Professional Documents
Culture Documents
2022
AMTRK-PRO
Hydraulic dock leveller
Type: AMTRK – PRO 25 / 30 / 35
AMTR ul. Kolejowa 44, 57-240 Kamieniec Ząbkowicki +48 606 418 819 biuro@amtr.pl www.amtr.pl
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Technical and opera�onal parameters of the AMTRK-PRO 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
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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 AMTRK-PRO hydraulic dock levellers.
2. Hydraulic part
• Complete hydraulic system as standard;
• One hydraulic cylinder to li� the drive-on pla�orm (Two cylinders for pla�orm widths from 2250mm);
• One hydraulic cylinder to li� and lower the levelling lip;
• Hydraulic adjustment of the leveller height to the varying vehicle height during unloading.
3. Electrical part
• Electrical drive as standard
• Napięcie 400V/230V – (24V control voltage);
• One-bu�on leveller control;
• Semi-automa�c or automa�c return to res�ng posi�on;
• 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
• 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�on on the galvanized surface is permissible, which, however, does not affect the quality and an�-corrosion parame-
ters of the galvanized layer).
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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 AMTRK-PRO 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” 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 equipment or
objects while the leveller is in opera�on. Failure to do so may result in danger to human life or health and damage to
the leveller. This also means that the guarantee for the leveller is voided.
10. It is prohibited 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 switch off the main switch.
12. During leveller opera�on, the leveller power supply must always be switched on - main switch in the “ON” posi�on.
13. Even in the event of a temporary power failure 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 complete 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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14. The permissible loading speed at the handling leveller is a maximum of 5 km/h.
15. It is forbidden to use the handling leveller in combina�on with a hydraulic HGV tailgate. The minimum support for
the leveller lip on a semi-trailer of the vehicle should be between 100 and 150 mm.
16. Rapid braking of transport trucks on the access pla�orm surface is forbidden.
17. In the event of malfunc�oning of the hydraulic dock leveller:
• stop all loading and unloading opera�ons and perform a complete cycle of the leveller several �mes;
• 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”.
18. 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 combu-
s�on forkli�s. The opera�ng ranges in this case are shown in the table in point 3. 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-flexible
wheels whose footprint (the contact between the forkli� wheels and the handling pla�orm) is approximately two 150
mm x 100 mm rectangles. It is forbidden to drive hard-wheeled machines (e.g. electric pallet trucks) on the handling
leveller.
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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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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.
7. When loading and unloading operations are complete and people have left the access platform and the levelling lip and
all objects have been removed press and hold down the button again
The leveller rises and the lip is retracted. Once the lip is fully retracted, release the control button to return the leveller to
its resting position.
CAUTION
• If there is a problem with full retraction of the lip, it may be necessary to correct the retraction by pressing the button
and the levelling lip and all objects have been removed, briefly press the button. AUTO
The leveller rises, the lip is retracted and there is a return to the resting position.
CAUTION
• If the button AUTO is pressed again during the execution of the auto return cycle, the cycle is aborted.
• In the event that the lip during the execution of the auto return cycle does not hit the language clamp, the action must
be repeated.
8. Upon comple�on of the above, the vehicle may leave the docking sta�on.
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Leveller installa�on
1. Check the correct installa�on of the technological supports which are responsible for the correct posi�oning
of the leveller on the dock.
2. Check that the transport eyes on the access pla�orm are correctly fi�ed (two transport eyes).
3. Check the oil level in the tank - top up if necessary.
4. 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 and the hydraulic system. The truck should have an adequate load capaci-
ty).
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. Move the leveller as far back as possible so that the rear angle bracket of the leveller rests on the rear wall of
the dock, crea�ng a gap between the rear flat bar of the dock where the installa�on welds will be made.
7. Posi�on the leveller so that the clearance between the side edge of the pla�orm and the side angle bracket of
the dock is the same on both sides, then brace so that the pla�orm cannot shi� during welding.
8. 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.
9. Release the a�achment of the front beam from the lip of the leveller, weld the front beam to the side flanges
of the dock using the rear technological supports that were previously used to seat the leveller and dismantled
(point 7.6).
10. 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.
11. 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.
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12. A�er consul�ng the owner, install the electrical control box in the place indicated by it. 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
lip during opening and closing
13. Fix the rubber wheel stops to the front angle brackets of the dock. Check that the leveller is func�oning correctly.
Carry out several complete leveller cycles checking that the leveller is func�oning correctly in each cycle. Leave the
leveller in the res�ng posi�on, i.e., the lip retracted, res�ng on the supports located on the lower front beam of the
leveller base, the access pla�orm aligned with the hall floor surface. Switch off the power supply to the leveller via the
main switch.
14. Protect all leveller fixing welds with paint and make up for any paint defects that may have occurred during
leveller installa�on.
15. Tidy up the work area a�er leveller installa�on.
16. Formally hand over the leveller to the owner or user and instruct the opera�ng team designated by the user in the
correct opera�on of the leveller. On comple�on of the training, the team should confirm by their signatures that such
training has taken place.
Hydraulic system
The AMTRK-PRO hydraulic dock levellers are powered by hydraulic power units.
The power unit system is designed to work only with mineral oils such as HV, HVLP, HDZ characterised by good
lubrica�ng and corrosion protec�on proper�es and low viscosity change with temperature (recommended oil
Mobil DTE 10 Excel 15).
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 actuator fully retracted. 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.
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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.
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 µm. 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.
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.
When changing the oil, the inside of the tank should be inspected and possibly cleaned of accumulated sludge
without using sharp tools.
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.
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ATTENTION!!!
The controller circuit has been designed in such a way that pressing the emergency “STOP” (Emergency Stop)
bu�on causes removing 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” (Emergency Stop) bu�on was pressed.
A�er unlocking the “STOP” (Emergency Stop) bu�on, pressing the “START” bu�on starts the controller from the
ini�al state.
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Leveller maintenance
1. Compliance with maintenance rules guarantees long-term, trouble-free use of the AMTK-PRO 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. Carry out visual inspec�ons at regular monthly intervals and call in an authorised service centre if necessary.
• checking the correct func�oning of all leveller cycles
• checking the �ghtness of the hydraulic system
• checking the oil level in the hydraulic power unit tank
• checking the correctness of welds fixing the leveller
• visual check of the electrical system
In addi�on, once a month the dirt under the leveller and in its immediate vicinity must be removed and the hinge
gap, rear hinges and accumulated dirt on the lip hinges must be cleaned. A�er cleaning, re-lubricate the hinges.
Lubrica�on with thick oil or ŁT43 grease is permi�ed.
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The method of connec�ng electrical wires to the terminal strip in the control box
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Safety
switch
Green
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6
6
10
3
10
4 9.2
9.1
8
9.3
7
7
11
1 2
2
1 Front beam
2 Fixing angle brackets
3 Pla�orm
4 Rear beam
12.2
5 Lip
9.2 12.1
13
6 Lip pin
7 Side guard
14 8 Maintenance support
13
9.1 Hydraulic power unit
14
9.2* Type A cylinder
13 9.1
9.3 Type B cylinder
15 9.4 Cylinder pin
9.3
14 9.5 Locking pin
10 Lip bumper
11 Tensioner
12.1 Hydraulic hose for li�ing
9.5
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Drawing of the AMTRK-PRO leveller dock 2022
Primary frame for the dock leveller with swinging lip (AMTRK-PRO)
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www.amtr.pl