Professional Documents
Culture Documents
2022
AMTRV-ESS
Hydraulic dock leveller
Type: AMTRV – ESS 25 / 30 / 35
AMTR ul. Kolejowa 44, 57-240 Kamieniec Ząbkowicki +48 606 418 819 biuro@amtr.pl www.amtr.pl
OMD ® January 2022
2022
Technical and opera�onal parameters of the AMTRV-ESS leveller with pull-out lip 4
Notes and warnings regarding the opera�on of the hydraulic dock leveller 5-7
Leveller maintenance 14
AMTR ul. Kolejowa 44, 57-240 Kamieniec Ząbkowicki +48 606 418 819 biuro@amtr.pl www.amtr.pl
OMD ® January 2022
2022
Introduc�on
The purpose of this Opera�on and Maintenance Documenta�on is to inform the user about the design,
opera�on and maintenance of the AMTRV-ESS hydraulic dock levellers.
2. Hydraulic part
• Complete hydraulic system as standard;
• Two hydraulic cylinders to li� the leveller pla�orm;
• One hydraulic cylinder pulling out the levelling lip;
• Automa�c adjustment of the leveller height to the varying vehicle height during loading or unloading.
3. Electrical part
• Electrical drive as standard;
• 400V/230V voltage;
• 24V control voltage;
• Four-bu�on leveller control;
• Protec�on (in the event of a power failure or use of the emergency stop switch) - need to return to the beginning of
the opera�ng cycle.
4. Other informa�on
• Op�onally: two rubber wheel stops - standard, JUMBO-PRO, movable or armoured;
• Leveller surface primed and painted in RAL 9005 (standard)
Steel surfaces protected with two-component resin paint in colours according to the RAL colour chart; standard colours
9005 and 7042 (due to the possibility of abrasions or impacts during transport or installa�on, the occurrence of point
corrosion spots on the leveller steel structure and other steel elements of the dock equipment such as housings, bases,
etc. is permissible (max. 20% of the total painted surface); in the case of leveller structure and other elements of dock
equipment protected against corrosion with a zinc layer, the en�re hot-dip galvanizing process is carried out according
to the EN ISO 1461 standard (due to different silicon and sulphur contents in structural steel, the occurrence of discolo-
ura�ons on the galvanized surface is permissible, which, however, does not affect the quality and an�-corrosion parame-
ters of the galvanized layer).
3 AMTR ul. Kolejowa 44, 57-240 Kamieniec Ząbkowicki +48 606 418 819 biuro@amtr.pl www.amtr.pl
OMD ® January 2022
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Technical and opera�onal parameters of the AMTRV-ESS leveller with pull-out lip.
Steel structure
TABLE 1
Itemisa�on Dimensions / values
AMTRV-ESS 25 AMTRV-ESS 30 AMTRV -ESS 35
1 Pla�orm length NL 2500 3000 3500
2 Leveller width NW 2000 2000 2000
3 Pull-out lip LL 500 / 1000 500 / 1000 500 / 1000
4 Opera�ng length (max) 3000 (3500*) 3500 (4000*) 4000 (4500*)
5 Effec�ve opera�ng range upwards 280 (335*) 235 (275*) 210 (245*)
6 Effec�ve opera�ng range downwards 410 (470*) 390 (440*) 365 (405*)
7 Leveller structural height H 710 710 710
8 Load bearing capacity 60 kN or 100 kN or 120 kN
*for the lip with a length of 1000 mm
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OMD ® January 2022
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Dimensions
Pla�orm length NL mm
Leveller width NW mm
Pull-out lip (max) LL mm
Opera�ng length mm
Opera�ng range upwards mm
Opera�ng range downwards mm
Leveller structural height H mm
Notes and warnings regarding the opera�on of the hydraulic dock leveller
1. Before using the leveller, read carefully this Opera�on and Maintenance Documenta�on and the terms of
guarantee.
2. If there is any doubt or ambiguity, contact your leveller vendor.
3. Compliance with the provisions of this OMD is the only condi�on and a guarantee for the proper func�on of
the AMTRV-ESS hydraulic dock levellers. Non-compliance with the condi�ons included in this OMD can lead to
an accident or damage to the leveller and voids the guarantee.
4. It is forbidden to operate the leveller for persons not trained to do so.
5. It is forbidden to operate the leveller if the person is under the influence of alcohol or other drugs.
6. It is forbidden to be in the immediate vicinity of the leveller, especially from the front of the leveller, when it
is in opera�on. Failure to do so could lead to a fatal accident when swinging and folding the levelling lip.
7. It is forbidden to enter under the leveller access pla�orm without first securing it with a technological
support and cu�ng off the electrical supply.
