastening 

6: leakage from the valve group due to melting 

defects 

Replace the valve group 


MAINTENANCE 

TROUBLE SHOOTING 

DEFECT CAUSE SOLUTION 

1: no feeding to the electrovalve Check the electric system 

2: the electrovalve coil is burnt Replace the coil 

3: the support device is inserted Remove the support device 

The dock leveller does not 

lower 

4: the safety valve activates because the load has 

been loaded on the dock leveller without the lip 

resting properly on the lorry tray 

5: the safety valve activates because of excessive 

density of the oil due to presence of dirt 

6: the safety valve activates because of excessive 

density of the oil due to room temperature less 

than - 10° C. 

Remove the load 

Replace the oil 

Replace the oil with one suitable for lower 

temperatures 


MAINTENANCE 

ANNUAL CHECKS 

Once a year, all dock levellers must undergo tests and checks. The checks, besides verifying suitability to safety requirements and 

dimensioning, must in particular include: 

• Visual checks concerning wearing and external damage. 

• Check of all functions (functioning cycle) 

• Check of the presence and efficiency of all safety installations (automatic safety device check and max pression valve 

adjustment check). 

It is necessary to perform the following checks and interventions: 

• Check that the main structure of the dock leveller does not show any deformation, damage or bumps that could jeopardize its 

correct functioning. 

• Check that the support device of the dock leveller is perfectly joined with it, that its hinge is in good condition and that it fits 

correctly into its seat. 

• Check that there are the yellow/black stripes on the sides of the plate and on the side panels of the chassis; check that they are 

not worn out and still perfectly visible. 

• Check the lateral flexibility of the dock leveller, which must equal approximately 5% of its total length. 

• Check that the cylinder is free of damage, scratches, rust or foreign bodies on the hinge of the piston. 

• Check that the flexible pipes are not bent excessively, squeezed or damaged. 

• Check that the electric wires are not cut or worn out. 

• Check that all bolts, nuts, joints and pipes are not loose and that there is not any leakage of oil from the cylinder and from the 

pipes. 

• Clean the hinging of the lip if necessary. 

Beware that it is necessary to replace the power pack oil at least once every 3 years. 

Also remember that after a working period of 6 years it is necessary to replace all flexible pipes. 

Every annual check needs to be recorded using its appropriate form. Lack of recording of this form 

will automatically nullify every form of insurance and/or warranty. 


MAINTENANCE 

SEVERE DANGEROUS SITUATIONS 

It’s important to underline that there are situations that can cause mortal danger. 

Lorry approach phase 

• Beware that no operator and no obstruction should be between the dock and the retreating truck. 

Dock leveller location phase 

• The user must be in place to follow easily all the dock leveller motions. This ensures him to action the controls only when the 

positioning is without the presence of loads, or there are not people on or in the vicinity of the dock leveller. 

Usage phase 

• The user authorizes the carry/unload only when the lip is correctly laying on the lorry tray, he can’t see the orange stripes that 

marked the maximum working gradient; the driver has provided the vehicle keys. 

• The forklift fully loaded weight including the operator, must not be greater than nominal carrying showed on the plate (6000 

daN). 

• The loading process must be carried out with forklifts for which the difference between the lorry tray width and the lifting device 

width should be less than 700 mm. 

• Don’t use the ramp for rising people. 

• The load overtake on the dock leveller is allowed only if the lip should be in a perfect vertical position, correctly laid on its 

supports and the dock leveller must form a continuous surface with the floor. 

Maintenance phase 

• Make sure that the safety maintenance bar is properly engaged. 

• Verify that the bar-fixed support has not been damaged by previously incorrectly usages. 

D o n ’ t u s e t h e l e v e l l e r i f y o u c a n s e e 

s i g n o f s a f e t y s y s t e m s t a m p e r i n g .

Hinge Dock Leveller NLS - Novoferm

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