Mantis Hydraulic Manual - Blue Giant Equipment Corporation

HYDRAULIC LEVELER MANTIS SERIES 

INSTALLATION & OWNER’S MANUAL 

! WARNING 

DO NOT INSTALL, OPERATE OR SERVICE THIS PRODUCT UNLESS YOU HAVE READ AND FULLY UN- 

DERSTOOD THE ENTIRE CONTENTS OF THIS MANUAL. FAILURE TO DO SO MAY RESULT IN PROPERTY 

DAMAGE, BODILY INJURY OR DEATH.

INTRODUCTION 

The following is intended to be a quick reference to some of the important procedures to follow while using the Mantis Series Model 

MTS-H Dock Leveler. It is not intended to cover, or suggest that it does cover, all procedures required to be followed to ensure safe 

operation. Operators should be aware of and abide by all workplace safety regulations that may apply to the operation of the Mantis 

Series Model MTS-H Dock Leveler. These laws and regulations include but are not limited to: 

- Occupational Safety and Health Act (USA). 

- Occupational Safety and Health Acts for Individual States (USA). 

- Canadian Material Handling Regulations. 

For further information on these regulations and / or industry standards that may apply to this equipment, please contact: 

American National Standards Institute (ANSI) 

1430 Broadway 

New York, NY 10018 

(212) 642-4900 

The operating instructions are not subject to notification of amendment. The descriptions and illustrations included in our operating instructions and 

replacement parts list are not binding. In the interests of continuing product development, we reserve the right to make any changes at any time to the 

modules, components and accessories, concurrent with our continuing product improvement program, specifications are subject to change without 

notice. Please contact manufacturer for latest information. 

1 

1. Untrained personnel shall not be allowed to install, operate 

and/or service mechanical dock leveler. 

2. Do not install this leveler, operate and/or service unless 

you have been trained and authorized to do so. 

3. Do not install, operate and/or service this leveler until 

you have read and understood all of the safety information 

and instructions contained herein and on the leveler. 

4. Do not operate this leveler until you have checked its 

condition. Report the need for leveler repairs to your 

supervisor immediately and do not operate leveler until 

repairs are made. Neglect may cause a minor repair to 

become a major service problem and cause the leveler to 

become unsafe. 

5. Do not work under or around leveler being installed 

without first placing adequate barriers to positively prevent 

vehicle traffic from entering the work area. 

6. All electrical wiring, hook-up, repair and troubleshooting 

must be perform by a qualified service personnel. 

All wiring, hook-up and repairs must be made to meet all 

applicable codes. Before doing any electrical work, make 

certain the power is disconnected and properly tagged 

and / or locked out. 

7. Before performing any maintenance, secure maintenance 

strut in place. 

8. Do not load leveler beyond capacity shown on serial 

name plate on leveler. 

9. Stay clear of dock leveler and truck when truck is backing 

in or leaving dock area. 

10. Secure Truck by chocking truck wheels or use of vehicle 

restraint, as detailed by OSHA, before operating dock 

leveler. 

11. Do not use or move the dock leveler if anyone is under, 

in front and/or on dock leveler. 

SAFETY PROCEDURES 

! WARNING 

12. Keep hands and feet clear of dock leveler pinch points 

at all times. Never use hands to lift dock ramp and/or lip 

onto truck or to store dock leveler. 

13. Never try to lift or move any part of the Dock Leveler 

without using the Release Chain. 

14. Do not drive on leveler unless lip is securely on truck 

bed and has a minimum of 4” (100mm) projection on truck 

bed. 

15. Do not exceed 4 mph when driving over dock leveler. 

16. Do not drive over edges of the leveler and / or dock 

bumper blocks (bumper blocks are not structural). 

17. Do not leave equipment or material unattended on leveler. 

18. Do not leave the leveler unattended in the deployed 

position. 

19. Do not use fork truck or any other material handling 

equipment to lower leveler ramp. 

20. Never attempt to perform repairs. Always defer repairs 

to a qualified service technician. 

21. Do wear safety equipment as required. 

22. Do not mix drugs or alcohol with your job. 

This manual is intended to be readily available. Keep it 

near the leveler as a ready reference for anyone who may 

operate or service it. If the leveler being operated is not 

equipped with a manual, request to obtain one and have 

it located near the leveler. 

An authorized dealer or distributor is readily available to 

answer questions about leveler operation and maintenance 

and will provide additional information should it 

be required. 

EXCLUSION OF LIABILITY 

The manufacturer assumes no liability for damage or injury to persons or property which have occurred as a result of defects or faults in the dock 

levelers delivered or due to incorrect use. The manufacturer also assumes no liability for lost profits, operating down times, or similar indirect losses 

which the buyer has incurred. Damage to third parties, irrespective of its nature, is not subject to compensation 

Mantis Series 110106-0 (Part #038-690E)

PROPER LOCK-OUT/TAG-OUT PROCEDURE 

The following is intended to be a quick reference to some of the important procedures to follow by the Occupational Safety and Health 

Administration (OSHA) that requires, in addition to posting safety warnings and barricading the work area, that the power supply must 

be locked in the OFF position or disconnected. OSHA mandates that an approved lockout device is used. The above example of 

proper lockout is shown above. The proper lockout procedure requires that the person responsible for the repairs is the only person 

who has the ability to remove the lockout device. 

LOCK RULES 

1. Use an appropriate “Lock-Out Device”. Each person must attach his or herown lock to the Lock-Out Device. 

2. Identify Locks - Each lock will be identified by a number or a name. A lock without a tag is not good enough. Additional information 

that identifies the person / persons doing the work must be on the tag. Also the type of work that is being performed should be on 

the tag. 

3. Sign The Tag - In some instances one tag is enough, however, the tag must be signed by each worker. In some circumstances a 

supervisor will also need to sign the tag. 

4. One Key Per Lock 

5. Never give your key to anyone else. 

Re-check controls and return to proper setting 

We recommend an entire safety program for the Control of Hazardous Energy (Lock-out/Tag-out). These regulations are available 

through OSHA publication 3120. 

Safety Signs and Safety Messages 

Improper operation can cause accidents. Don’t take chances with incorrect or damaged equipment. Read and understand the procedures 

for safe operation and maintenance outlined in this manual. Do not hesitate to ask for help. 

Stay alert! Follow safety rules, regulations, and procedures. Avoid accidents by recognizing dangerous procedures or situations 

before they occur. 

Safety signs and messages are placed in this manual to provide instructions and identify specific areas where potential hazards exist 

and special precautions should be taken. Know and understand the meaning of these instructions, signs, and messages. Damage 

to the equipment, death, or serious injury to you or other persons may result if these messages are not followed. If warning decals 

are damaged, they must be replaced. Contact your Distributor for replacements. 

! DANGER 

This message indicates an imminently hazardous 

situation which, if not avoided, will result in death or 

serious injury 

! CAUTION 

This message indicates a potentially hazardous situation 

which, if not avoided, may result in minor or moderate 

injury 

Mantis Series 110106-0 (Part #038-690E) 

SAFETY WARNINGS 

! WARNING 

Always lock-out and tag-out any power source before performing 

any work on any electrical devices or electrical controls according 

to OSHA regulations and approved local electrical codes. 

! WARNING 

This message indicates a potentially hazardous situation 

which, if not avoided, could result in death or 

serious injury. 

IMPORTANT 

This message is used when special precautions should 

be taken to ensure a correct action or to avoid damage 

to or malfunction of the Dock Leveler or a component. 

2

3 

TABLE OF CONTENTS 

Safety .......................................................................................................... 1-2 

Table of Contents ............................................................................................3 

Owner’s Record of Purchase ..........................................................................3 

Check Shipment Notice ..................................................................................3 

Installation Instructions ............................................................................... 4-6 

Operating Instructions ................................................................................. 7-8 

Maintenance ............................................................................................. 9-10 

Hydraulic Dock Leveler Components Diagram .............................................11 

Overhead Door Electrical Interlocks - Optional .............................................11 

Trouble Shooting - Units With No Auto Return ....................................... 12-16 

Trouble Shooting - Units With Auto Return ............................................. 17-18 

Power Unit Diagram & Parts .........................................................................19 

Hydraulic Cylinders & Velocity Fuse .............................................................20 

Control Stations & Parts ...............................................................................21 

Interlock Switches & Parts ............................................................................22 

Lip Cylinder Assembly - Auto-Return & Parts ...............................................23 

Safety Strut ...................................................................................................22 

Hydraulic Hoses ............................................................................................24 

Lip Weldment Assembly ...............................................................................25 

Lip & Deck Hinge Pin Diagram & Parts ........................................................26 

Safety Skirts Assembly Diagram & Parts ......................................................26 

Electrical & Hydraulic Diagrams ............................................................. 27-30 

Warranty .......................................................................................................32 

CHECK SHIPMENT BEFORE INSTALLATION 

The leveler has been carefully checked at the manufacturer’s plant before shipment. In order to ensure that no damage 

has occurred during transport, the dock leveler should be checked upon receipt for transport damage and to ensure correct 

operation. Damage due to transport is to be listed on the signed copy on the freight document. The freight forwarder 

must be notified of any damage within 48 hours. Damaged dock levelers must not be put into use. 

OWNER’S PURCHASE RECORD 

Dealer: Date in Service: 

Owner: Number of Units: 

Order Number: Year of Construction: 

Serial Number(s): 

The manufacturer offers a full line of dock levelers, dock safety equipment, accessories, ergonomic and scissor lift 

equipment, and industrial trucks. Concurrent with our continuing product improvement program, specifications are subject 

to change without notice. Please contact manufacturer for latest information. Some features illustrated may be 

optional in certain market areas. 


! WARNING 


INSTALLATION INSTRUCTIONS 

Use caution when lifting or moving the leveler. Do not attempt to lift without suitable hoisting equipment capable of lifting 

as much as 3500 lbs. 

FORK LIFT TRUCK HANDLING SLING HANDLING 

SHIM 4" x 4" 

(102mm x 102mm) 

STITCH WELD 

1/4" 6” 

DOCK LEVELER 

BASE FRAME 

SHIM LIFT HYDRAULIC 

ARM 

BASE BRACKET 

5" X 5" - 127mm x 127 mm 

SHIM BOTH SIDES 

5" X 5" - 127mm x 127 mm 

Figure 1 : Dock Leveler Installation Pictorial 

SHIM BOTH SIDES 

5" X 5" - 127mm x 127 mm 

4

Do not install, operate and/or service this leveler until you 

have read and understood all of the safety information 

and instructions contained herein and on the leveler. 