8. It is forbidden for untrained persons to enter under the leveller pla�orm without being assisted by other
persons who are outside the working area of the leveller at that �me.
9. ATTENTION! It is forbidden to drive onto the leveller, for people to be on the leveller or to set up any equip-
ment or objects while the leveller is in opera�on. This also means that the guarantee for the leveller is voided.
10. It is not permi�ed to drive onto or across the leveller when the leveller is in the rest posi�on (levelling lip folded
and supported).
11. If there is any danger while the leveller is in opera�on, immediately press the red “STOP” bu�on with a
vigorous movement and move the main switch to posi�on “0”.
12. During leveller opera�on, the leveller power supply must always be switched on - main switch in the “ON” posi�on.
13. In the event of a power failure, even temporary, during leveller opera�on or loading/unloading opera�ons, all work
must be stopped immediately and the cause checked. If a power failure has occurred during leveller opera�on, two com-
plete leveller cycles should be carried out a�er the power has been switched back on in order to check that the leveller
is func�oning correctly and to compensate for the pressure difference in the hydraulic power unit. If a power failure has
occurred during loading and unloading opera�ons, the leveller should be emp�ed of all equipment and objects on it and
a�er switching the power back on, two complete leveller cycles should be carried out to check its correct opera�on and
to compensate for the pressure difference in the hydraulic power unit. Once this has been done, further work can be
carried out.
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OMD ® January 2022
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14. Only a�er the danger has been removed, release the “STOP” bu�on by turning it in the direc�on indicated by
the arrow, turn the main switch to the “ON” posi�on.
15. The permissible loading speed at the handling leveller is a maximum of 5 km/h.
16. Rapid accelera�on and braking of transport trucks on the access pla�orm surface is forbidden.
17. It is forbidden to exceed the maximum dynamic load bearing capacity of the leveller.
18. In the event of malfunc�oning of the hydraulic dock leveller:
• stop all loading and unloading opera�ons and perform 3-5 complete leveller cycles;
• perform the first complete cycle of leveller opera�on - i.e. raise the leveller access pla�orm as much as possible and
then lower the access pla�orm onto the safety technological support under maximum safety condi�ons;
• check the oil level in the power unit tank;
• check that the electrical connec�ons are correct;
• stop using the faulty device, cut off the power supply and urgently contact the manufacturer of the device, marking
the leveller with a clear tag “FAULTY DEVICE - DO NOT USE”.
19. It is forbidden to make any structural changes to the leveller without the consent of the manufacturer.
• The difference in height between the warehouse floor and the vehicle loading surface determines the inclina�on
of the pla�orm in working posi�on. The maximum inclina�on must not exceed 12.5 % (7 degrees) for internal com-
bus�on forkli�s. The opera�ng ranges in this case are shown in Table 1.
For electric trucks - 10 %.
Small electrically driven equipment e.g. electrically driven pallet truck - 7 %.
Small hand-powered devices, e.g. a pallet truck - 3 - 5 %.
• The nominal value of the handling leveller is the maximum load resul�ng from the sum of the weights of the objects
moving on the pla�orm. This value takes into account the dynamic effects caused by the truck moving correctly and in
accordance with the OMD. The permissible weight of the truck with accessories, driver and load must not exceed the
pla�orm's nominal value.
• The nominal values of standard handling pla�orms are only fulfilled by forkli�s with pneuma�c or super-flexi-
ble wheels whose footprint (the contact between the forkli� wheels and the handling pla�orm) is approxima-
tely two 150 mm x 100 mm rectangles. It is forbidden to drive hard-wheeled machines (e.g. electric pallet
trucks) on the handling leveller.
6 AMTR ul. Kolejowa 44, 57-240 Kamieniec Ząbkowicki +48 606 418 819 biuro@amtr.pl www.amtr.pl
OMD ® January 2022
2022
The small contact area of small wheels with higher hardness may cause permanent deforma�on of a pla�orm
unsuitable for this type of tyre. This type of deforma�on (ruts) is permi�ed within the limits specified in EN 1398.
However, in order to prevent such changes, we recommend that you do not exceed the total weight given below
with a rated load bearing capacity of 60 kN:
air-inflated tyres /
super flexible
6t 6t
High-li� truck
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OMD ® January 2022
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2. Posi�on the HGV against the rubber wheel stops of the leveller
fixed on the front flat bars of the leveller. The vehicle should not
push against the wheel stops with its whole weight. In this
posi�on the vehicle should be locked in such a way that it cannot
be moved in any direc�on.
5. Press the bu�on to raise the leveller. Do this regardless of whether the car floor is above or
below the hall floor level.
6. With buttons and extend the lip of the leveller towards the vehicle to a distance enabling safe opening
the vehicle's trailer door.
