EZ-Pull Edge of Dock Leveler - Owner's Manual

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Engineering Design Dock Parameters Specifications & Features Safety PrecautionsMaintenance
Installation Instructions Operating Instructions Troubleshooting Guide Parts List

*Read entire manual prior to unit installation.

Engineering Design

The EZ-Pull dock leveler offers a superior ergonomic solution compared to other dock levelers. Its simple, smooth performance and easy-to-position lip eliminate the lifting and difficult positioning often associated with hook-type designs.

The latch assembly allows the operator to easily position the unit by pulling and then pushing the handle, causing it to glide forward. Retraction and storage are automatic when a truck pulls away from the dock. The leveler can also be manually closed while a truck is at the dock by pulling the arm back until the lip falls, then pushing the handle forward to complete the cycle.

Dock Parameters

The Edge of Dock Leveler accommodates a maximum of 5 inches above and 5 inches below the dock, providing an 18.5% downward grade and a 20% upward grade. This is suitable for most gas or propane forklifts, but not for most pallet trucks or many electric forklifts.

• Freight trailers range from 46 to 56 inches in height, so the dock leveler should be mounted at **51 inches** above the driveway.
• Refrigerated trailers range from 50 to 60 inches in height, so the dock leveler should be mounted at **55 inches** above the driveway. This application also requires a **reefer lip** (17" lip length) to accommodate the trailer's offset floor.
• Flatbed trailers have a wide range of trailer heights. **Dock boards** or other equipment may be needed for extreme variations.
• Containers have variations in both floor heights and door configurations.
• Captive Fleets require mounting the leveler midway between the highest and lowest trailers, provided the ±5 inch range is maintained.

Pallet trucks and electric forklifts can be used with a trailer that is 3 inches above or 3 inches below the dock level. **Dock boards** or other equipment may be needed for a greater service range for pallet jacks and electric forklifts due to their limited clearance and grade-ability.

Note that edge of dock levelers **will not** accommodate refrigerated and freight trailers at a single dock location due to the limitations specified above.

Dock Leveler Specifications & Features

This edge of dock leveler is designed with a fully hinged lip and a torsion spring counterbalance assembly for easy positioning. The unit conforms to OSHA and US Department of Commerce standard CS-202-55.

The leveler has an operating range of 5 inches above and below the dock surface for propane and gas trucks, and a 3-inch range for pallet jacks and electric forklifts.

• The lip section tilts up to 1 inch for out-of-level compensation.
• The unit is designed to float, allowing for vertical corner deflection when the lip is in contact with the truck bed.
• Positioning tabs ensure correct height placement on the dock surface during installation, making this model one of the easiest to install in the industry.
• The unit comes with a one-year structural warranty.

Safety Precautions

READ AND UNDERSTAND ALL SAFETY PRACTICES AND OPERATING INSTRUCTIONS before installing, servicing, or operating the dock leveler. Failure to do so could result in damage to the unit, property, and personal injury.

1. Do not stand between the leveler and a truck backing up to the dock.
2. Do not operate the leveler with equipment, material, or people on its deck section.
3. Do not stand or travel across the leveler unless the lip is placed securely on the truck bed floor.
4. Never attempt to work under the dock leveler without properly securing the front and center sections.
5. Keep clear of the dock leveler while it is in operation.
6. Do not exceed the capacity rating.
7. If the dock leveler is not operating normally, discontinue use. Request maintenance personnel to inspect it and contact Loading Dock Supply at 1800-741-1258.
8. Keep clear of all pinch points that could cause injury.
9. Do not use the leveler if it appears to be damaged or broken.
10. Damage to the leveler could occur if the product is misused or used in an abusive manner.
11. For additional information or concerns, contact your Loading Dock Supply representative at 1800-741-1258.

Maintenance

The edge of dock leveler will provide years of efficient operation if properly maintained. Preventative maintenance should be performed every **six months** for normal usage. For levelers used in multiple shifts (above normal usage), maintenance should be performed every **30 days**.

