Inkema RH11 Manuel utilisateur

Inkema

Loading Bays • Dock Shelters • High-Speed Doors

Fire Doors • Free Standing Frames and Dock Houses • Scissor Lifts

Loading Bridges • Industrial Doors

Instructions manual

Hydraulic dock leveller

Models: RH11 and RH12

EMBEDDED AND SELF-SUPPORTING

RH11

RH12

Contents

Instructions manual RH11 and RH12 Inkema

V03 –2016

www.inkema.com

01 –Introduction........................................................................................................................................ 3

02 –Technical specifications................................................................................................................... 4

02.01 –Usage conditions and limits .................................................................................................................4

02.02 –RH11 embedded pit.............................................................................................................................4

02.03 –RH12 self-supporting pit ...................................................................................................................... 5

02.04 –Platform ...............................................................................................................................................5

02.05 –Lip........................................................................................................................................................5

02.06 –Bedplate...............................................................................................................................................5

02.07 –Hydraulic power unit ............................................................................................................................6

02.07.01 –Hydraulic unit version 03..................................................................................................6

02.07.02 –Hydraulic unit version 07..................................................................................................7

02.08 –Electrical control panel.........................................................................................................................7

02.09 –Safety systems .................................................................................................................................... 7

02.10 –Maintenance........................................................................................................................................ 8

02.10.01 –Hydraulic oil ..................................................................................................................... 8

02.10.02 –Grease points................................................................................................................... 8

02.10.03 –Dock leveller descent speed regulation............................................................................ 8

02.10.04 –Lip opening speed............................................................................................................8

02.10.05 –Maintenance plan.............................................................................................................9

02.11 –Instructions for use............................................................................................................................... 9

02.11.01 –Before use........................................................................................................................ 9

02.11.02 –During use...................................................................................................................... 10

02.11.03 –After use......................................................................................................................... 10

02.11.04 –Precautions during use .................................................................................................. 10

03 –CE Declaration................................................................................................................................. 11

04 –Machine units and parts ................................................................................................................. 12

05 –Installation........................................................................................................................................ 14

05.01 –Positioning in the pit........................................................................................................................... 14

05.02 –Securing the leveller in the pit............................................................................................................ 14

05.02.01 –Securing in the case of an embedded model................................................................. 14

05.02.02 –Securing in the case of a self-supporting model............................................................. 15

05.03 –Installing the electrical control panel.................................................................................................. 16

05.04 –Completed installation........................................................................................................................ 16

05.05 –Electrical control panel connection..................................................................................................... 17

05.05.01 –Connecting the power input ........................................................................................... 17

05.05.02 –Motor input connection................................................................................................... 17

05.05.03 –Electro valves connection .............................................................................................. 17

05.05.04 –Description of the connection terminals ......................................................................... 18

05.05.05 –Actions Selection............................................................................................................ 19

05.05.06 –Timers............................................................................................................................ 19

05.05.07 –Operation....................................................................................................................... 19

05.05.08 –Accessories.................................................................................................................... 19

05.05.09 –Characteristics ............................................................................................................... 19

06 –Dismantling...................................................................................................................................... 20

06.01 –Dismantling an embedded leveller..................................................................................................... 20

06.02 –Dismantling a self-supporting leveller ................................................................................................ 20

07 –Incidents........................................................................................................................................... 22

07.01 –The panel DOES NOT light up........................................................................................................... 22

07.02 –The ramp DOES NOT rise................................................................................................................. 23

07.03 –The leveller DOES NOT descend...................................................................................................... 24

07.04 –The lip DOES NOT open or functions very slowly ............................................................................. 24

07.05 –The lip opens before the leveller is raised.......................................................................................... 24

08 –Contact............................................................................................................................................. 25

Instructions manual RH11 and RH12 Inkema

V03 –2016

www.inkema.com

01 –Introduction

This manual is a guide for the correct, safe installation, use and maintenance of the RH11 and RH12 dock

levellers.

Compliance with the instruction set forth herein ensures the long life of the machine and respect for the safety

guidelines prevents the most common work or maintenance-related accidents.

The instructions in this manual do not, in themselves, guarantee safe working and do not release operators from

their obligation to observe the safety code, legislation or local or national regulations.

The service rule set out in this manual is only valid for mobile ramps and for loading and unloading trucks.

In the event of mislaying the instructions and maintenance manual, another copy that is specific for the machine

should be requested. It is essential and absolutely necessary to keep this manual with the machine, in order to

consult it at any time, or settle any doubts regarding its use.

The manufacturer has no direct control over the operations, locations or maintenance of the machine. Operators are

responsible for using best safety and maintenance practices.

Operators have the obligation to read and make sure they understand this manual before they use the machine.