Do not work under or around leveler being installed without 

first placing adequate barriers to positively prevent 

vehicle traffic from entering the work area. 

Keep hands and feet clear of dock leveler pinch points 

1. Prior to installation, clean pit thoroughly and verify that all dimensions 

are in accordance with Blue Giant specifications. 

2. Measure height of rear corners of dock leveler, bottom of frame 

to top of deck plate, typically 19” or 23”(485 or 585mm). Measure 

depth of pit at both rear corners where rear bottom corners of 

frame will be positioned. Locate and place suitable shims (not 

supplied) in pit corners to produce a depth to match frame height. 

See Figure 2, Page 3. 

3. Measure height of front corners of dock leveler, bottom of frame 

to top of deck plate, typically 19-1/2” or 23-1/2” (495 or 595mm). 

Measure depth of pit at both front corners where front bottom corners 

of frame will be positioned. Locate and place suitable shims 

(not supplied) at both front corners to produce a depth to match 

frame height. See Figure 2, Page 3. 

4. Prepare for temporary hook-up of electrical wires and hydraulic 

hoses if required. Identify hose ends as “Lip” and “Deck”. 

- For units with self-contained (mounted under deck) power pack, 

make a temporary electrical hook-up to allow deck to be raised 

and lowered during installation. 

- For units with a wall mounted (remote) power pack, prepare hydraulic 

hoses for “pulling” through conduit and electrical wires for 

temporary hook up or pulling through conduit. 

5 

! WARNING 

IMPORTANT 

The following information is essential for proper installation 

Pit Curb Angles 

A. Must be level side-to-side and front-to-back. 

B. Must be square at both rear corners. 

C. Side curb angles must be parallel to each other. 

D. Finished floor to be flush with top surface of curb angle. 

The leveler must be welded to a firmly embedded steel or 

other dock steel as described in the installation instructions. 

Do not attempt to use only bolts or anchors, to attach 

the dock leveler to the concrete. 

! WARNING 

All electrical work to be performed by a Qualified Electrician. 

! WARNING 

Use caution when lifting or moving the leveler. Do not 

attempt to lift without suitable hoisting equipment capable 

of lifting as much as 3500 lbs. 

Do not work beneath a raised object. Follow all hoisting 

safety requirements. 


Typically 19” or 

23”(485 or 585mm) 

C 

PIT MUST BE 

KEPT SQUARE 

5. Using extreme caution, sling dock leveler into place squarely 

above pit and lower gently onto pre-located shims. Locate 

and square dock leveler to best suit pit and dock face. Space 

between sides of deck and sides of pit should be equal. See 

Figure 2 Page 5. 

6. If rear angle does not line up squarely with rear curb angle, 

use 3” x 6” (75mm x 150mm) shims of suitable thickness to fully 

support top rear and bottom rear of rear beam at weld areas. 

Weld rear angle to curb steel with 1/4” x 6” (6mm x 150mm) 

welds, on 9-5/8” (250mm) centers. See Figure 1, Page 2. 

7. Remove sling brackets, chains, etc. from the deck. Remove 

and discard the shipping bolt from the front of the dock 

leveler lip plate. 

8. Check deck height to assure it is flush with top of side curb 

angles and tack-weld all front shims to front curb angle and 

front frame. 

D 

DOCK BUMPERS 

Figure 2 : Pit Layout - Typical 

IMPORTANT 

Typically 19-1/2” or 

23-1/2” (495 or 595mm). 

It is important that these shims fill space between bottom 

edge of back angle and face of curb angle as well 

as top edge, behind each hinge lug. Assure the top of 

the back angle is flush with the top surface of rear curb 

angle and finish weld back beam to curb angle as detailed 

in Figure 1, Page 2. 

! WARNING 

Use caution when unbanding the leveler. Keep hands 

clear of pinch points and wear appropriate safety attire 

- glasses, gloves and work boots. Note: There is the potential 

for the dock leveler to deploy when the shipping 

bolt is removed. The holdown mechanism must be engaged 

prior to removal of shipping bolt. 


9. Mount push button / control box assembly in a suitable location. 

Mount power unit in a suitable location if applicable 

(remote power pack). 

10. If power unit is mounted remote from pit (wall mounted) 

permanently attach hydraulic hoses. “Lip” hose is attached to 

the top fitting on the power unit manifold block and the “Lift” 

hose is attached to the side fitting. 

11. Perform a temporary electrical hook-up to allow use of 

power unit to raise dock leveler. See appropriate electrical 

wiring diagram, refer to table of contents. Assure correct motor 

rotation on start-up of 3 phase units – if motor runs but 

deck will not raise, qualified personnel to interchange any two 

motor leads. 

12. Push and hold “Up” button to raise deck and extend lip. 

Raise and position maintenance strut. Release “Up” button 

and allow dock leveler to lower onto maintenance strut. 

12. Install additional blocking to assure deck can not lower unexpectedly 

and place traffic barriers as required. 

MAINTENANCE 

STRUT 

! WARNING 

All electrical work to be performed by a Qualified Electrician. 

! WARNING 

Do not work beneath dock leveler without engaging 

maintenance strut. 

! WARNING 

Do not work beneath dock leveler without folling proper 

lock-out procedures on page 2. Disconnect and lockout 

electrical power supply as required, to assure there 

is no electrical power to dock leveler control panel, and 

that electrical power can not be turned on accidently. Do 

not work under dock leveler with power supply turned 

“ON” - power must be “OFF”. 

13. Rear frame on most models has one or more vertical frame 

members in addition to rear corner vertical members. Place 

adequate shims directly under each vertical member to fill 

space between bottom frame and floor of pit. Finish weld all 

rear shims. 

14. Measure thickness of shims that were installed under middle 

of front frame and place same thickness of 6” x 6” (150mm 

x 150mm) shims under base of deck cylinder. Finish weld to 

cylinder mounting plate. 



UPPER REAR 

PIT ANGLE 

REAR FRAME 

ANGLE 

15. Finish weld all shims securely to front curb angle and front 

frame. 

IMPORTANT 

Do not allow Dock Leveler to be used without bumpers, 

as damage to building and dock leveler may result. 

16. Install specified dock bumpers as required. 

17.Release bottom safety skirts by removing and discarding 

shipping bolts, one bolt each side. 

18. Make permanent electrical and hydraulic connections as required. 

17. Remove pin from telescopic maintenance strut, extend the 

maintenance strut to the desired height, reinsert pin and walk the 

deck down to engage the maintenance strut. 

18. Mount “Operating Hazards DANGER” placard, provided with 

these Instructions to the wall in plain view of dock leveler operations. 

19. Mount No. 2 envelope containing Owner / Operator Manual 

and Warranty Validation Form to be returned to the manufacturer. 

20. Perform a final inspection and determine that all work is 

completed satisfactorily. Clean pit and work area thoroughly 

and apply touch-up paint to weld burn areas, scratches, etc. 

21. Test operate the unit through several full cycles of all functions. 

Refer to Owner’s Manual for Operating Procedures. 

If adjustments are required, refer to Troubleshooting 

Installation Inspection 

1. Clean up the entire work area and apply touch-up paint to all 

welds, scratches and burns. 

2. Ensure all concrete wedge anchors have been securely 

tightened. 

! WARNING 

Read and understand this entire manual prior to 

operating. 

3. Test operate the unit through several full cycles of operation. 

Refer to: Operating Procedures. If problems are noted, See 

Section on Troubleshooting. 

4. Leave these Instructions with the Dock Leveler for use by 

owner. 

6

Do not install this leveler, operate and/or service unless 


Do not install, operate and/or service this leveler until 

you have read and understood all of the safety information 

and instructions contained herein and on the 

leveler. 

Do not operate the dock leveler beyond its rated capacity. 

Do not operate this leveler until you have checked its 

condition. Report the need for leveler repairs to your 

supervisor immediately and do not operate leveler until 

repairs are made. Neglect may cause a minor repair 

to become a major service problem and cause the leveler 

to become unsafe. 

Never try to lift or move any part of the Dock Leveler 

manually. 

Keep hands and feet clear of dock leveler pinch points 

at all times. Never use hands to lift dock ramp and/or 

lip onto truck or to store dock leveler. 

Do not drive on leveler unless lip is securely on truck 

bed and has a minimum of 4” (100mm) projection on 

truck bed. 

Do not exceed 4 mph when driving over dock leveler. 

Do not drive over edges of the leveler and / or dock 

bumper blocks (bumpers blocks are not structural). 

FUNCTIONAL DESCRIPTION 

The Dock Leveler is intended to be used as a bridge located 

between a loading dock floor surface and the rear deck upper 

surface of a Transporter Vehicle. 

The Dock Leveler upper deck plate complete with a hinged, 

vertically hanging lip plate is located flush with the floor surface 

and the edge of the Dock, in a shallow pit. 

The rear deck surface of a transporter vehicle is parked and 

blocked in place against the outer wall of the loading dock, in 

working alignment with the Dock Leveler. A Dock Leveler and 

Vehicle Restraint are ideal for this application. Consult your 

local Dealer/Distributor. 

The Dock Leveler is operated by maintaining pressure on a 

push button switch to raise the front of the deck. The hinged 

lip plate raises with the deck and it’s leading edge swings out 

horizontally over the rear of the transporter vehicle, when the 

deck reaches its fully raised position. 

The Dock Leveler operator releases the push button and the 

deck and extended lip lower together until the underside of 

the extended lip makes contact on the load bed of the transporter 

vehicle. 

A bridge is now formed that is supported at the building end 

by the dock floor and at the transporter vehicle end by the 

load bed. 

No other means of support is provided when in this position. 

During loading / unloading operations, the deck and lip automatically 

follow the raising and lowering movement of the 

transporter vehicle. 

The Dock Leveler is returned to its original stored position by 

the Dock Leveler operator. In the stored position, both ends 

of the Dock Leveler upper deck plate are supported. The 

building end is supported by the dock floor and the load bed 

end is supported by the lip, lip keepers, and the pit floor. 

