CHALLENGER HYDRAULIC
OWNER'S AND OPERATIONS
MANUAL
SYSTEMS, INC.
P.O. BOX 309
Germantown, WI 53022
Phone 414-255-1510
Fax 414-255-4199
11/96 - 695221
TABLE OF CONTENTS
Safety ...................................................................................................... 1
Introduction............................................................................................... 2
Preparation .............................................................................................. 3
Installation ............................................................................................. 4-7
Adjustment and Testing ....................................................................... 8-11
Operation ............................................................................................... 12
Operating Instructions ............................................................................. 13
Preventive Maintenance .................................................................... 14-16
Troubleshooting Guide ...................................................................... 17-18
Parts Breakdown .............................................................................. 19-21
INTRODUCTION
Congratulations on your
choice of Poweramp
docklevelers. Your manual
covers the standard
Challenger series hydraulic
docklevelers.
Figure 1
Designed by Poweramp to be a marvel of simplicity and efficiency, your dockleveler,
when properly installed will provide many years of trouble-free performance with an
absolute minimum of maintenance. It's revolutionany hydraulic system efficiently
controls and operates every function. To obtain maximum performance and longest
possible use, a simple program of preventative maintenance is recommended.
The Challenger control assembly allows
pushbutton operation of the dockleveler
functions. Each unit has been factory prewired and tested to insure satisfactory
operation.
Figure 2
Electrical drawings are included with each unit to illustrate which connections are to
be made in the field. Once again, thank you and congratulations on your purchase
of a Poweramp hydraulic dockleveler.
2
PREPARATION
WARNING
Barricade the work
area to prevent unauthorized use of the unit
before installation has
been completed.
WARNING
Be sure power supply
circuit is opened at
main service box or
circuit breaker box
prior to electrical
installation. Failure to
disconnect power
supply could result in
equipment damage
and/or personal injury
or death.
CAUTION
Have all electrical work
performed only by
qualified electricians.
WARNING
Do not ground welding
equipment to any
hydraulic or electrical
components of the
unit.
Do not make any final
electrical connections
until all welding is
complete.
1. Remove all debris from pit and sweep out.
2. Check entire dockleveler pit for proper construction according to approved/certified
pit drawings. Check to be sure that pit walls are square and plumb. Check electrical service to the pit to assure it agrees with the correct location for the junction
box.
Figure 3
3. If conduit must be installed (replacing an existing mechanical dockleveler) do so
at this time. Refer to the conduit requirements on the pit detail sheet. Follow all
applicable electrical codes and standards.
4. Some units are shipped with the bumpers and control assembly banded to the
frame of the dockleveler. Remove these items from the frame at this time.
DO
NOT remove the shipping bands around the frame and platform at this time.
Some units are shipped with 2 x 4's attached to the frame. The
2 x 4's must be removed before the unit is placed in the pit.
5. Mount the control assembly and wire at this time. Refer to the electrical drawings
provided to determine required field connections.
PUSHBUTTON
CONTROL
ASSEMBLY
All welding required for
installation is at the
frame of the unit.
Always ground to the
frame to prevent
possibility of hydraulic
or electric component
failure. Failure to
follow these warnings
could result in injury or
death.
48"
Figure 4
3
INSTALLATION
Poweramp
docklevelers are
designed with
installation in
mind. Each unit is
shipped with lifting
lugs bolted thru
the outboard
joists. The lifting
lugs should be
used whenever
lowering or lifting a
dockleveler into or
out of a pit.
Figure 5
To allow for inconsistant pits, Poweramp docklevelers are designed with a nominal
3/4" shimming distance. Shims are to be located under each of the 3 rear vertical
supports. Also place shims under the 2 lip keeper/cross traffic supports, hoist
cylinder trunnion supports and under the maintenance prop. (See Figure 6).
LIFTING
LUG
1. Place shims on the pit floor in the locations shown. Continue to stack shims
until the dimension from the top of the shims to the dock floor matches the
dockleveler height. A string line may be stretched across the pit opening over
the shims so an accurate measurement can be taken. (See Figure 7).