Using the machine with caution and adequate training not only protects the operator but also the people who

depend on his work.

The information set out in the manual is valid at the time of publication.

The photographs and drawings are generic; as a result, this information may be changed, due to the constant

development and research carried out by INKEMA.

In the event of discrepancy, please consult the technical department.

The manual is an inseparable part of the machine and must be kept with it in the event of sale.

Instructions manual RH11 and RH12 Inkema

V03 –2016

www.inkema.com

02 –Technical specifications

Ramp designed pursuant to the UNE-EN 1398 standard

Calculated for a maximum nominal load of: (See its plate characteristics)

02.01 –Usage conditions and limits

Nominal load capacity 6t

Motor electrical voltage 230/400 volt. 3F 50Hz

Motor electrical power 0.75 Kw.

Electrical output voltage to emergency electro valve 24 volt. AC.

Max. operating pressure of the hydraulic circuit 140 kg/cm² (Bar)

Operating temperature range (-10ºC +40ºC)

Noise level generated <70db

Max. transit speed 10Km/h

Max. operating gradient 12.5% (7º)

Do not work with the machine while the emergency stop is activated or if the power supply has been cut off.

02.02 –RH11 embedded pit

(*) Pit tolerance

Detail A of subframe

Note: Metal profile joints with continuous cord and a neck of 6mm

Floor of at least H250 concrete with a thickness greater than or equal to 200mm

PIT FRAME

2 un.

(1+1) Un. **

15 un. **

LPN-80.8 x (L3 – 10)

LPN-80.8 x (W3 + 160)

LPN-80.8 x H3

#3x40x200

(**) Parts with some type of machining (Ask the Technical Department for drawings)

The diagonals of the pit must be equal ± 5 mm

Detail A

Recess tube Ø50mm. for electrical conductors as far as

the electrical panel.

Allow for a cable guide inside the tube.

Position electrical cables 500 mm from the door opening

01- LPN-80.8

Weld on forged

04 - Claw

Obra civil (Ver nota)

Instructions manual RH11 and RH12 Inkema

V03 –2016

www.inkema.com

02.03 –RH12 self-supporting pit

Detail A Detail B

Note: Metal profile joints with continuous cord and a neck of 6mm

Floor of at least H250 concrete with a thickness greater than or equal to 200mm.

02.04 –Platform

Superior tear plate (thickness 6/8mm.), quality ST-37.

10 cold rolled profiles

2 cold rolled lateral profiles (non-shear safety panels).

Front hinge unit (lip joint).

Rear hinge unit (platform joint).

Safety bar for executing maintenance work.

02.05 –Lip

Tear plate (thickness 13/15mm.), quality ST-37.

Press stroke 5º 150mm. from the end (for perfect adjustment to the truck).

Milled at the end (to ease the passage of the fork-lift trucks).

02.06 –Bedplate

Rear assembly (head) formed by rolled profiles.

Front assembly with profiles for supporting the lip.

Side profiles joining the front assembly with the rear assembly.

The movements of the platform and lip are executed through an electro hydraulic unit.

Recess tube Ø50mm. for electrical conductors as far as

the electrical panel.

Allow for guide cable inside the tube.

Detail A

Position electric cable 500 mm from the door opening

Corrugated steel notches Ø20 embedded in concrete and

laid out on either side.

Detail B

Civil engineering (See note)

Instructions manual RH11 and RH12 Inkema

V03 –2016

www.inkema.com

02.07 –Hydraulic power unit

1.0CV electric motor. 0’75kw 230/400Volt 3F 50Hz.

Hydraulic pump with flowrate of 5 litres/minute.

7-litre tank with oil level viewer.

Logicblock where all the elements are incorporated (including 24V electro valve).

Ø50mm. cylinder with rod for raising platform and parachute safety valve.

1 Ø30mm. cylinder with rod for lip raising.

Leads, connection fittings, etc…

The machine may be supplied with any of the following hydraulic unit versions, both are identical and perform the

same function.

02.07.01 –Hydraulic unit version 03

Leveller regulation

Lip regulation

Lift cylinder

Lip cylinder

Screw and spring

Limit valve

Sequence valve

Instructions manual RH11 and RH12 Inkema

V03 –2016

www.inkema.com

02.07.02 –Hydraulic unit version 07

02.08 –Electrical control panel

(See electrical control panel connections, page 17)

Transformer for manoeuvring circuit at 24Volt. AC.

Green light indicating ON.

Emergency stop/section switch.

Thermal switch.

Fuses.

Terminal block.

Box 190X*240Y*105Z (IP-55)

02.09 –Safety systems

Emergency and/or power failure electro valve

Emergency stop/section switch.