7 

! WARNING 

OPERATING INSTRUCTIONS 

Operating Procedure 

! WARNING 

Secure the truck with a vehicle restraint, wheel 

chocks or other method before commencing traffic 

across the dock leveler. 

1. In the stored position, the dock leveler is available for use. 

IMPORTANT 

Releasing the push button will stop the upward 

travel of the dock. 

2. To raise the dock leveler, the dock attendant operates the push 

button causing the deck to raise fully and the lip to extend fully. 

3. With the deck fully raised and the lip fully extended the operator 

releases the push button and the deck and extended lip 

lower together until the underside of the extended lip makes 

contact on the deck of the vehicle. 

4. Ensure full width of lip overlaps the vehicle deck a minimum 

of 4” (100mm) to provide full Dock Leveler support. 

5. In use, the Dock Leveler adjusts itself to tilted vehicle load 

beds and raises and lowers automatically with movements of 

the load bed. 

6. Perform and complete the loading / unloading operation. 

7. When completed, assure all personnel and material handling 

equipment are clear of transport vehicle and dock leveler. 


8. Maintain pressure on the push button to raise front of deck 

only enough to allow the tip of the lip to slide off vehicle deck 

and swing down. 

9. Release push button and allow deck and lip to lower to the 

original stored position. 

10. Assure deck is level with floor surface and tip of lip is in the 

supporting position inside the lip keepers. 

! WARNING 

The truck should never be allowed to depart 

with the lip plate resting on the loadbed. 

11. The operator releases the vehicle restraint or removes 

the wheel chocks to allow the truck to depart. 

The operator then indicates to the truck driver that it is 

safe to depart. 

Below Dock Level Control: End Loading 


Note: 

For units equipped with auto-return 

option, selector switch must be set to 

manual operation (MAN). 

1. Dock attendant follows standard operating procedures on 

page 7 to assure vehicle is securely positioned and restrained. 

Attendant then raises dock leveler deck until lip begins to extend 

and immediately releases the ‘Up’ push button. 

OPERATING INSTRUCTIONS 

2. Push and hold push button to raise deck. As the deck 

reaches fully raised position and the lip begins to swing out, 

immediately release push button and allow deck with partially 

extended lip (approximately 2” [50mm]) lowers to the fully below 

dock height position and is supported by the below level 

stops. Lip is hanging down between face of dock and rear of 

vehicle. Fork lift truck may now remove the end load / loads. 

3. On completion of removing the end loads, the deck and lip 

are raised and placed in normal working position on the truck 

bed for further loading / unloading as required. Continue with 

standard operating procedures on page 7 and 8. 

Auto-Return To Stored Position - Optional 

The dock attendant selects either manual (MAN) or autoreturn 

(AUTO) operation modes by turning a selector switch 

that is mounted on the control station. 

The selector switch may be left in either position indefinitely. 

Manual Setting: 

Operator uses the “UP” push button to 

return the dock leveler to stored 

position (Standard Operation). 

Autor-Return Setting: 

Dock Leveler is automatically returned 

to stored position when truck departs. 

1. Dock attendant assures truck is restrained and follows standard 

operating procedures on page 7, When loading/unloading 

is completed and equipment and personnel are clear, follow 

operating procedure 11, dock leveler will automatically return 

to store position after truck departure. 

8

Planned Maintenance 

In addition to the daily operator inspection, the manufacturer 

recommends and local Government regulations 

may require that a planned maintenance (PM) and 

safety inspection program be performed by a trained 

and authorized service technician on a regular basis 

to maintain the equipment in safe operating condition. 

The PM will provide an opportunity to make a thorough 

inspection of the safety and operating condition of the 

Dock Leveler. Necessary adjustments and repairs can 

be done during the PM, which will increase the life of 

components and reduce unscheduled downtime and increase 

safety. The PM can be scheduled to meet any 

particular application and Dock Leveler usage. 

The procedures for a periodic planned maintenance 

program that covers inspections, operational checks, 

cleaning, lubrication, and minor adjustments are outlined 

in this manual. An authorized dealer or distributor 

is prepared to assist with a Planned Maintenance Program 

by trained service personnel who possess expertise 

in Dock Leveler safety and efficiency. 

Operator Daily Inspection 

The Dock Leveler should always be examined by the 

9 

INSPECT 

CLEAN 

IMPORTANT 

Improper adjustments and/or lubrication may cause operational 

equipment problems. 

MAINTENANCE 

operator to ensure it is safe to operate, PRIOR TO ANY 

USE. The importance of this procedure is emphasized 

in this manual with a brief illustrated review and later 

with more detailed instructions. The manufacturer recommends 

making multiple photocopies of Operator’s 

Daily Checklist. The operator should make a daily inspection 

prior to use; filling out this form in order to keep 

a daily record of operation and maintenance issues. 

Routine Servicing And Maintenance 

Regular maintenance and care of the Dock Leveler is 

very important for cost and operation efficiency and more 

importantly; operator safety. A faulty Dock Leveler is a 

potential source of danger to the operator, and to other 

personnel working near it. As with all quality equipment, 

keep the Dock Leveler in good operating condition by 

following the recommended schedule of maintenance. 

Failure to properly maintain or operate the dock leveler 

within its rated capacity can void the manufacturer warranty. 

Complete the Warranty Validation Form provided with 

this manual and return it to factory. 

Recommended Hydraulic Fluids 

Normal, All Season Weather Conditions: 

- Valvoline All Weather 36 or equivalent. 

Note: Dextron II Automatic Transmission Fluid may be 

used if other suitable oils are not available. 

Extreme Low Temperature Conditions: 

- Esso Univis N15 or Gulf Harmony Arctic 15 or suitable 

equivalent. 

DECK DECK SAFETY LIP HINGE LIP HYDRAULIC 

CYLINDER ASSEMBLY LEGS ASSEMBLY CYLINDER OIL RESERVOIR 

ALL THE ABOVE EVERY 90 DAYS 

ALL THE ABOVE EVERY 90 DAYS 

(Lip Clean As Required) 

LUBRICATE As Needed Every 90 Days Every 90 Every 90 Every 90 Days Drain, 

Pivot Points Days Days (Light Oil) Flush & Change 

(Light Oil) (Light Oil) (Grease) Once Per Year 

ADJUST As Needed Not Required Not Required Not Required As Needed Fill As Needed 

Note: In many localities, all lifting devices must be inspected a minimum once per year. 


! WARNING 

Do not install this leveler, operate and/or service unless 



P M C H E C K L I S T – DOCK EQUIPMENT 

Customer Tel SWO# 

Location Cust. Contact 

Date Inspected By 

Barricade Work Area 

CLEAN Repairs? OK CHECK / ADJUST / LUBE 

Check Main Lift Cylinder 

Repairs? OK 

Pit Area Check Lip Lift Cylinder 

Deck Hinge Check Clevis Pins & Lubricate 

Lip Hinge Check Push-Button Station 

CHECK Repairs? OK Check Wiring Harness 

Check Full Operating Cycle Check Oil Level (Top off as needed) 

Check Instruction, Caution, Danger 

Check Automatic Return To Dock 

Labels 

Check Welds On Dock Leveler Check Dock Bumpers 

Check Maintenance Strut / Lip Latch Check Weather Seals 

Check Ramp Rear Hinges 

Check Dock Leveler Structure, Sub 

Frame, Shim 

Lubricate Rear Hinges & Pins 

Lubricate Dock Leveler Lip Hinge 

Structural Damage 

Check Dock Seal/Dock Shelter 

Check Lip Crown 

Dock Bumpers / Extensions 

Overhead Door 

Check For Proper Operation 

Curb Angle 

Place Updated Service Sticker On 

Equipment 

Safety Skirts Clean Up Of Dock Leveler Area 

COMMENTS 

REPAIRS RECOMMENDED 

PM CHECK LIST - DOCK EQUIPMENT 

10

11 

HYDRAULIC DOCK LEVELER COMPONENTS 

OVERHEAD DOOR ELECTRICAL INTERLOCKS - OPTIONAL 

This option prevents operation of the Dock Leveler when the overhead door is closed or only partially open. 

Photo-Reflective Type: 

The non-contact photoelectric device is wall mounted in close 

proximity to the flat surface ends of the door panels, at a height 

that will allow the dock leveler to operate only after the door 

has been opened. 

Kit Part Number: 783-300-1 

Mechanical Type: 

The mechanical / electrical switch device is wall mounted in 

close proximity to, and extended out from the wall slightly beyond 

the door roller track, at a height that will not allow the 

dock leveler to be used until the switch has been operated. 

The operating cam-rod is mounted on the extreme outside 

edge of the lower door panel so that the cam-rod will rotate the 

switch operating lever as it passes by. The switch operating 

lever is a maintained contact type that remains in the position 

it is rotated to, by the passing cam rod. 

Kit Part Number: 783-300 


TROUBLE SHOOTING - UNITS WITH NO AUTO-RETURN 

Only Trained and Authorized Personnel should perform repairs or adjustments. 

Contact your local Distributor for assistance. 

Problem Problem Cause 

Deck will not raise when push 

button is operated. 

- Motor does not attempt to run, 

no sound is heard. 



- Motor attempts to run, but power 

supply breaker switch trips to the 

off position, turning the power off 

before the motor reaches full 

running speed. 



- Motor does start and run. 


1. Interlock devices not operated, Eg. Overhead door interlock or vehicle restraint. 

- Open overhead door or repair sensor. 

- Engage vehicle restraint or chock and bypass. 

2. No power supply to control station. 

- Breaker tripped. 

- Fuse blown. 

- Disconnect switch open. 

3. Thermal overload tripped open. 

- Reset by pushing the reset button on the control station. 

- If trip-off recurs, repair motor circuit as required. 

4. Faulty control box component – fuse, push button, contactor, transformer. 

- Repairs by qualified personnel as required. 

1. Not normally a fault in the controls or power unit. 

2. Occurrence is more prevalent with 115/1/60 power supply. 

3. Power supply circuit is overloaded by other equipment or components being used on a 

branch circuit controlled by the same breaker switch. 

4. For permanent correction of this problem, the power supply line circuit must be upgraded to 

meet the requirements of the power unit. 