SHIM
LOCATIONS
Figure 6
WARNING
Do not grind or weld if
hydraulic fluid or other
flamable liquids are
present. Always keep a
fire extinguisher of the
proper type nearby.
4
INSTALLATION
REAR PIT CURB ANGLE
2. Remove the stacks of
shims and weld to the
dockleveler frame directly
STRING
LINE
DOCK FLOOR
PIT FLOOR
Figure 7
beneath the corresponding
vertical support.
3. Position the dockleveler in the pit. The rear edge of the dockleveler must be tight
against the rear pit curb angle.
4. Use 1/4" thick shims to shim the front of the dockleveler. Shims are to be placed under
the 2 lip keeper/cross traffic supports and under the maintenance prop pivot point. To
determine the correct number of shims, position the dockleveler so that it is level with
the dock floor.
5. With the front shims in place, check to insure that a smooth transition exists
between the dock floor and dockleveler. Add or remove shims as required to
achieve this condition.
6. Check alignment of dockleveler with the pit. If the pit conforms to the certified
pit drawings, there will be a 1/4" gap between the ends of the upper frame angle
and the side curb steel. There should also be a 1" gap between the leveler
platform and pit sides (See Figure 8).
REAR PIT CURB ANGLE
1/4"
1"
RAMP
Figure 8
1/4"
REAR HINGE ASSEMBLY
1"
PIT SIDE CURB ANGLE
7. With the rear frame upper angle tightly against the curb steel, weld the rear
frame upper angle to the rear curb angle in the pattern for the width of the
dockleveler being installed. Note: Weld pattern will vary based on dockleveler
width. Figure 9 illustrates a typical weld pattern.
5
INSTALLATION
REAR PIT CURB ANGLE TOP REAR FRAME ANGLE
X
X
X
X
X
3/8" SKIP
WELD (6"
WELD, 12"
SKIP)
X
X
X
X
X
X
X
REAR HINGE TUBE
Figure 9
8. With the rear angle welded in place, cut and remove the shipping bands.
9. Raise the platform by external means (crane or fork truck) and place maintenance prop in position to support platform. Be sure shims are located between
prop attachment point to the frame and pit floor before supporting platform with
maintenance prop.
10. Weld shims in place under front edge of dockleveler. Position shims so that
fillet welds can be used to secure shims. Weld shims in place under rear
vertical supports if not done previously.
11. With the dockleveler safely supported by the maintenance prop and the frame
shims welded in place, position shims to support the hoist cylinder trunnion.
Both sides of the hoist cylinder trunnions must be solidly shimmed for their
entire length. When positioning the shims, always check to make sure the
hoist cylinder trunnion is level from side to side as well as from front to back.
Once the required shims have been positioned, weld in place using fillet welds.
12. With the welding complete, the power cable can now be connected to the field
wires in the pit junction box.
WARNING
Be sure to securely
block platform in raised
position before entering
pit to weld shims. Do
not use maintenance
prop to support raised
platform until shims
have been welded
beneath maintenance
prop support plate
.
WARNING
Be sure power supply
circuit is opened at main
service box or circuit
breaker box prior to
electrical installation.
Failure to disconnect
power supply could
result in equipment
damage and/or personal
injury or death.
CAUTION
Have all electrical work
performed only by
qualified electricians.
13. After all of the electrical connection in the pit have been made, use the lifting
lugs to again lower the dockleveler off the maintenance prop. Remove lifting
chains or sling from lifting lugs.
14. Check to be sure the leveler is flush with dock floor and that the lip con
tacts
both lip keepers evenly.
6
INSTALLATION
WARNING
Always barricade the
work area to prevent
unauthorized use of
the unit before
maintenance is
complete.
Always lock off all
electrical disconnects
after raising platform
and setting maintenance prop when
service under the unit
is required. More
than one electrical
disconnect switch
may be required to
de-energize the
equipment.
Always stand clear of
the dockleveler lip
when working in front
of the unit.
15. Depress and hold the raise button until the maintenance prop can be positioned
properly. This will require 2 people should a remote raise button be unavailable.
16. With the maintenance prop supporting the platform, remove the lifting lugs.
17. Depress the raise button again until you hear the maintenance prop return to its
stored position.