7. Press and hold in order to raise the leveller. Perform this operation regardless of the fact that the car floor
is above or below the hall floor level.
8. Press button and keep it pressed until the lip protrudes from 100 to 150 mm above the vehicle's load box.
11. Upon comple�on of the above, the vehicle may leave the docking sta�on.
ATTENTION!!!
IT IS STRICTLY FORBIDDEN TO PRESS MORE THAN ONE BUTTON AT THE SAME TIME!
8 AMTR ul. Kolejowa 44, 57-240 Kamieniec Ząbkowicki +48 606 418 819 biuro@amtr.pl www.amtr.pl
OMD ® January 2022
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Leveller installa�on
1. Check the correctness of the transport safety devices linking the access pla�orm to the leveller base.
2. Check the correct installa�on of the transport eyes on the access pla�orm (four eyes with hole diameter φ12 or
so-called transport eyes 2).
Connect the hydraulic power unit to the control box (connec�on for the �me of installa�on only). (Descrip�on of
connec�ons CONNECTING THE CONTROL - How to connect the electrical wires to the control terminal strip).
3. Check the oil level in the tank - top up if necessary.
4. Hook the sling hooks into the transport eyes and, using a crane, insert the leveller into the installa�on slot. It is
permissible to place the leveller into the dock by means of a forkli� - however, only with the use of suitably prepared
extensions for the forks of the forkli� truck, which prevent damage to the leveller base and the hydraulic system.
5. Place the leveller in the dock on the technological supports mounted in the back of the leveller and on the
sides of the pla�orm.
6. Align the leveller so that the rear angle bracket of the leveller (...) rests on the angle bracket of the dock and
the gap for the posi�on of the fixing joint is 5-10 mm. The clearance between the sides of the leveller pla�orm
and the dock walls should be the same on both sides (approximately 15 mm).
7. Weld the rear angle bracket of the leveller to the angle bracket of the dock (10 cm long fillet welds with breaks
every 20 cm from the star�ng point of the rear angle bracket of the leveller), then dismantle the rear technologi-
cal supports.
8. Weld the fixing angle brackets that were previously used to seat the leveller to the side flanges of the dock, then release
and bolt the front beam to them.
9. Check the tension linking the front beam to the rear angle bracket of the leveller, �ghten or loosen if necessary
using the bolts fi�ed.
10. Connect the hydraulic power supply to the control box, switch on the power and raise the access pla�orm upwards.
Lock the pla�orm on the technological support. Switch off the electrical supply. Unscrew the transport eyes and the
side process supports from the access pla�orm. Make the final power connec�on.
11. Connect a safety system to ensure that the leveller is raised when the gate is closed.
12. Install the electrical control box at the loca�on indicated in the design.
Safety requirements, applicable regula�ons and standards must be complied with. The loca�on of the box must
ensure that the person opera�ng the leveller has a full view of the device during opera�on, paying par�cular a�en�on
to the opera�on of the pull-out lip.
9 AMTR ul. Kolejowa 44, 57-240 Kamieniec Ząbkowicki +48 606 418 819 biuro@amtr.pl www.amtr.pl
OMD ® January 2022
2022
Hydraulic system
The AMTRV-ESS hydraulic dock levellers are powered by special hydraulic power units. The power unit system is
designed to work only with mineral oils such as HDZ, HV, HVLP, characterised by good lubrica�ng and corrosion
protec�on proper�es and low viscosity change with temperature. The use of other working fluids such as water,
water-oil emulsions or synthe�c fluids is not permi�ed.
1. Opera�ng manual
1.1 General recommenda�ons
The task of the maintenance services is to maintain the constant func�onality and long service life of the device.
Keep the oil level in the tank in the upper range - with the cylinder fully retracted. The need to top up the oil to
the upper level is signalled by the oil level indicator (first indica�on threshold).
If the oil level drops below the minimum value, the hydraulic system will malfunc�on. Periodically check the
cleanliness of the oil and its level of wear. The frequency of total oil changes and the degree of wear at which
oil changes are necessary should be agreed with the oil manufacturer. We recommend hydraulic oil
Mobil DTE 10 Excel 15.
The op�mum opera�ng temperature for the en�re system is between -20°C and +40°C. It is not permissible for
the oil temperature to exceed 60°C.
Oil filtering takes place throughout the opera�on of the system. Opera�on of the hydraulic equipment with oil
which does not meet the requirements of the purity class 16/13 according to ISO 4406 may lead to incorrect
opera�on of the valves (valve freezing, internal leakage, change of ini�al se�ngs, etc.) and releases the manufac-
turer from its guarantee obliga�ons. Repair or rec�fica�on of any leaks in the system must only be carried out
when the pumps are not running and there is no pressure in the system. The hydraulic system may only be
operated by a person trained in high-pressure hydraulics.