5. A temporary measure to allow use of the dock leveler is to purposely misadjust the pressure 

relief valve to allow a minimal bypass of oil at motor start up, to cause a reduction of amper- 

age draw during start up. (See Fig. 1 Trouble Shooting, page 12) 

- Turn relief valve adjusting screw counter-clockwise 1/4 turn and test operate. Repeat as 

required to a setting that will allow motor to start and deck and lip to raise and extend fully. 

Readjust to normal settings after line voltage problem has been corrected. (See Fig. 1 Trouble 

Shooting, page 12) 

Failure to readjust to normal setting will result in unnecessary, frequent, service call backs. 

Note: 

(1) Hydraulic oil must be replaced if contaminated by 

foreign material. 

(2) Count and record turns when removing or replacing 

adjustable parts. 

Figure 1 Trouble Shooting 

1. Foreign material lodged between side of deck and pit wall. 

- Remove and discard foreign material as required. 

2. Damaged or missing bumpers allowing truck to contact and hold lip. 

- Move truck as required and replace bumpers. 

3. Equipment or goods parked on dock leveler deck. 

- Remove. 

4. No hydraulic fluid in power unit. 

- Damaged hose or other oil leak, repair and refill with approved hydraulic oil as required. 

5. Incorrect motor rotation, three phase power supply only. 

- Qualified personnel to interchange any two motor leads. 

6. Relief valve is bypassing. 

- Re-set relief valve adjustment. Turn adjusting screw clockwise until it bottoms out and then 

back off 1/8 turn. (See Fig. 1 Trouble Shooting, page 12) 

- Contamination between relief ball and seat, holding valve open. Remove, disassemble, clean thor- 

oughly, reassemble, replace, reset adjustment, test operate. (See Fig. 1 Trouble Shooting, page 12) 

7. Sequence Valve Shuttle Sticking in Left-Hand Position. 

- Foreign material in hydraulic fluid causing shuttle to stick in bore. Remove sequence springs, 

shuttle, and shuttle stop components, clean all parts thoroughly, clean bore thoroughly, change 

oil, replace all components. Adjust to original settings, test operate. (See Fig. 1 Trouble Shooting, 

page 12) 

12


Only Trained and Authorized Personnel should perform repairs or adjustments. Contact 

your local Distributor for assistance. 


Deck will not begin to raise immediately 

when motor begins 

to run. 

- Usually occurs only after the 

deck cylinder hose has been 

replaced with a new hose that 

was not pre-filled with oil. 

Deck raises slower than normal. 

- Fluid level in reservoir is normal. 

Deck raises partially and stops. 

- Motor continues to run and 

power unit makes more noise 

than normal. 

13 

Air is trapped in the deck lifting cylinder. Bleed as follows: 

1. Place selector switch in ‘MAN’ position if applicable. 

2. Operate dock leveler and place in fully below level position. 

3. Allow to rest in place for 60 – 90 seconds, and repeat as required until deck begins to raise 

immediately the motor starts to run. 

1. Deck or damaged skirts dragging on side of pit. 

- Repair as required. 

2. Pressure Relief Bypassing. (See Fig. 1 Trouble Shooting, page 12) 

- Foreign material lodged between ball and seat. Change oil. Flush by raising deck and lip to 

maximum height and continue to run motor for 30 seconds maximum. 

- Remove relief valve, disassemble clean thoroughly, change oil, replace valve, adjust to 

original setting, test operate. 

- Ball seat is damaged and must be reseated. Remove relief valve, disassemble, clean thor- 

oughly, using a brass punch firmly hit the ball onto its seat, re-clean, change oil, replace 

valve, adjust to original setting, test operate. 

3. Sequence Valve Shuttle Sticking. (See Fig. 1 Trouble Shooting, page 12) 

- Foreign material in hydraulic fluid causing shuttle to drag and stick in bore.Remove se- 

quence springs, shuttle, and shuttle stop components, clean all parts thoroughly, clean bore 

thoroughly, change oil, replace all components, adjust to original settings, test operate. 

4.Faulty Pump. 

- Change oil, replace as required 

1. Oil level in reservoir is low. 

- Add appropriate hydraulic oil to the reservoir. 

- Locate oil leak and repair as required. 

- Top-up oil reservoir with dock leveler in parked position. Correct oil level is 1” below top of reservoir 

when dock leveler is in parked position. 








Deck raises fully - Lip does not 

attempt to extend. 

Lip does not extend fully. 

- Oil level in reservoir is not low. 

Lip extends before deck is fully 

raised. 

Lip will not remain extended. 

- Lowers as deck is floating down. 

Lip does not lower when deck 

is raising, or does not lower 

with smooth motion. 



1. Relief valve is by-passing. (See Fig. 1 Trouble Shooting, page 12) 

- Adjust to produce higher pressure. 

- Turn adjusting screw clockwise until it bottoms out and then back it off 1/8 turn. 

2. Sequence valve operating pressure set too high. (See Fig. 1 Trouble Shooting, page 12) 

- Adjust to operate at lower pressure. 

- Turn adjusting screw counter-clockwise in 1/2 turn increments until lip will extend with no hesitation 

after deck has reached fully raised height. 

3. Check oil level in reservoir. 

- Power unit sound will be louder than normal if oil level is low. 

- Top-up oil tank with appropriate hydraulic oil if required. 

1. Lip plate bent causing hinge to bind. 

- Repair and lubricate as required. 

2. Foreign material lodged in the lip hinge area. 

- Clean thoroughly as required. 

3. Relief valve is by-passing. 

- In some instances slight mechanical imperfections can be overcome by increasing the 

hydraulic pressure. 

- Turn adjusting screw clockwise until it bottoms out and then back off 1/8 turn. (See Fig. 1 

Trouble Shooting, page 12) 

Note: Repair is not completed until mechanical damage is corrected. 

1. Sequence valve operating pressure setting too low. (See Fig. 1 Trouble Shooting, page 12) 

- Adjust to operate at higher pressure. 

- Turn adjusting screw clockwise in 1/2 turn increments until lip does not extend until after deck has 

reached fully raised height. 

Note: Lip must extend with no hesitation after deck has reached fully raised height. 

1. Sequence valve shuttle sticking. (See Fig. 1 Trouble Shooting, page 12) 

- Shuttle is not moving fully back to its left hand position when motor stops. 

- Foreign material in hydraulic fluid causing shuttle to drag and stick in bore. Remove sequence 

springs, shuttle and shuttle stop components, clean all components thoroughly, clean bore thoroughly, 

change oil, replace all components, adjust to original settings, test operate. 

1. Sequence valve operating pressure set too low – shuttle moves too far to the right closing or partially 

closing the lip cylinder return oil flow path. Adjust to operate at higher pressure. (See Fig. 4 Trouble 

Shooting, page 14) 

- Turn adjusting screw clockwise in 1/2 turn 

increments until lip lowers smoothly as deck is 

raising. 

2. Lip must lower by gravity, check for bent or damaged lip, thoroughly clean and lubricate. 

14





Lip lowers slowly in normal 

temperatures and very slowly in 

extremely cold weather. 

- Deck lowering speed is correct. 

Deck lowering speed is too slow 

or too fast. 

15 

1. A valve adjustment will not correct this problem. Adjusting the shuttle stop position will cause the 

deck to lower too fast which will in turn cause the fall-safe velocity fuse to lock. 

2. The lip lowers by gravity and must pivot freely on its full length hinge. 

- Thoroughly clean and lubricate the lip hinge. 

- Inspect cylinder hose to assure it is not pinched, causing a restriction. 

- Hose should not be over 18 feet long. Shorten hose and increase hose diameter to reduce restrictions 

if possible. 

- Change to special low temperature hydraulic fluid and change seasonally. 

- If problem is extreme, modify to the power-down hydraulic lip system – a double acting cylinder forces 

the lip to lower as the deck raises. 


Lowering speed adjustment required. 

1. To Increase Lowering Speed. 

- Turn lowering speed adjusting screw counter-clockwise in 1/4 turn increments to a setting 

that causes the deck to lower from fully raised with lip extended to fully lowered below level 

with lip extended in 7 seconds maximum. 

Note: Fall-safe velocity fuse will lock closed if lowering speed is too fast, and deck will not 

lower. 

2. To Decrease Lowering Speed. 

- Turn lowering speed adjusting screw clockwise in 1/4 turn increments until desired lowering 

speed is reached. 

Note: Slower than normal lowering speed will not adversely affect the dock leveler systems 







Deck will not lower from fully 

raised, lip extended position. 

- Lip does lower. 

Lip remains extended after deck 

has lowered to bottom of pit. (Lip 

will not fold to stored position). 


1. The fall-safe velocity fuse located at the bottom of the deck cylinder is in the locked-closed position. 

- Deck lowering speed is set too fast. Turn lowering speed adjusting screw clockwise in 1/4 turn 

increments until travel time is 7 seconds maximum from fully raised to fully lowered positions. 

- Air is entrapped in the deck cylinder and hose. Bleed system as instructed by operating deck to fully 

below level and allow to sit for 60 – 90 second intervals. Repeat as required. 

Note: To open a locked velocity fuse, remove deck weight from cylinder by lifting with a fork truck or 

other means if cylinder is fully extended or jog ‘up’ if not. 

1. A valve adjustment will not correct this problem. 

2. The lip lowers by gravity only and must pivot freely on hinge. 

- Thoroughly clean and lubricate hinge. 

- Disconnect lip cylinder and move lip by hand through full arc to ‘feel’ if it pivots freely. Lip 

may have been bent by truck backing into it. Replace or repair as required. Extend and retract 

lip cylinder by hand. Cylinder rod may be bent and binding because of worn hinge pin. 

3. Inspect for pinched hose restricting oil flow. 

4. Lip cross-over check valve must open to provide an 

oil flow path for return oil from the cylinder. 

- Remove, inspect, test and clean as required 



16

TROUBLE SHOOTING - UNITS WITH AUTO-RETURN 




Deck does not return to stored 

position automatically. 

- Motor does not attempt to run 

after lip lowers. 

- Operation is normal when push 

button is used. 

17 

! WARNING 

Turn Power Supply “OFF” and Lock-Out before attempting adjustment (see page 2). 