18. Cycle the dockleveler 4 or 5 times throughout its complete operating range to
assure proper operation.
19. Install bumpers.
7
ADJUSTMENT AND TESTING
While you were cycling the dockleveler upon completion of the installation, you
should have noticed that the dockleveler would raise to a certain point after which
time the lip would extend. Releasing the raise button would allow the dockleveler to
lower to the full below dock position after which the lip would fold. Pressing the raise
button would then cause the dockleveler to raise. When the lip cleared the keepers,
the raise button could be released and the dockleveler would rest in the cross traffic
(stored) position. If this operation was not apparent, one of three adjustments may
be required:
1. If the dockleveler did not raise but pump/motor was running, the main pressure
relief may need adjustment. Pressure relief can be found in the steel block that
connects the reservoir to the motor.
The adjustment is an allen wrench adjustment located directly beneath a hex
plug on the side of the block. Remove the hex plug to access the allen screw.
Turning the screw clockwise will increase the pressure. Remember, if you
have a 3 phase power source, the motor may be running backwards.
NUT/PLUG
MOTOR
ADJUSTMENT SCREW
SECTION A
RELIEF VALVE LOCATION RESERVOIR
A
Figure 10
8
ADJUSTMENT AND TESTING
If the dockleveler lip did not extend, or extended too early, the cable weight may need
adjusting. The cable weight is located underneath the dockleveler directly behind
the valve block. As the platform raises, the cable moves the valve lever. When the
cable force exceeds the force necessary to shift the valve spool, the spool shifts
causing the oil to flow to the lip cylinder. The factory setting will result in the lip
extending with approximately 1" of travel left in the hoist cylinder. Sliding the weight
up the cable will result in the lip extending earlier. Be sure to tighten the weight
down securely to the cable to avoid the weight from sliding on the cable.
PLATFORM
LOGIC BLOCK
CABLE WEIGHT
Figure 11
If the dockleveler did not lower, it is possible that the speed control requires adjustment. The speed control is located in the logic block. It is an allen wrench adjustment located in the casting directly behind the upper front hose connection. Clockwise adjustments will slow the lowering speed of the dockleveler. To avoid stops
while the dockleveler is lowering, the speed of the dockleveler should be decreased.
LOGIC BLOCK
ALLEN WRENCH ADJUSTMENT
Figure 12
9
ADJUSTMENT AND TESTING
Your dockleveler may be equipped with Auto Return to Dock. Auto Return to Dock
is an option available on Challenger series dock levelers that will automatically
reposition the dockleveler into the stored, cross traffic position after the truck departs. This option utilizes a switch under the dock leveler and a target fastened to
the lip. See Figure 13.
LIP HINGE TUBE
TARGET
LOCK NUTS
BRACKET
PROXIMITY SWITCH
CABLE
INDICATOR LIGHT*
Typical factory settings for dimensions "A" & "B"
are approximately 1" & 1/4" respectively. The
values for dimensions "A" & "B" for this application may be different than the typical factory
settings. The switch and/or target are to be
adjusted to obtain the results indicated in figures
15 through 17 below. Dimension "A" can be
changed by bending the target. Dimension "B"
can be changed by moving the switch in the
bracket.
COMPONENT IDENTIFICATION
LIP
Figure 13
B
A
LIP FULLY
FOLDED
IMPORTANT: Work lip by hand when making
Figure 14
adjustments to make sure that the target does
not make contact with switch. Damage to
switch will ocur if target contacts switch.
IMPORTANT: Maximum tightening torque for
lock nuts is 27 N-m (20 FT-LBS). Damage to
switch will occur if maximum tightening torque
is exceeded.
* Figure 13 shows the indicator light at the back end of the housing. Some
switches have the light in the side of the housing.
10
ADJUSTMENT AND TESTING
Dockleveler at cross traffic position. Lip fully
folded, inside keepers. (Lip also fully folded when
leveler on maintenance prop.)
1. Target not in sensing area of switch.
2. Switch "OFF" = open (no signal sent to load).
LIP
KEEPER
Figure 15
Dockleveler at full below dock position. Lip
partially extended, outside keepers.
3. Switch indicator light "OFF".
4. The dockleveler does not automatically raise &
return to dock.