1. Cleaning: Check hinge tube areas for any debris. Use a wire brush to remove any foreign objects.
2. Grease: The unit should be greased twice a year or as needed. Grease zerts are located underneath the leveler's deck.
3. Structural Check: Check the unit for any obvious structural wear, including signs of cracking or wearing on the hinge tubes.
4. Spring Assembly: Check the spring assembly to ensure a proper float in the deck. Check the spring linkage rod for any signs of bending.
5. Handle Check: Check the handle for any signs of bending or cracking, as an improperly bent handle can prevent the unit from latching correctly.
6. Latch: Check the latch and latch catch for signs of wear. Excessive wear can decrease the height-up allowance and prevent the latch from disengaging.

Any damaged parts should be replaced immediately. Parts can be purchased from Loading Dock Supply at 1800-741-1258. All levelers offered by Loading Dock Supply are designed to be modular, allowing for adjustments for low dock, hydraulic, and bumper retrofitting.

Standard Model Installation Instructions
Imbedded C Channel

Dock Edge with existing imbedded C channel

CAUTION: STAND CLEAR OF UNIT WHEN CUTTING STEEL BANDING.

NOTE: Remove the handle and bumpers before beginning installation. The handle is attached to the mount plate for shipping purposes only.

1. Check the straightness of the imbedded channel with a plumb line. Shimming may be necessary if it is out of alignment, as this can cause a binding problem.
2. Clean and prepare all surfaces for installation.
3. Center the dock leveler against the dock, with the positioning tabs resting on top of the imbedded channel.
   
4. Tack weld the mount plate to the imbedded channel, alternating from the right and left of the center tack point and down the vertical sides.
5. Shim where necessary to keep the leveler straight and plumb.
6. Weld out the top of the mount plate from the center out to the edges and down the vertical sides.
7. Position the bumpers flush with the top of the mount plate and butted against the sides of the mount plate.
   
8. Mark the bottom hole location of the bumper beam, drill an anchor hole, and install a 3/4" x 4" wedge anchor bolt.
   
9. Re-position the bumper on the dock and weld it to the imbedded channel. Secure the bottom of the bumper with the anchor bolt and nut.
10. Re-grease the unit, as welding may burn out some grease in the hinge tubes.
11. Re-paint any burned areas using Rustoleum smoke grey (7786) or blue (7727) aerosol.
12. The latch is factory-installed with the notch against the mount plate. The latch should swing freely when the leveler is in its rest position.
    
13. Remove the bolt from the bottom of the handle and position the handle into the sleeve with the bend facing away from the dock face. Re-install the bolt and nut.
14. Test the unit for correct operation.

Standard Model Installation Instructions
Approach Plate

Loading docks without imbedded C channels

CAUTION: STAND CLEAR OF UNIT WHEN CUTTING STEEL BANDING.

NOTE: Remove the handle and bumpers before beginning installation. The handle is attached to the mount plate for shipping purposes only.

1. Docks without an imbedded steel channel require an **approach plate**, such as our EPAP12C model.
2. Center the beveled approach plate in the desired location, flush with the dock face. Cut it to fit the door opening if required. An approach plate requires five heavy-duty expansion shield anchor bolts with 1/2" flat head socket cap screws. Locate the approach plate and drill pilot anchor holes with a 9/16" concrete drill bit. Remove the approach plate and drill over the anchor holes with a 7/8" concrete bit. Install the expansion shields into the holes, then re-position and anchor the approach plate.
   
3. Center the dock leveler against the dock, with the positioning tabs resting on top of the approach plate.
4. Tack weld the top of the mount plate at the center to the approach plate.
5. Ensure the leveler is straight and plumb, shimming as necessary.
6. Drill five 3/4" anchor holes along the mount plate and install five 3/4" x 4" wedge anchors.
   