Be aware that the sensor switch mounted on the hydraulic cylinder performs the same function as the control station push button switch. 

When the sensor switch is operated, the motor will start and the deck will raise if the power supply is “ON”. 

Do Not work under the Dock Leveler unless the Electrical Power Supply is turned “OFF” and Locked-Out. 

Auto-Return Sequence 



1. Selector switch not positioned to ‘Auto” setting. 

- Select desired operating mode. 

2. Operating cam adjustment required. 

- Lip controlled operating cam does not travel far enough to operate sensor switch. 

- Adjust cam away from lip in 1/16” increments and retest. 

3. Faulty lip cylinder mounted sensor switch. 

- Replace as required. 

4. Faulty wiring between sensor switch and control station. 

- Replace or repair as required. 

5. Faulty selector switch. 








Motor starts, deck raises, lip 

swings in fully but motor does 

not shut off. 

- Deck raises to full height and lip 

extends partially, motor stops, 

deck lowers and cycle repeats, 



- Lip operated cam does not travel past the sensor switch as the lip swings in. 

- Adjust cam away from lip in 1/16” increments and test operate. 


Above Illustration Shows: 

- Deck Partially Raised 

- Lip Fully Lowered 

- Cam Moved Past Sensor Switch 

18

19 

Complete Power Unit 

Includes all Components Shown Above 

ITEM QTY PART NUMBER DESCRIPTION 

--------------- 1 033-403 115-230/1/60 

--------------- 1 033-407 115-230/1/50 

--------------- 1 033-411 208/1/60 

--------------- 1 033-410 208/1/50 

--------------- 1 033-412 208-416/3/60-50 

--------------- 1 033-404 230-460/3/60-50 

--------------- 1 033-405 575-600/3/60-50 

Parts 


2 1 --------------- Coupling-Motor to Pump 

3 1 033-425 Manifold c/w Valves 

4 1 033-427 Pump 

5 1 035-425 Pick up Tube 

POWER UNIT COMPONENTS 

Motor Only 

Shown as Item #1 Above 


1 1 031-115 115-230/1/60 

1 1 031-116 115-230/1/50 

1 1 031-117 208/1/60 

1 1 031-118 208/1/50 

1 1 031-120 208-416/3/60-50 

1 1 031-119 230-460/3/60-50 

1 1 031-121 575-600/3/60-50 

Parts 


6 1 035-426 Filter Screen 

7 1 035-427 Gasket 

8 1 035-428 Oil Tank 

9 1 035-238 Breather / Filler 



HYDRAULIC CYLINDERS 

HYDRAULIC DECK LIFTING CYLINDER 

ITEM QTY PART NUMBER GENERAL DESCRIPTION 

--------------- ------------- 788-635-1 Deck Lifting Cylinder – MTS-H (16” & 18” Lip) 

--------------- ------------- 788-636-1 Deck Lifting Cylinder – MTS-H (20” Lip) 

--------------- ------------- 036-205 Seal Kit for all Deck Lifting Cylinders 

HYDRAULIC LIP EXTENSION CYLINDER 


--------------- 1 788-599-1 Lip Extension Cylinder - MTS-H All Capacity (Single Acting) 

--------------- 1 036-204 Seal Kit for all MTS-H All Capacity Capacity Models 

VELOCITY FUSE – FALL SAFE 


1 1 033-661 Velocity Fuse – All Models 

20

21 

PUSH BUTTON CONTROL STATIONS 

STANDARD CONTROL STATION 


1 1 027-006 115/1/60-50 Standard Unit – No Auto-Return 

1 1 027-007 208-230/1/60 Standard Unit – No Auto-Return 

1 1 027-007-1 230/1/50 Standard Unit – No Auto-Return 

1 1 027-008 208-230/3/60-50 Standard Unit – No Auto-Return 

1 1 027-005 460/3/60 or 415/3/50 Standard Unit – No Auto-Return 

1 1 027-009 575-600/3/60-50 Standard Unit – No Auto-Return 

STANDARD CONTROL STATION 


1 1 027-163 115/1/60-50 With Auto-Return Option 

1 1 027-164 208-230/1/60-50 With Auto-Return Option 


1 1 027-049 415/3/50 With Auto-Return Option 

1 1 027-157 460/3/60-50 With Auto-Return Option 


Note: Replacement supplied is interchangeable with the original and may not be identical in appearance 



INTERLOCK SWITCHES 

Dock Leveler will not operate until the sensor switch has been 

operated by the door moving toward the open position. 

OVERHEAD DOOR – MECHANICALLY OPERATED SENSOR SWITCH 


1 1 028-068 Sensor Switch – Maintained Contact Type 

1 1 028-070 Operating Arm – Double Roller Type 

Complete Kit – See Page 11 

Dock Leveler will not operate when the door is closed. The 

switch operates when the door moves toward the open position. 

OVERHEAD DOOR – ELECTRONICALLY OPERATED SENSOR SWITCH 

PHOTO-REFLECTIVE TYPE 


1 1 028-120 Sensor Switch – Proximity Type 

Complete Kit – See Page 11 

VEHICLE RESTRAINT LOCKOUT – 

MECHANICALLY OPERATED SENSOR SWITCH 


1 1 028-126 Sensor Switch c/w Operating Wand 

The Vehicle Restraint will not release until the Dock Leveler 

has been returned to stored position. The sensor switch is operated 

by the dock leveler lip returning to stored position. 

22

23 

LIP CYLINDER ASSEMBLY - AUTO-RETURN 

LIP CYLINDER ASSEMBLY - AUTO-RETURN 


--------------- ------------ 213-5027 Lip Cylinder Ass’y-Auto Return - MTS-H (16” & 18” Lip) 

--------------- ------------ 213-5027-1 Lip Cylinder Ass’y-Auto Return - MTS-H (20” Lip) 

6 

1 1 788-599-1 Lip Cylinder – MTS-H All Capacity 

2 1 788-345 Rod Assembly – Cam Mounting MTS-H All Capacity 

3 1 788-346 Cylinder Bracket - MTS-H All Capacity 

4 1 113-300 Switch Activator Auto Return - MTS-H All Capacity 

5 2 011-515 Nut, Hex #8-32 Machine Screw - MTS-H All Capacity 

6 1 010-040 Capscrew, Hex Hd. 3/8”-16x1-1/2” - MTS-H All Capacity 

7 1 011-552 Nut, Hex 3/8”-16 Nylon Insert - MTS-H All Capacity 

8 1 014-001 Setscrew, Sckt Hd Cp 1/4”-20 X 1/4 - MTS-H All Capacity 

9 1 025-601 Switch, Micro – Auto-Return MTS-H All Capacity 

SAFETY STRUT ASSEMBLY 


2 

1 1 200-5001 Safety Strut Assembly MTS-H All Capacity 

7 

4 

3 

8 

1 

5 


9


HYDRAULIC HOSE 

DECK LIFTING CYLINDER - HOSE MTS-H All Capacity 


1 1 300-5000-20 6’ and 8’ Models (Nominal Deck & Lip Length) MTS-H All Capacity 

1 1 300-5000-48 10’ Models (Nominal Deck & Lip Length) MTS-H All Capacity 

LIP EXTENSION CYLINDER - HOSE MTS-H ALL CAPACITY 


2 1 300-5000-22 6’ and 8’ Models (Nominal Deck & Lip Length) MTS-H All Capacity 

2 1 300-5000-24 10’ Models (Nominal Deck & Lip Length) MTS-H All Capacity 

24

25 

LIP WELDMENT ASSEMBLY 

LIP WELDMENT ASSEMBLY 

ITEM QTY PART NUMBER GENERAL DESCRIPTION SPECIFIC DESCRIPTION 

1 1 200-02643 Lip weldment (1/2” x 16” x 72”) MTS-H Dock (25 & 30K) 



1 1 200-02643-1 Lip weldment (1/2” x 18” x 72”) MTS-H Dock (25 & 30K) 






1 1 200-02646 Lip weldment (5/8” x 16” x 72”) MTS-H Dock 35K 



1 1 200-02646-1 Lip weldment (5/8” x 18” x 72”) MTS-H Dock 35K 
















Deck Pin 


LIP & DECK HINGE PIN 

Hinge Pin 

LIP TO DECK HINGE PIN 

ITEM QTY PART NUMBER GENERAL DESCRIPTION SPECIFIC DESCRIPTION 

1 1 200-02354 Deck Pin MTS-H (6’ Width Dock) 

1 1 200-02493 Deck Pin MTS-H (6’6” Width Dock) 

1 1 200-02492 Deck Pin MTS-H (7’’ Width Dock) 

2 1 200-02353 Lip Pin MTS-H (6’ Width 25&30K) 

2 1 200-02468 Lip Pin MTS-H (6’6” Width 25&30K) 

2 1 200-02469 Lip Pin MTS-H (7’ Width 25&30K) 

2 1 200-02577 Lip Pin MTS-H (6’ Width 35K) 

2 1 200-02578 Lip Pin MTS-H (6’6” Width 35K) 



2 1 109-687-1 Lip Pin MTS-H (6’6” Width 40K) 


3 

4 

5 

7 8 9 6 

7 8 6 

SIDE SAFETY SKIRTS 

1 2 

ITEM QTY PART NO. DESCRIPTION ITEM QTY PART NO. DESCRIPTION 

------- ------- 202-5024 Safety Skirt Package - 6’ Long 4 2 012-252 Washer,Flat -3/8”ID BS Washer 

------- ------- 202-5024-1 Safety Skirt Package - 8’ & 10’ Long 5 2 011-552 Nut, Hex 3/8”-16 Nylon Insertt 

1 2 202-0036 Safety Skirt, Lower - 6’ Long 6 4 011-135 Capscrew, Sckt Butn/Hd 5/16”-18x3/4 

1 2 202-5036-1 Safety Skirt, Lower - 8’ & 10’ Long 7 4 011-543 Nut, Hex - 5/16”-18 Nylon Insert 