1. Target in sensing area of switch.
2. Switch "ON" = closed (signal sent to load).
3. Switch indicator light "ON".
4. The dockleveler automatically raises, after
an approximate 6 second delay, & returns to
dock**.
Dockleveler on truck bed. Lip fully
extended.
1. Target not in sensing area of switch.
2. Switch "OFF" = open (no signal sent to
load).
3. Switch indicator light "OFF".
4. The dockleveler does not automatically
Figure 17
raise & return to dock.
LIP KEEPERS
Figure 16
**The 6 second delay is in the switch. The dockleveler will raise after
approximately 6 seconds after the target is sensed by the switch.
11
OPERATION
The Challenger dockleveler is designed to compensate for +/- 12" of height difference between the loading dock and the truck bed. To position the dockleveler, the
operator utilizes the Challenger pushbutton controls. When the raise pushbutton is
pushed and held, a motor is activated that in turn drives a hydraulic pump which
raises the dockleveler platform. Releasing the pushbutton allows the platform to
lower.
A cable attached between the platform and valve lever shifts a spool in the hydraulic
logic block redirecting the flow of oil to the lip cylinder extending the lip. After fully
extending the lip, releasing the pushbutton will allow the dockleveler to lower.
After loading/unloading, the dockleveler can be repositioned to the stored position by
depressing and holding the raise pushbutton. As the platform raises, the lip folds to
the pendant position. Once the lip clears the truck bed, the raise button can be
released allowing the leveler to lower to its level to the stored position.
The Challenger Hydraulic dockleveler utilizes hydraulic logic and simple one button
operation for ease of use.
12
OPERATING INSTRUCTIONS
1. Check to make sure truck is positioned squarely against dock bumpers.
2. Instruct the driver to remain at the dock until the loading/unloading process is
complete.
WARNING
Do not operate the
unit if any personnel
are on or in front of
the unit.
Do not operate the
unit until the truck/
trailer is parked
squarely against the
dock bumpers.
Do not enter the
truck/trailer unless:
1. The dockleveler
lip is resting securely
on the truck/trailer
bed.
Truck/trailer wheels
must be chocked if
the truck restraint is
not utilized.
Failure to follow
these instructions
could result in
serious personal
injury or death.
3. Chock trailer wheels.
4. If loading dock is equipped with trailer restraint, engage restraint.
5. If required, remove end loads with dockleveler in the cross traffic (stored)
position.
6. To extend dockleveler lip onto the trailer:
A. Depress and hold the raise pushbutton. The dockleveler platform will
raise.
B. Shortly before the dockleveler platform reaches its highest position, the lip
will extend.
C. When the lip is fully extended, release the raise pushbutton.
D. The dockleveler will lower resting on the truck bed.
7. Verify that the lip is fully extended and supported by the truck bed along its
entire width.
8. Proceed with loading/unloading.
9. When loading/unloading is complete, or to load end loads, return dockleveler to
the stored position by:
A. Push and hold the raise button. The dockleveler platform will raise. While
the platform is raising, the lip will fold.
B. Release the raise button when the lip clears the trailer bed. The leveler will
lower to the dock level (stored) position.
C. Check that the lip is in the keepers. Leveler should be level with dock floor.
10. Unchock trailer wheels and release truck, if it is being restrained.
11. Tell driver that truck may leave.
13
PREVENTIVE MAINTENANCE
SERVICING UNDER THE DOCKLEVELER
If the maintenance to be performed requires access to the unit from the pit, support
the dockleveler platform and lip with the maintenance prop. Position the prop
behind the front header plate of the platform as illustrated in figure 20. Stay clear of
the lip. The lip will fold after the platform has rested on the maintenance prop.
FRONT HEADER PLATE
MAINTENANCE PROP
WARNING
Always barricade the work
area to prevent unauthorized use of the unit before
maintenance is complete.
Always lock off all electrical disconnects after
raising platform and setting
maintenance prop when
service under the unit is
required. More than one
electrical disconnect
switch may be required to
de-energize the equipment.
Always stand clear of the
dockleveler lip when
working in front of the unit.