Elevation cylinder safety valve

Toe guards

Instructions manual RH11 and RH12 Inkema

V03 –2016

www.inkema.com

Non-slip surface

02.10 –Maintenance

The correct operation and long life of the ramp depend largely on the preventive maintenance work carried out.

Advanced maintenance may only be carried out by the INKEMA technical service or staff authorised by the latter.

This maintenance is carried out to ensure that the product conserves the safety and usage characteristics it had when

it was first installed.

All changes, repairs or manipulation of the product that fail to comply with these regulations will lead to the

cancellation of the one-year warranty term and the liability of INKEMA for the product will automatically end.

Continuous greasing, painting and vigilance is the best way to guarantee its performance for many years.

02.10.01 –Hydraulic oil

The hydraulic oil must be replaced every two years.

The oil must contain agents that prevent the formation of foam, oxidation and water absorption. If the winter

temperatures are very low, the oil must not be too thick and its viscosity index must remain stable at low

temperatures.

Never mix different oils, as the new oil may have a different resistance to oxidation and affect the life of the

original oil.

It is important to check the oil level every 6 months. The oil tank must be filled until it almost overflows from the

closing cap, in the lowest possible position.

The machine is supplied already containing T-15 oil

Hydraulic oil for ramps in refrigerated storerooms must have specific properties of use, in accordance with the

temperatures to which it is exposed. For this reason, if the need arises, the manufacturer must be informed about the

conditions in which the machine will be operating to ensure it contains the special oil.

02.10.02 –Grease points.

Every six months, check the grease points shown in the diagram

12345

02.10.03 –Dock leveller descent speed regulation

The speed will be regulated using the respective adjuster (1). (See hydraulic unit, page 6)

02.10.04 –Lip opening speed

The lip opening/closing speed is determined in the factory, but can be regulated using the respective adjuster (2).

(See hydraulic unit, page 6)

Instructions manual RH11 and RH12 Inkema

V03 –2016

www.inkema.com

02.10.05 –Maintenance plan

Maintenance job

Daily

Every

month

6 months

1 year

2 years

General state of the machine



Greasing



Hydraulic oil level



Oil leak inspection



Weld inspection



Axle inspection



Inspection of lateral adhesive bands



Paint inspection



Flexible conduits and connection fittings



Manoeuvring speed



Check parachute valve



Change hydraulic oil



02.11 –Instructions for use

02.11.01 –Before use

Make a visual check to ensure the leveller is in perfect conditions of use.

Centre the vehicle against the rubber stops of the leveller.

Check that the vehicle is completely immobilised and blocked. (Switch off the engine, apply the handbrake and

place chocks on the wheels).

To raise the leveller to the load surface level, connect the manoeuvring circuit by turning the red section switch.

The green pilot light will come on.

To raise the leveller and open the lip, press the elevation button without releasing it.

If you stop pressing the button, the leveller will descend at a controlled speed, due to its own weight.

Raise the leveller until the lip starts to open. Once the lip is open completely, release the elevation button.

Let the leveller descend at a steady speed until it rests on the load surface of the truck.

Check that the whole width of the lip is resting on the load surface of the vehicle in an area NO smaller than

130mm.

Instructions manual RH11 and RH12 Inkema

V03 –2016

www.inkema.com

02.11.02 –During use

The dock leveller will merely rest on the load surface (truck). The hydraulic cylinders MUST NOT be blocked to

allow the leveller to adapt to the height of the load surface (which will vary, depending on the variation in the truck

suspension).

Check that the emergency stop is NOT activated and that the leveller is supplied with power.

VERY IMPORTANT:

It is strictly prohibited to perform loading and unloading operations with the emergency stop activated, or

while the leveller is not supplied with power.

Never exceed the maximum nominal load. (See its plate characteristics).

Ensure that the leveller continues to rest on the load surface during transit. If this is not the case, press the

emergency stop button immediately.

Fork-lift trucks must be driven with caution. The maximum transit speed calculated for the leveller is 10 km/hour.

02.11.03 –After use

Raise the leveller and close the lip before the truck leaves the loading position. To do this, press the elevation

button and raise the leveller just enough for it to clear the truck.

Release the button and wait for the leveller to descend at a steady speed and rest on the closed lip on the front of the

bedplate.

02.11.04 –Precautions during use

Check that the emergency stop is not activated.

Never exceed the maximum nominal load. (See its plate characteristics).

Before each manoeuvre check that no-one is in the working area.

Check that the leveller is resting properly on the load surface of the truck, with the entire lip coupled to a surface of

approximately 130 mm along its whole width.

The hydraulic unit has the sole function of making the necessary movements to manipulate only the dock leveller.

It must never be used to support and/or lift loads.

Before raising the device ensure that its movement is not blocked by other equipment. (Doors, etc...)

After completing the operation check that the lip is properly inserted in the closed leveller position.

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