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OMD ® January 2022
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A�er comple�on of the installa�on work, the hydraulic power unit must be thoroughly cleaned before filling the
tank with hydraulic oil. Fill the tank with the required hydraulic oil; it is recommended that the tank be filled
using a unit equipped with a filter element with a filtra�on accuracy of 10 mm.
Before connec�ng the sta�on, the en�re associated hydraulic system must be thoroughly flushed. For flushing,
use the same grade of oil that will be used in opera�on.
1.3 Start-up
1.3.1 Ini�al start-up
Carry out a test li�ing cycle. If there is no response to the start pulse, disconnect the power supply and check the
connec�ons again. Repeat the whole procedure un�l the correct result is obtained.
The above-men�oned opera�ons may only be carried out by a person trained in high-pressure hydraulics or by
the SOT 24 service team.
1.4 Bleeding
The hydraulic system of the leveller has a self-bleeding func�on during several ini�al cycles.
The oil with which the sta�on tank was originally filled should be changed a�er approx. 500 to 1000 opera�ng
hours. Subsequent changes should take place every 3000 to 5000 opera�ng hours. The sizes given here are
approximate. Devia�ons from the specified intervals are permissible depending on the load on the unit's hydrau-
lic system. It is not recommended to top up used oil with fresh oil, as sufficient lubricity and corrosion protec�on
cannot then be ensured.
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OMD ® January 2022
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When changing the oil, the inside of the tank should be inspected and any accumulated sludge should be cleaned
out.
Operators of the devices are required to receive high pressure hydraulics training, func�onal and job-specific
training and OSH training required in the plant for each job. All repair work must be carried out with the drives
switched off, the electrical voltage switched off and no pressure in the system.
12 AMTR ul. Kolejowa 44, 57-240 Kamieniec Ząbkowicki +48 606 418 819 biuro@amtr.pl www.amtr.pl
OMD ® January 2022
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ATTENTION!!!
The controller circuit has been designed in such a way that pressing the emergency “STOP” bu�on causes remo-
ving voltage from the control circuit, thus the program is interrupted (the actuators are disconnected), the ramp
remains in the posi�on it was in when the “STOP” bu�on was pressed. A�er unlocking the “STOP” emergency
bu�on, pressing the “START” bu�on starts the controller from the ini�al state.
13 AMTR ul. Kolejowa 44, 57-240 Kamieniec Ząbkowicki +48 606 418 819 biuro@amtr.pl www.amtr.pl
OMD ® January 2022
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Leveller maintenance
1. Compliance with maintenance rules guarantees long-term, trouble-free use of the AMTRV-ESS hydraulic dock
leveller.
2. When carrying out any work underneath the access pla�orm, it is always necessary to secure the pla�orm by
means of technological supports to prevent it from falling unexpectedly.
3. Maintenance should be carried out regularly at monthly intervals through:
• checking the correct func�oning of all leveller cycles
• cleaning of any dirt and old grease and re-lubrica�on of: the rear hinges of the access pla�orm, the guides and
guide rollers, pull-out levelling lip, the actuator pins for the leveling lip and the access pla�orm.
• checking the hydraulic system for leaks (any leaks must be rec�fied)
• checking the oil level in the hydraulic power unit tank (topping up if necessary)
• checking the correctness of welds fixing the leveller to the dock angle brackets
• restora�on of damages and defects in the paint coa�ng
• remove all dirt from under the leveller and its immediate surroundings.
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OMD ® January 2022
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PE N L1 L2 L3 PE U V W - + - + - +
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5.1
5.2
4 9.1 8
6 2 1 2 6
1 Front beam
2 Fixing angle brackets
3 Pla�orm
11
4 Rear beam
9.3
12
5.1 Lip
11 12
5.2 Tarpaulin
13 6 Cylinder pin
9.2 7 Bearing
8 Tensioner
11 9.1 Hydraulic power unit
9.3
11 9.2 Type D cylinder / Type H cylinder *
12
12
9.3 Type B1 cylinder
13
9.4 Cylinder pin
9.5 Locking pin
10 Hydraulic hoses are:
9.5 9.4
9.1
11 1/4” connector
12 Metal-rubber sealant
13 Protec�on against hose rupture
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OMD® January 2022
Circuit diagram of the AMTRV-ESS leveller control 2022
green
Safety
safety switch
switch
safety
switch
18 AMTR ul. Kolejowa 44, 57-240 Kamieniec Ząbkowicki +48 606 418 819 biuro@amtr.pl www.amtr.pl
OMD ® January 2022
Drawing of the AMTRV-ESS leveller dock 2022
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