Figure 20
To assure normal operation of the unit, the following hydraulic fluids are
recommended:
• Aero Shell fluid #4 Code #60421 by Shell Oil Co.
• Mobil Aero HFA Mil-Hs606A by Mobil Oil Co.
• Texaco Type BB
• Filmite No. 530
• Exxon "Univis J13"
Use of hydraulic fluids with equivalent specifications to those listed above are
acceptable. Use of fluids that do not have equivalent specifications will result in
abnormal operation of the unit and possible voiding of warranty.
14
PREVENTIVE MAINTENANCE
2. Check the hydraulic fluid level in the reservoir of the powerpack (i.e. motor/
pump/reservoir) when the dockleveler is safely supported by the maintenance
prop. The fluid level should be approximately 2" from the top of the reservoir. A
low fluid level or the use of non-recommended fluids will cause abnormal
operation of the unit.
BREATHER CAP
RESERVOIR
FLUID LEVEL
2"
Figure 19
3. When finished checking the fluid level, replace the breather cap and return the
leveler to the cross traffic position (the lip folded inside the keepers, with the platform level with the dock floor).
15
PREVENTIVE MAINTENANCE
Maintenance on your Challenger Hydraulic dockleveler can be classified as both
weekly and monthly.
WEEKLY MAINTENANCE
1. At least once each week, operate the unit through all of its operating cycles to
maintain lubrication.
2. Inspect the dockleveler platform hinge area and lip area. The hinge areas
should be kept free of debris and dirt. Build up of foreign material in the hinge
areas will cause abnormal operation. NOTE: Position the dockleveler in the
full below dock position to thoroughly inspect the platform (rear) hinge area.
MONTHLY MAINTENANCE
1. Lubricate the unit as shown in figure 18. Failure to properly lubricate the unit
will cause abnormal operation of the unit.
OIL AT ALL
REAR HINGES.
APPLY OIL AT
TOP OF
HINGES WHEN
LEVELER IS
FULL BELOW
DOCK.
OIL PIVOT
POINTS ON
LOGIC
BLOCK
GREASE AT HOIST
CYLINDER
TRUNNION
Figure 18
OIL ALONG
ENTIRE LIP HINGE.
APPLY OIL AT TOP
OF HINGE WHEN
LEVELER IS FULL
BELOW DOCK
WITH LIP FOLDED.
OIL LIP LIFTER AND PIN
16
TROUBLESHOOTING GUIDE
WARNING
Always barricade the work area to prevent unauthorized use of the unit during repair or maintenance procedures.
Always lock OFF all electrical disconnects when servicing the unit. Always stand clear of the
dockleveler lip when working in front of the unit.
Perform the following procedures prior to beginning detailed troubleshooting:
A. Check all fuses inside the control assembly(s). Replace any bad fuse with one of
equivalent specification.
B. Confirm presence of necessary voltages inside the control assembly(s).
DOCK LEVELER
Problem Cause(s) Solution
Leveler does not operate.
Motor does not energize
Leveler does not operate.
Motor energizes but does not
run (motor hums, overload
device should trip).
1. Motor overload device
tripped.
2. Motor starter (3 phase) or
motor relay (1 phase) not
energizing.
1. 3 phase units only - voltage
at one line is absent (motor
being single phased).
2. 1 phase units only - motor
centrifugal switch faulty.
1. Reset Overload relay (3 phase) or replace fuse(s) (1
phase). Determine cause of device tripping. NOTE: If
replacing fuse(s), replace with device of equal
specifications.
2. Check voltage at starter or relay coil. If voltage is
present and starter or relay does not energize then
replace device. If voltage is not present check all
components in series with the starter or relay coil for
proper operation.
1A. Fuses at motor branch circuit overcurrent device only
- check for tripped fuse. Replace fuse. Determine cause
of fuse tripping.
1B. Check motor starter for component failure.
Disconnect wires at load side of starter. Use voltmeter to
read line-to-line voltages at line side and load side of
starter when starter is energized. Line side and load side
voltage values should be nearly identical. Replace starter
if values not identical.
1C. Check all wiring to motor for high resistance (loose)
or no connection.
2. Replace motor.
Leveler will not raise. Pump
operates in pressure relief.