2 2 202-0037 Middle Safety Skirt - 6’ 8 4 012-211 Washer, Zinc 5/16” Bs Flat 

2 2 202-5037-1 Middle Safety Skirt - 8’ & 10’ Long 9 4 012-312 

Washer Nylon Fender 5/16”IDx 

7/8”ODx1/16”TH 

3 2 010-039 Cap Screw, Hex Hd. - 3/8”-16x1” 10 2GA 039-059 Paint,Safety Yellow 

26

27 

ELECTRICAL AND HYDRAULIC 110 – 240/1/60 – NO AUTO-RETURN 

POWER 

SUPPLY 

GND 

REMOTE PUSHBUTTON STATION 

L1 

N OR L2 

HYDRAULIC 

GEAR PUMP 

MOTOR CONTACTOR 

MOTOR 

(M) 

1 3 5 

2 4 6 

A1 

A2 

95 

RESET 

2 4 6 96 

RESERVOIR 

HYDRAULIC POWER PACK 

(MC) 

THERMAL 

OVERLOAD 

(OL) 

START OL MC 

3 4 

L1 

OPTIONAL 

CS 

1 3 5 

2 

2 

4 

4 

N OR L2 

M 

6 

6 

OPTIONAL 

DS 

MC 

OL 

96 A2 A1 

95 

3 

4 

START 

JUNCTION 

BOX 

LIP 

CYLINDER 

OPTIONAL 

OVERHEAD DOOR 

INTERLOCK SWITCH (DS) 

(NOTE: REMOVE JUMPER 

BETWEEN BUTTON #3 & 

CONTACTOR #5 WHEN INSTALLING 

DOOR SWITCH 

VELOCITY 

FUSE 

(FALLSAFE) 

OPTIONAL 

CYLINDER 

SWITCH (CS) 

LIFT 

CYLINDER 


ELECTRICAL AND HYDRAULIC 110 - 240/1/60 - WITH AUTO-RETURN 

1 PHASE 

POWER 

SUPPLY 

GND 

L1 

N 



MOTOR CONTACTOR (MC) 

M1 

HYDRAULIC 

GEAR PUMP 

M1 M2 

MOTOR 

(M) 

1 3 5 

2 4 6 

RESERVOIR 

A1 

A2 

95 

2 4 6 

RESET 

96 

THERMAL 

OVERLOAD 

(OL) 

M2 


FUSE 

MAY BE USED 

WHEN REQUIRED 

MAN/AUTO 

CS 

CS CS 

CS 

3 4 

N 

1 3 5 

2 

2 

L 

3 

CS 

4 

4 

M 

CS 

6 

6 

(F) 

4 

3 

3 

FUSE 

MAY BE USED 

WHEN REQUIRED 

UP 

MAN/AUTO 

4 

OPTIONAL 

OVERHEAD DOOR 





DOOR SWITCH 

JUMPER (SEE NOTE) 

JUNCTION 

BOX 

MC 

OL 

DS (OPTIONAL) 

(SEE NOTE) 

UP 

MC 

4 

DS 

LIP 

CYLINDER 

VELOCITY 

FUSE 

(FALLSAFE) 

FUSE 

MAY BE USED 

WHEN REQUIRED 

OL 

JUMPER 

(SEE NOTE) 

WD1888 - Rev. C - 05/10/04 

LIFT 

CYLINDER 

WD1888 - Rev. C - 05/10/04 

28

29 

ELECTRICAL AND HYDRAULIC 208-230/3/60 - WITH AUTO-RETURN 

3 PHASE 

POWER 

SUPPLY 

GND 

L1 

L2 

L3 

JUNCTION 

BOX 


HYDRAULIC 

GEAR PUMP 

M1 M2 M3 


MOTOR 

(M) 

RESERVOIR 

1 3 5 

2 4 6 

A1 

A2 

95 

RESET 

2 4 

96 

6 

THERMAL 

OVERLOAD 

(OL) 

M1 

M2 

M3 CS 

CS DS 


FUSE (F) MAY 

BE USED 

WHEN REQUIRED 

CS 

L1 L2 L3 

M 

3 4 

(F) 

MC 

4 

3 

3 

4 

UP 

FUSE MAY BE USED 

WHEN REQUIRED 

MAN/AUTO 


LIP 

CYLINDER 

VELOCITY 

FUSE 

(FALLSAFE) 

FUSE (F) MAY 

BE USED 

WHEN REQUIRED 

DS (OPTIONAL) 

(SEE NOTE) 

UP 

MC OL 

MAN/AUTO 

CS 

CS 

3 4 



BETWEEN “DS” AND “4” 

TERMINALS WHEN 

INSTALLING DOOR SWITCH 

OL 

DS 

WD1885 Rev. B - 06/01/01 

OPTIONAL 

OVERHEAD DOOR 

INTERLOCK SWITCH 





CYLINDER 

SWITCH (CS) 

LIFT 

CYLINDER 

WD1885 Rev. B - 06/01/01 


PLASTIC RESERVOIR 

POWER PACK 

TROUBLE SHOOTING & 

ELECTRICAL / HYDRAULIC 

SCHEMATICS

POWER PACK VALVE ADJUSTMENT ILLUSTRATION 

Deck Lowering 

Speed Adjustment 

Deck Port 

VIEW FROM 

RESERVOIR 

SIDE 

Lip Cylinder Port 

Sequence valve 

Relief valve 

All power units are factory tested & pre-set to the following specifications. All adjustable 

valves (3) are preadjusted and locked by a hexagonal locking nut. Main system relief also c/w 

sealing washer. 

Should readjustments be necessary please follow the procedures as instructed below. 

A) Pressure Relief Valve (7) : Loosen locking hex nut. Turn Allen screw clockwise until deck 

begins to lift & continue 1/2 a turn clockwise & retighten lock nut while holding the Allan screw 

adjustment in place. 

B) Sequence Valve (6): Loosen locking hex nut. Turn Allen screw counter-clockwise until lip 

begins to lift & continue 1/8 a turn counter-clockwise & retighten lock nut while holding the 

Allan screw adjustment in place. 

C) Lowering Speed (Deck): Needle Valve - The Deck Lowering speed is to be set so the 

dock lowering speed is 6-7 seconds from the fully raised to the deployed/ stored positon. 

Failure to adjust this as describe will result in difficult adjustment of the Pressure Relief Valve 

and Sequence Valve . 

Loosen locking hex nut. Turn knob clockwise to slowdown deck lowering speed. Turn knob 

counter-clockwise to increase deck lowering speed. Retighten lock nut while holding the knob 

adjustment in place. 

The power unit is now set-up to suit your model dock. If the unit does not perform properly at 

these settings, locate the specific fault description that suits your operating problem in the 

following Trouble Shooting information. Re-adjust only the specific valve mentioned and 

adjust only as instructed in the Trouble Shooting information.


POWER 

SUPPLY 

GND 


L1 

N OR L2 


MOTOR 

(M) 

1 3 5 

2 4 6 


A1 

A2 

95 

RESET 

2 4 6 96 

RESERVOIR 

(MC) 

THERMAL 

OVERLOAD 

(OL) 

START OL MC 

3 4 

L1 

1 3 5 

2 

2 

N OR L2 

M 

OPTIONAL 

DS 

3 

4 

JUNCTION 

BOX 

96 A2 A1 

95 

MC 

64 

OL 

64 

START 

OPTIONAL 

OVERHEAD DOOR 




CONTACTOR #5 WHEN INST 

DOOR SWITCH 

VELOCITY 

FUSE 

(FALLSAFE) 

OPTIONAL 

CYLINDER 

SWITCH (CS) 

LIP 

CYLINDER 

LIFT 

CYLINDER


1 PHASE 

POWER 

SUPPLY 

GND 

L1 

N 



M1 M2 

MOTOR 

(M) 

1 3 5 

2 4 6 

A1 

A2 

95 

2 4 6 

RESET 

96 

THERMAL 

OVERLOAD 

(OL) 

MAN/AUTO 

RESERVOIR 

CS CS 

CS 


FUSE 

MAY BE USED 

WHEN REQUIRED 

CS 

3 4 

N 

CS 

1 3 5 

2 

2 

L 

3 

CS 

4 

M 

6 

(F) 

4 

3 

3 

FUSE 

MAY BE USED 

WHEN REQUIRED 

UP 

MAN/AUTO 

4 

OPTIONAL 

OVERHEAD DOOR 





DOOR SWITCH 


JUNCTION 

BOX 

MC 

OL 

64 

DS (OPTIONAL) 

(SEE NOTE) 

UP 

MC 

4 

FUSE 

MAY BE USED 

WHEN REQUIRED 

DS 

OL 

JUMPER 

(SEE NOTE) 

VELOCITY 

FUSE 

(FALLSAFE) 

LIP 

CYLINDER 

LIFT 

CYLINDER

ELECTRICAL AND HYDRAULIC 208-230/3/60 - WITH AUTO-RETURN 

3 PHASE 

POWER 

SUPPLY 

GND 

L1 

L2 

L3 

JUNCTION 

BOX 


M1 M2 M3 


MOTOR 

(M) 

FUSE (F) MAY 

BE USED 

WHEN REQUIRED 

1 3 5 

2 4 6 

A1 

A2 

95 

RESET 

2 4 

96 

6 

THERMAL 

OVERLOAD 

(OL) 

M1 

M2 

M3 CS 

RESERVOIR 


L1 L2 L3 

M 

3 4 

MC 

CS DS 

MAN/AUTO 

CS 

CS 

3 4 






OL 

DS 

CS 

(F) 

4 

3 

3 

4 

FUSE (F) MAY 

BE USED 

WHEN REQUIRED 

DS (OPTIONAL) 

(SEE NOTE) 

UP 

MC OL 

UP 

FUSE MAY BE USED 

WHEN REQUIRED 

MAN/AUTO 


VELOCITY 

FUSE 

(FALLSAFE) 

OPTIONAL 

OVERHEAD DOOR 

INTERLOCK SWITCH 





CYLINDER 

SWITCH (CS) 

LIP 

CYLINDER 

LIFT 

CYLINDER


3 PHASE 

POWER 

SUPPLY 



TRANSFORMER 

(T) 

H1 

H2 

PRIMARY 

FUSES 

GND 

L1 

L2 

L3 

X1 

X2 

L1 L2 L3 M1 M2 M3 CS CS DS 

MOTOR 

(M) 

RESERVOIR 


PRIMARY 

FUSES (F) 

FUSE (F) 

MAN/AUTO 

THERMAL 

OVERLOAD 

(OL) 

RESET 

FUSE (F) 