7. Weld the top of the mount plate to the approach plate with a continuous weld from the center outward.
8. Remove weld slag and re-grease as needed, as welding may burn grease out of the hinges.
9. Re-paint any burned areas using Rustoleum smoke grey (7786) or blue (7727) aerosol.
10. The latch is factory-installed with the notch against the mount plate. The latch should swing freely when the leveler is in its rest position.
    
11. Remove the bolt from the handle and position it into the sleeve tube with the bend facing away from the dock face. Re-install the bolt and nut.
12. Test the unit for proper operation.

Mechanical Edge of Dock and Low Dock Leveler
Operating Instructions

1. Step 1: With the truck backed into position and the trailer door open, pull the EP handle up until the dead bolt hits the bottom of the 2" square tube sleeve.
2. Step 2: Pull the handle back until the latch mechanism falls into the catch position.
   
3. Step 3: Push the handle forward to extend the unit outward toward the truck bed.
   
4. Step 4: Continue to push forward until the front lip rests fully on the truck bed.
5. Step 5: Return the handle to its rest position while in use.
6. Step 6: When returning the unit to the stored position, repeat Step 1.
7. Step 7: Pull back on the handle until the front lip clears the truck floor. Once the lip falls, allow the weight of the leveler to drop the unit back into its rest position.
8. Step 8: Return the handle to its rest position.

Leveler Assembly and Parts

PART	DESCRIPTION
EP72LIP	FRONT LIP ASSY (STD) - 15" LIP LENGTH
EP72LIPR	FRONT LIP ASSY (REEFER) - 17" LIP LENGTH
EP72DECK	CENTER SECTION ASSY
EPBUMPBASE	BUMPER SUPPORT
EPSA	SPRING ASSY (INCLUDES LINKAGE ROD)
ERB10	MOLDED BUMPER - 13" X 10" X 4" W/ FASTENERS
EPLINKROD	LINKAGE ROD WITH PINS
EPHANDLE	HANDLE W/ BOLT
EPLAT	LATCH W/ BOLT
EPCB10	BUMPER WITH STEEL BASE

Complete Hydraulic Set-up Installation Instructions
For Factory Issued Hydraulic Unit

NOTE: For lo-dock applications, call Loading Dock Supply @ 1800-741-1258.

CAUTION: ONLY QUALIFIED PERSONNEL SHOULD PERFORM THE FOLLOWING WIRING INSTRUCTIONS.

IMPORTANT

1. Prior to mounting, refer to the EZ-Pull dock parameters and mounting instructions for mechanical edge-of-dock levelers or lo-dock levelers for mounting the unit.
2. Lift the lip of the EZ-Pull leveler to expose the brackets as shown in the illustration.
3. Anchor the mount plate as shown.
4. Weld the EPHLBKT lower bracket in-line with the EPHUBKT upper bracket.
   
5. Mount the MPOWERUNIT on the pump mount bracket EPPMBKT.
   
6. Mount the MHYDCYLINDER onto the lower bracket EPHLBKT.
7. Install and connect the hoses as shown.
   
8. Mount the switch (MPUSHBUTTON) on the interior of the building wall.
   
9. The item ships without hydraulic fluid. **FILL RESERVOIR WITH COMMON GRADE HYDRAULIC FLUID.** (Common Grade fluid is 150 46 viscosity-20W)
10. Power the MPOWERUNIT and jog the motor to test the wiring.
11. Jog the motor to extend the MHYDCYLINDER to attach to the upper bracket EPHUBKT using the provided pin and keepers.
    
12. Carefully lower the lip to its rest position.
13. Press the forward and reverse button to complete a full cycle.
14. Refer to the trouble-shooting guide if the unit does not function properly.

Operating Instructions
Hydraulic Dock Levelers

1. Step 1: With the truck backed into position and the trailer door open, depress the reverse button until the latch falls into position.
   
2. Step 2: Once the latch falls into position, release the reverse button and depress the forward push button.
3. Step 3: The front lip will begin to extend forward. Continue to hold the forward button until the front lip rests fully on the truck floor, or the latch kicks off and the front lip lowers onto the truck floor.
4. Step 4: To return the hydraulic leveler to its resting position, depress the reverse button until the front lip clears the truck bed and raises into a vertical position.
5. Step 5: The hydraulic fluid will return to the tank. The deck section will slowly lower to its resting position parallel to the dock face.