Leveler operates slowly. 1. Low hydraulic fluid. 1. Add fluid. See Preventive Maintenance section, page
1. Load on platform. 1. Remove load. Unit is designed to raise no more than its
own weight as a safety feature.
14.
17
TROUBLESHOOTING GUIDE
DOCK LEVELER (Continued)
Problem Cause(s) Solution(s)
CONTINUED 2. Pressure relief valve set too
low.
3 Damaged or blocked
hydraulic hose(s).
Leveler platform does not raise
to its full height OR platform
raises to full height but lip does
not fully extend OR motor
overcurrent device and/or
overload device continuously
tripping.
While leveler is descending, it
locks into "safety". Lip drops
to vertical position.
Platform reaches full height, but
lip does not automatically
extend when the pushbutton is
pressed.
1. Low hydraulic fluid. 1. Add fluid. See Preventive Maintenance section, page
1. Platform down-speed is too
fast.
1. Weight on operating arm
cable has slipped down on
cable.
2. See Item #1 of adjustment and testing, page 8. NOTE:
The valve set point should NOT be set at a level that will
cause the motor operating current to exceed its full load
amp value at any time, including when the unit is operating
in pressure relief.
3. Replace damaged hose(s). Remove blockage from
hose(s).
14.
1. Slow speed as follows: Loosen jam nut in radius of
fluid logic block. Using 1/8" Allen wrench, turn Allen
screw CW approximately one full turn; tighten jam nut.
Check down-speed. If leveler still descends too rapidly,
repeat above. If leveler descends TOO SLOWLY repeat
above, BUT turn Allen screw CCW.
1. Loosen setscrews on operating cable weight. DO NOT
LOSE steel ball under each screw. Raise weight 1/2" to
3/4" and secure screws. If spring is worn, replace.
Lip extends almost immediately
when the pushbutton is
pressed. Platform will raise
after lip extends.
Lip does not extend. 1. Spool extending through top
Units with auto return to dock
only. Leveler will not
automatically return to cross
traffic position.
1. Spool extending through top
of logic block stuck ON or
operating arm binding causing
arm to prematurely press
down on and activate spool.
of logic block stuck OFF or,
operating arm binding so that
arm will not press down on
and activate spool.
1. Auto return proximity switch
that senses when leveler lip at
below dock target and/or
switch out of adjustment.
18
1. Free-up operating arm. If necessary, detach arm from
logic block. Spray WD-40 penetrating oil or equivalent
over top of logic block. Work spool to free-up spool.
Replace spool if arm not contacting spool and problem
persists.
1. Free-up operating arm and spool. If necessary, detach
arm from logic block. Spray WD-40 penetraing oil or
equivalent over top of logic block. Work spool to free-up
spool.
1. Locate switch. Adjust switch and/or target so that
target is in sensing range of switch when unit is at below
dock. See Page 11.
39 333736 14 32
DOCKLEVELER ASSEMBLY
38
11
353834
40 43 31
5" CHANNELS ON PLATFORM
NOTE: POWERPACK IS REMOVED FROM THIS VIEW
41
28272
1
985
30 102925
13
26
29
20
18
16
*42
21223
6
15
17
16
19
23
7
24
RETURN
PRESSURE
POWERPACK DETAIL
CROSS SECTION OF DOCKLEVELER
44
45
46
4
19
PARTS LIST
ITEM QTY. PART NUMBER DESCRIPTION
1 1 8435-_____ FRAME WELDMENT
2 1 9515-_____ PLATFORM WELDMENT
3 1 0595-_____ LIP WELDMENT
4 1 3411-0001 MOTOR 1 PHASE
1 3411-0002 MOTOR 3 PHASE
5 1 0525-0044 HOIST CYL FOR 24" & 23-1/2" DEEP PIT
1 0525-0043 HOIST CYL FOR 19-1/2" DEEP PIT
6 1 0525-0050 LIP CYLINDER - STD
1 0525-0051 LIP CYLINDER - LONG
7 1 0522-0006 LIP LIFTER
8 2 7942-0001 HOIST CYLINDER - KEEPER
9 4 2101-0011 HHCS
1 9904-0074 HYD. HOSE ASSY. 3/8 100R1 - LIP CYL. 6' LG.