UP 

MAN/AUTO 


OPTIONAL 

OVERHEAD DOOR 


REMOVE JUMPER 

BETWEEN “DS” AND “CS” 



JUNCTION 

BOX CYLINDER 

SWITCH (CS) 

UP MC 

CS 

H1 

M1 M2 M3 

X1 

CS 

L1 L2 L3 

M 

120V 

H2 

T 

MC 

OL 

X1 

OPTIONAL 

OVERHEAD DOOR 


CS DS 

VELOCITY 

FUSE 

(FALLSAFE) 

LIP 

CYLINDER 

OL 

LIFT 

CYLINDER 

JUMPER 

REMOVE JUMPER 




WD1487 Rev. E 10/18/00


POWER 

SUPPLY 

GND 

L1 

L2 

L3 



1 3 5 

2 

MOTOR 

(M) 

4 

5 

A1 

A2 

95 

RESET 

2 4 6 96 

RESERVOIR 

(MC) 

THERMAL 

OVERLOAD 

(OL) 


START OL MC 

3 4 

L1 

L2 L3 

1 3 5 

2 

2 

M 

OPTIONAL 

DS 

3 

4 

JUNCTION 

BOX 

96 A2 A1 

95 

MC 

64 

OL 

64 

START 

OPTIONAL 

OVERHEAD DOOR 





DOOR SWITCH 

VELOCITY 

FUSE 

(FALLSAFE) 

OPTIONAL 

CYLINDER 

SWITCH (CS) 

(NOTE: FOR USE WITH ALL 3 

PHASE, 200-600 VOLT WITHOUT 

AUTO RETURN, OR FOR 

200-240/3/60 WITH AUTO RETURN) 

LIP 

CYLINDER 

LIFT 

CYLINDER

! WARNING 

PROBLEM 

Deck will not raise when 

push button is operated. 

- Motor does start and run. 

Deck will not begin to raise 

immediately when 

motor begins to run. 

- Usually occurs only after the 

deck cylinder 

hose has been replaced with a 

new hose that 

was not pre-filled with oil. 

13.1 TROUBLE SHOOTING 

Do Not attempt to install, make repairs or adjustments. Only a trained and authorized 

service technician should perform the installation process. 

Contact your local dealer or distributor for assistance. 

PROBLEM CAUSE 

1. Foreign material lodged between side of deck and pit wall. 

- Remove and discard foreign material as required. 

2. Damaged or missing bumpers allowing truck to contact and hold lip. 

- Move truck as required and replace bumpers 

3. Equipment or goods parked on dock leveler deck. 

- Remove. 

4. Low hydraulic oil fluid in power unit. 

- Damaged hose or other oil leak, repair and refill with approved hydraulic oil as required. 

5. Incorrect motor rotation, three phase power supply only. 

- Qualified personnel to interchange any two motor leads. 

6. Relief valve is bypassing. 

- Re-set relief valve (7) adjustment. Turn adjusting screw clockwise until deck lifts then 

continue 1/2 turn & relock 

- Contamination between relief ball and seat, holding valve open. Remove, disassemble, 

clean thoroughly, reassemble, replace, reset adjustment, test operate. 

7. Pilot Operated to close Check Valve (9) will not close. 

- Foreign material in hydraulic fluid causing check valve seat to be held open. Remove SAE 

plug, remove zero profile valve assembly from cavity. Clean all parts thoroughly, clean 

bore thoroughly, change oil, replace all components. Adjust to original settings, test 

operate. 

Relief Valve (7) 

Pilot Operated to close 

Check Valve (9) 

Air is trapped in the deck lifting cylinder. 

Bleed as follows: 

METHOD #1 

1. Place selector switch in ‘MAN’ position if applicable. 

2. Operate dock leveler and place in fully below level position. 

3. Allow to rest in place for 60 – 90 seconds, and repeat as required until deck begins to 

raise immediately the motor starts to run. 

METHOD #2 

1. Raise Dock and let Dock rest on mantenance stand. Remove and invert Cylinder the 

collapse ram fully. Power up to extend ram then re-install. 

UP 

RESET MAN AUTO

! WARNING 

PROBLEM 



- Motor does not attempt to 

run, no sound is heard from 

motor / power pack and 

control box. 



-Motor attempts to run, but 

power supply breaker switch 

trips to the off position, turning 

the power off before the motor 

reaches full running speed 





PROBLEM CAUSE 

1. Interlock devices not operated, Eg . Overhead door interlock or vehicle restraint. 

- Open overhead door or repair sensor. 

- Engage vehicle restraint or chock wheels and key switch bypass. 

2. No power supply to control station. 

- Breaker tripped. 

- Fuse blown. 

- (Disconnect) switch open. 

3. Thermal overload tripped open. 

- Reset by pushing the reset button on the control station. 

- If trip-off recurs, repair motor circuit as required. 

4. Faulty control box component – fuse, push button, contactor, transformer. 

- Repairs by qualified personnel as required. 

- Single phase condition on a three phase system. 

UP 

RESET MAN AUTO 

1. Not normally a fault in the controls or power unit. 

2. Occurrence is more prevalent with 115/1/60 power supply. 

3. Power supply circuit is overloaded by other equipment or components being used 

on a branch circuit controlled by the same breaker switch. 

4. For permanent correction of this problem, the power supply line circuit must be 

upgraded to meet the requirements of the power unit. 

5. A temporary measure to allow use of the dock leveler is to purposely misadjust the 

pressure relief valve to allow a minimal bypass of oil at motor start up, to cause a 

reduction of amperage draw during start up. 

- Turn relief valve adjusting screw counter-clockwise 1/4 turn and test operate. Repeat as 

required to a setting that will allow motor to start and deck and lip to raise and extend fully. 

Readjust to normal settings after line voltage problem has been corrected. 

Failure to readjust to normal setting will result in unnecessary, frequent, service call backs. 

UP 

RESET 

Relief Valve (7)

! WARNING 

PROBLEM 

Deck raises slower than 

normal. 

- Fluid level in reservoir is 

normal. 

Deck raises partially and 

stops. 

- Motor continues to run and 

power unit makes more 

noise than normal. 





PROBLEM CAUSE 

1. Deck or damaged skirts dragging on side of pit. 

- Repair as required. 

Note: 

(1) Hydraulic oil must be replaced if contaminated by foreign material. 

(2) Count and record turns when removing or replacing adjustable parts. 

2. Pressure Relief Bypassing. 

- Foreign material lodged between ball and seat. Change oil. Flush by raising deck and 

lip to 

maximum height and continue to run motor for 30 seconds maximum. 

- Remove relief valve (7), disassemble clean thoroughly, change oil, replace valve, 

adjust to original setting, test operate. - Ball seat is damaged and must be re seated. 

Remove relief valve, disassemble, clean thoroughly, using a brass punch firmly hit 

the ball onto its seat, re-clean, change oil, replace valve, adjust to original setting, 

test operate. 

3. Pilot Operated to close Check Valve (9) will not close. 

- Foreign material in hydraulic fluid causing check valve seat to be held open. Remove 

SAE plug, remove zero profile valve assembly from cavity. Clean all parts thoroughly, 

clean bore thoroughly, change oil, replace all components. Adjust to original settings, 

test operate. 

4. Faulty Power Pack 

- Replace Power Pack 

Pilot Operated to close Check Valve 

(9) Deck Lowering 

Relief Valve (7) 

1. Oil level in reservoir is low. 

- Add appropriate hydraulic oil to the reservoir. 

- Locate oil leak and repair as required. Top-up oil reservoir with dock leveler in parked 

position. 

- Correct oil level is 1” below top of reservoir when dock leveler is in parked position.

! WARNING 

PROBLEM 

Lip extends before deck 

is fully raised. 

Lip will not remain extended 

- Lowers as deck is floating 

down. 

Lip remains extended after 

deck has lowered to bottom 

of pit. (Lip will not 

auto-return). 

Lip does not lower when deck 

is raising, or does not lower 

with smooth motion. 

Deck raises fully 

– Lip does not attempt 

to extend. 





PROBLEM CAUSE 

1. Sequence valve operating pressure setting too low. 


- Turn adjusting screw clockwise in 1/2 turn increments until lip does not extend until after deck 

has reached fully raised height. 

Note: Lip must extend with no hesitation after deck has reached fully raised height. 

1. Sequence valve shuttle sticking. 

- Foreign material in hydraulic fluid causing sequence spool to stick in bore. Remove Sequence 

Valve Cartridge (6) from manifold cavity, clean all components thoroughly, change oil, replace 

all components, adjust to original settings, test operate. (The Sequence Valve Cartridge (6) 

should not be disassembled.) 

1. A valve adjustment will not correct this problem. 

2. The lip lowers by gravity only and must pivot freely on hinge. 

- Thoroughly clean and lubricate hinge. 

- Disconnect lip cylinder and move lip by hand through full arc to ‘feel’ if it pivots freely. Lip may 

have been bent by truck backing into it. Replace or repair as required. Extend and retract lip 

cylinder by hand. Cylinder rod may be bent and binding because of worn hinge pin. 

3. Inspect for pinched hose restricting oil flow. 

4. Pilot Operated Check Valves (8 & 9) are sticking due to contamination. 

- Remove, inspect, test and clean as required 

1. Sequence Valve Cartridge (6) operating pressure set too low 


- Turn adjusting screw clockwise in 1/2 turn increments until lip lowers smoothly as deck is 

raising. 

2. Lip must lower by gravity, check for bent or damaged lip, thoroughly clean and 

lubricate. 

1. Sequence valve operating pressure set too high. 

- Adjust to operate at lower pressure. 

- Turn adjusting screw counter-clockwise out 1/2 turn increments until lip will extend with no 

hesitation after deck has reached fully raised height. 

2. Check oil level in reservoir. 

- Power unit sound will be louder than normal if oil level is low. 

- Top-up oil tank with appropriate hydraulic oil if required see the maintenace section 7.6 for 

recommended oil. 

Pilot Check Valve (9) 

Pilot to Close, Deck Lowering Function 

Sequence Valve Cartiridge (6) 

Pilot Check Valve (8) 

Lip Fold Function

! WARNING 

PROBLEM 


- Oil level in reservoir is not 

low. 