Note: When the leveler is not in use, keep it in the lowered, stored position.

Complete Hydraulic Set-up Installation Instructions
For In-field Retro-fit of Existing Leveler Unit

NOTE: The leveler selected for the hydraulic retro-fit package must be in acceptable working condition.

CAUTION: ONLY QUALIFIED PERSONNEL SHOULD PERFORM THE FOLLOWING WIRING INSTRUCTIONS.

IMPORTANT

1. Lift the front lip of the dock leveler to expose the brackets as shown.
2. Remove the spring assembly, leaving the deck stop and gusset.
   
3. Clean the surface and weld the brackets as shown.
   
4. Anchor the lower bracket to the side of the dock.
5. Mount the MPOWERUNIT on the pump mount bracket EPPMBKT.
   
6. Mount the MHYDCYLINDER onto the lower bracket EPHLBKT.
7. Install and connect the hoses as shown.
   
8. Mount the switch (MPUSHBUTTON) on the interior building wall.
   
9. Item ships without hydraulic fluid. **FILL RESERVOIR WITH COMMON GRADE HYDRAULIC FLUID.** (Common Grade fluid is 150 46 viscosity-20W)
10. Power the MPOWERUNIT and jog the motor to test the wiring.
11. Jog the motor to extend the MHYDCYLINDER so that it can be attached to the upper bracket EPHUBKT using the provided pin and keepers.
    
12. Carefully lower the lip to its rest position.
13. Press the forward and reverse buttons to complete a full cycle.
14. Refer to the troubleshooting guide if the unit does not function properly.

Troubleshooting Guide
(For all types of edge of dock units)

SYMPTOM	POSSIBLE PROBLEM
Leveler will not pivot	No grease in hinge and tube joints. No hydraulic fluid in the tank. Missing or broken component. Check for an obstruction preventing proper operation.
Leveler will not extend forward	Latch is installed incorrectly (reversed). Latch did not engage. Leveler is installed below the dock level, preventing the unit from pivoting back enough for the latch to engage. No hydraulic fluid in the unit, or a leak in a hose. Broken or missing part.
Lip not returning to stored position	Latch not disengaging. Insufficient grease in hinges. Check for debris or obstructions.
Leveler not moving (motor running)	Check fluid level. Pushing the wrong button. Faulty hose, damaged valve stem. Incorrect wiring. Damaged components.
Leveler will not move (motor not running)	Check wiring, voltage, etc. Motor is damaged. Bad push-button switch. Power outage. The unit cannot be operated manually.

Hydraulic Assembly Parts

Ref.	QTY.	PART	Description
A	1	MHYDCYLINDER	6" STROKE, TIE ROD HYD. CYLINDER
B	2	Y3414B	FITTING REDUCER
C	1	MADAPTER90	90 DEG. ELBOW SHORT
D	1	MADAPTER90XL	90 DEG. ELBOW LONG
E	1	YFCV	FLOW CONTROL VALVE
F	1	MPOWERUNIT	AC HYD-PWR UNIT
G	1	Y90ML	90 DEG. ELBOW
H	1	Y30HH	30" HYDRAULIC HOSES
I	2	**	SOLENOID CONNECTORS
J	2	F3834H	PUMP MOUNT BOLTS
K	1	EPHUBKT	EP-HYD. UPPER BRACKET
L	1	EPPMBKT	EP PUMP MOUNT BRACKET
M	1	MPUSHBUTTON	WALL MOUNTED PUSH BUTTON
N	1	M442GANGBOX	ELECT. JUNCTION BOX
O	1	M123RIGIDNIPPLE	3" PIPE FITTING
Q	1	EPHDS	EP-HYD. DECK STOP
**INCLUDED MPOWER UNIT