10 1 9904-0075 HYD. HOSE ASSY. 3/8 100R1 - LIP CYL. 8' LG.
1 9904-0076 HYD. HOSE ASSY. 3/8 100R1 - LIP CYL. 10' LG.
11 1 9575-0001 LOGIC BLOCK
12 2 9512-0024 TUBE - FILLER
13 1 9904-0078 HYD. HOSE ASSY. 3/8 100R1 - HOIST CYL. 6' LG.
1 9904-0074 HYD. HOSE ASSY. 3/8 100R1 - HOIST CYL. 8'&10' LG.
14 1 7952-0002 NICRO SLEEVE
15 1 0522-0002 SPRING - LIP CYLINDER
*16 2-12 2101-0060 FLAT WASHER
17 1 9455-0001 LIP CYLINDER HOLDDOWN
18 2 2101-0040 LOCKNUT
19 2 2101-0155 HHCS
20 1 9202-0004 PIN - LIP CYLINDER
21 1 9202-0003 PIN - LIP HINGE 6' WIDE
1 9202-0014 PIN - LIP HINGE 6.5' WIDE
1 9202-0006 PIN - LIP HINGE 7' WIDE
22 2 2101-0046 COTTER PIN
23 1 0522-0005 CLEVIS PIN
24 1 2101-0045 COTTER PIN
25 1 0015-____ TOEGUARD ASSEMBLY - LEFT HAND SIDE
26 1 0015-____ TOEGUARD ASSEMBLY - RIGHT HND SIDE
27 3 9202-0002 REAR HINGE PIN
28 6 2101-0047 COTTER PIN
29 4 2101-0049 CLIP HAIRPIN
30 1 9202-0005 PIN - HOIST CYINDER
31 2 9904-0006 HYD. HOSE ASSY - 3/8 100R1 - 24-1/2
32 2 9301-0143 STRAIGHT FITTING
33 1 5402-0007 OPERATOR LEVER
34 1 2101-0014 HEX HEAD CAPSCREW
35 7 2101-0039 LOCKNUT
36 1 7952-0001 CABLE
37 1 8102-0001 WEIGHT
38 7 2101-0163 WASHER
39 1 9572-0004 SPRING
40 2 2101-0015 HEX HEAD CAPSCREW
41 1 4305-0173 FLEX CONDUIT ASSEMBLY
*42 2 9452-0006 SPACER
43 1 9574-0001 SPOOL ASSEMBLY
44 2 9301-0116 90 DEGREE ELBOW
45 1 9301-0020 BREATHER CAP
46 1 9391-0008 POWERPACK
20
* NOTE: FOR DOCKLEVELERS USING 5" CHANNEL, ITEM #16 QUANTITY IS 4 &
ITEM #42 (QUANTITY OF 2) IS USED. FOR DOCKLEVELERS USING 6" CHANNEL,
ITEM #16 QUANTITY INCREASES TO 12 AND ITEM #42 IS OMITTED.
LIP CYLINDER
12
3
4
6
5
ITEM QTY. PART NUMBER DESCRIPTION
1 1 0521-0109 WEAR RING
2 1 0521-0110 PISTON SEAL
3 1 0522-0087 CYLINDER HEAD
4 1 0521-0003 "O" RING
5 1 0521-0004 RETAINING RING
6 1 0521-0002 SEAL - ROD
7 0525-0059 SEAL KIT - INCLUDES ALL ABOVE
HOIST CYLINDER
2
ITEM QTY. PART NUMBER DESCRIPTION
1 1 PISTON WELDMENT
2 1 TUBE - WELD ASSEMBLY
3 1 0521-0013 RETAINING RING
4 1 0521-0105 EXCLUDER PLUS
5 1 0521-0103 SLYDRING
6 1 0521-0008 "O" RING
7 1 0521-0009 BACK-UP RING
8 1 0521-0104 STEPSEAL
9 1 0522-0120 GLAND - ALUMINUM
10 0525-0048 SEAL KIT - INCLUDES ALL ABOVE
8
9
5
7
1
6
3
4
21
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