Lip lowers slowly in normal 

temperatures and very slowly 

in extremely cold weather. 

- Deck lowering speed is 

correct. 

Deck lowering speed is too 

slow or too fast. Refer to 

manifold cross section 

drawing on previous page. 

See NEEDLE VALVE 

Needle Valve (1) 

Deck lowering speed Needle 

Valve. Turn C.C.W. to increase 

deck lowering speed. 





PROBLEM CAUSE 








- Turn Relief Valve adjusting screw clockwise until it bottoms out and then back off 1/8 turn. 


1. A valve adjustment will not correct this problem. Opening the Needle Valve will cause 

the deck to lower too fast which will in turn cause the fall-safe velocity fuse to lock. 

2. The lip lowers by gravity and must pivot freely on its full length hinge. 

- Thoroughly clean and lubricate the lip hinge. 

- Inspect cylinder hose to assure it is not pinched, causing a restriction. 

- Hose should not be over 18 feet long. Shorten hose and increase hose diameter to reduce 

restrictions if possible. 

- Change to special low temperature hydraulic fluid and change seasonally. See the 

maintenace section 7.6 for recommended low temperature oil. 

- If problem is extreme, modify to the power-down hydraulic lip system 

- A double acting cylinder forces the lip to lower as the deck raises. 

Lowering speed adjustment required. 

1. To Increase Lowering Speed. 

- Turn lowering speed adjusting Needle Valve counterclockwise in 1/4 turn increments to a 

setting that causes the deck to lower from fully raised with lip extended to fully lowered below 

level with lip extended in 7 seconds maximum. Note: Fall-safe velocity fuse will lock closed if 

lowering speed is too fast, and deck will not lower. 

2. To Decrease Lowering Speed. 

- Turn lowering speed adjusting Needle Valve clockwise in 1/4 turn increments until desired 

lowering speed is reached. Note: Slower than normal lowering speed will not adversely affect 

the dock leveler systems 

Relief Valve (7)

! WARNING 

PROBLEM 

Deck will not lower from 

fully raised, 

lip extended position.- Lip 

does 

lower. 


- Oil level in reservoir is not 

low. 





PROBLEM CAUSE 

1. The fall-safe velocity fuse located at the bottom of the deck cylinder is in the 

locked-closed position. 

- Deck lowering speed is set too fast. Turn lowering speed adjustment NEEDLE VALVE 

clockwise in 1/4 turn increments until travel time is 7 seconds maximum from fully raised 

to fully lowered positions. 

· Air is entrapped in the deck cylinder and hose. Bleed system as instructed by operating 

deck to fully below level and allow to sit for 60 – 90 second intervals. Repeat as required. 

Note: To open a locked velocity fuse, remove deck weight from cylinder by lifting with a 

fork truck or other means if cylinder is fully extended. Jog the up button if cylinder is not 

extended. Repairs are needed before up jog is performed. Example: leaking hydraulic 

hose 








- Turn Relief Valve adjusting screw clockwise until it bottoms out and then back off 1/8 turn. 


Be aware that the sensor switch mounted on the hydraulic cylinder performs the same function as the control 

station push button switch. 

When the sensor switch is operated, the motor will start and the deck will raise if the power supply is “ON”.

! WARNING 

PROBLEM 

Dock does not return to 

parked position 

automatically. 

- Motor does not attempt 

to run after lip lowers. 

- Operation is normal 

when push button is used 

Motor Starts and deck 

begins to raise but stops 

before lip clears lip 

keepers and swings in. 

-Deck lowers and motor 

starts again, repeating the 

up-down cycle. 

Motor Starts, deck raises, lip 

swings in fully but motor does 

not shut off. 

- Deck raises to full height and 

lip extends partially, motor 

stops, deck lowers and cycle 

repeats. 

UP 

RESET MAN AUTO 





PROBLEM CAUSE 

1. Selector switch not positioned to ‘Auto” setting. 

- Select desired operating mode. 


- Lip controlled operating cam does not travel far enough to operate sensor switch. 

- Adjust cam away from lip in 1/16” increments and retest. 

3. Faulty lip cylinder mounted sensor switch. 


4. Faulty wiring between sensor switch and control station. 

- Replace or repair as required. 

5. Faulty selector switch. 


- Lip controlled operating cam travels too far rearward over the 

sensor switch as the lip and deck raise. 

- Adjust cam toward lip in 1/16” increments and retest. 


- Lip controlled operating cam travels too far rearward over the 

sensor switch as the lip and deck raise. 

- Adjust cam toward lip in 1/16” increments and retest.


3 PHASE 

POWER 

SUPPLY 




TRANSFORMER 

(T) 

H1 

H2 

PRIMARY 

FUSES 

GND 

L1 

L2 

L3 

X1 

X2 

HYDRAULIC 

GEAR PUMP 

L1 L2 L3 M1 M2 M3 CS CS DS 

MOTOR 

(M) 

RESERVOIR 


PRIMARY 

FUSES (F) 

FUSE (F) 

MAN/AUTO 

THERMAL 

OVERLOAD 

(OL) 

RESET 

FUSE (F) 

UP 

MAN/AUTO 


JUNCTION 

BOX CYLINDER 

SWITCH (CS) 

LIP 

CYLINDER 

UP MC 

CS 

H1 

X1 

L1 L2 L3 

CS 

M1 M2 

M 

120V 

M3 

H2 

T 

MC 

OL 

X1 

OPTIONAL 

OVERHEAD DOOR 


CS DS 

VELOCITY 

FUSE 

(FALLSAFE) 

OL 

JUMPER 

REMOVE JUMPER 



OPTIONAL 

OVERHEAD DOOR 


REMOVE JUMPER 




LIFT 

CYLINDER 

WD1487 Rev. E 10/18/00 

30

31 

WARRANTY 

HYDRAULIC DOCK LEVELER 

The Manufacturer’s Base Warranty covers the following Product Classes, each of which is covered under additional warranties (if 

applicable) specific to each class. 

Hydraulic Dock Leveler 

BASE WARRANTY 

The manufacturer warrants to the original purchaser its loading dock equipment to be free from defective material and workmanship 

under normal use for a period of 1 year (365 days). All warranty coverage is to commence from the date of receipt by the first 

user or sixty (60) days after date of shipment, whichever comes first. The said equipment must be properly installed, operated and 

maintained by trained personnel, and must be operated in compliance with the manufacturer’s recommendations with regards to 

rated capacities, duty cycle limitations, grade limitations and/or design specific application(s) agreed upon at the point of sale. 

Initial field set up, adjustment, lubrication and other maintenance are not covered under this warranty and are the sole responsibility 

of the installer and / or end user. The Warranty Registration Form must be completed in full and returned to the manufacturer within 

sixty (60) days of receipt in order for the warranty to be deemed valid. 

The manufacturer shall remedy any defects deemed covered under this warranty by replacing or repairing any equipment or parts 

while incurring reasonable expenses for all parts, labor and freight unless otherwise stated herein. Freight expenses for shipping 

repair/replacement parts will be incurred under conditions of standard shipping terms. Any overnight or special freight requirements 

will be billed to the end user or authorized dealer as determined by the manufacturer. 

Any Original Equipment Manufactured (OEM) part that is replaced during the Base Warranty time period will be either: further covered 

for the remainder of the Base Warranty time period, or for a further 90 days: whichever is longer. 

ADDITIONAL WARRANTY TIME PERIODS: 

Parts or components which fail under normal usage and are proven to be defective will be deemed eligible for repair or replacement, 

(providing no special conditions apply, as stated below) providing the failure occurs within the Additional Warranty Time 

Period of a given Product Class as stated below. Replacement parts will be supplied F.O.B. factory. 

Hydraulic Dock Leveler 

Structural: Covered for an additional four (4) years following the expiration of the Base Warranty time period. 

Components include: Deck, frame, support beams, lip and hinge. Freight is covered under the Base Warranty time period only. 

Hydraulics: Covered for an additional one (1) year following the expiration of the Base Warranty time period. 

Components include: Powerpack, hose and fittings. Freight is covered under the Base Warranty time period only. 

Parts and Labor: No further coverage beyond the Base Warranty time period for any components (including Options) not listed 

above. 

WARRANTY IS VOID IF: 

1) Warranty Registration Form is not fully completed and returned to the manufacturer within sixty (60) days of receipt. 

2) The original purchaser does not notify the manufacturer of the defect within ninety (90) days after the defect has been 

identified. 

3) Equipment is modified in any manner not approved in writing by the manufacturer. 

4) Equipment has been operated: 

• beyond its rated capacity, 

• in excess of its determined duty cycle, 

• or operated in excess of its determined maximum grade, 

• or combination of the above therein, which can directly be attributed to be the cause of failure. 

5) Equipment is used in abrasive or corrosive conditions, or conditions of excessive cold or moisture without having been 

factory specified to be engineered to withstand such conditions. 

THE FOLLOWING ARE NOT COVERED UNDER WARRANTY: 

1) Adjustments, including initial field set-up. Adjustments are considered part of normal maintenance procedures. 

2) Repairs required as a result of: 

• Failure to follow maintenance and/or lubrication procedures specified in the owner’s manual. 

• Abuse, willful damage, accident, or neglect. 

• Shipping damage. (Claim must be made with the freight carrier.) 

THE MANUFACTURER DOES NOT ASSUME RESPONSIBILITY OR LIABILITY FOR INCIDENTAL, CONSEQUENTIAL OR SPE- 

CIAL DAMAGES, OR FOR LOSS OF PROFIT OR DAMAGE TO TRADE OR BUSINESS WHICH RESULTS FROM THE EQUIP- 

MENT. 

THE ABOVE WARRANTIES ARE IN LIEU OF ANY OTHER WARRANTIES, EITHER EXPRESSED OR IMPLIED, INCLUDING 

BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. 

THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION CONTAINED HEREIN. 



NOTES 

32

33 

NOTES 



NOTES 

34

© 2006 Blue Giant Equipment Corporation 

85 Heart Lake Road South 

Brampton, Ontario, Canada L6W 3K2 

Phone: 905-457-3900 • Fax: 905-457-2313 

www.BlueGiant.com 

BLUE GIANT EQUIPMENT CORPORATION

Mantis Hydraulic Manual - Blue Giant Equipment Corporation

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